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Aerco AM 1000B - User Manual

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AM Series Boilers and Water Heaters
OMM-0100_0D AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 1 of 154
GF-146 Ph.: 800-526-0288 03/28/16
USER MANUAL
AM Series
Natural Gas & Propane Modulating Condensing Boilers & Water Heaters
Applies to the following AM Series models:
Latest Update: 03/28/16
AM Boilers
AM 399B
AM 500B
AM 750B
AM 1000B
AM Water Heaters
Standard Models:
AM 399W
AM 500W
AM 750W
AM 1000W
Rapid Recovery
Option:
AM 399RS
AM 500RS
AM 750RS
AM 1000RS

Table of Contents

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Summary

CHAPTER 1: GENERAL INFORMATION

1.1 Warnings & Cautions

Installation requirements, safety warnings, and unit cautions.

FOR YOUR SAFETY READ BEFORE OPERATING

Safety instructions for appliance operation, including gas leak response.

1.2 Emergency Shutdown

Procedure for emergency shutdown and location of manual gas shutoff valve.

CHAPTER 2: FUNCTIONAL OVERVIEW

2.2 Intended Use - Boilers

Intended application of AM Series boilers in central heating systems.

2.3 Intended Use - Water Heaters

Intended application of AM Series water heaters for domestic hot water.

CHAPTER 3: INSTALLATION - SITE

3.1 Choosing the Installation Location

General considerations for selecting the proper installation site for AM Series units.

3.2 Boiler and Water Heater Installation Location Factors

Factors to consider when choosing the installation location for boilers and water heaters.

3.3 Safety Concerns

Important safety considerations regarding the installation area of the unit.

3.7 Vent and Combustion Air Piping

Requirements for the special vent system and combustion air piping.

3.8 Prevention of Combustion Air Contamination

Measures to prevent contamination of combustion air for proper unit operation.

CHAPTER 4: INSTALLATION - PIPING

4.2 Water Quality

Guidelines for water quality to prevent damage and ensure proper operation.

4.4 Freeze Protection

Methods for freeze protection using glycol solutions and related warnings.

4.8 Safety Relief Valve

Information on safety relief valves, their installation, and requirements.

4.12 Domestic Hot Water System Piping with Direct Water Heater - Water Heaters

Recommended piping for AM Series water heaters with direct water heater setup.

4.13 Scalding - Water Heaters

Information on scald hazards and protective measures for water heaters.

4.14 Condensate Disposal

Procedures and requirements for condensate disposal from the unit.

CHAPTER 5: INSTALLATION - ELECTRICAL

5.2.3 Indirect Water Heater Connection - Boilers

Steps for connecting an indirect water heater to the boiler.

CHAPTER 6: INSTALL - VENT & COMBUSTION AIR PIPING

6.1 Combustion Air Contamination Prevention

Measures to prevent contamination of combustion air and avoid unit damage.

6.2 General Venting and Air Piping Systems

General requirements for pressurized venting and air piping systems.

6.4 General Venting and Combustion Air Piping Installation

General guidelines for installing vent and air piping and ensuring airtightness.

6.5.6 Determining Vent Termination Location

Guidelines for selecting the proper location for vent termination.

6.5.8 Combustion Air and Ventilation Openings

Requirements for providing outdoor combustion air through openings.

6.5.17 Determining Location of Vertical Termination

Guidelines for locating vertical vent and air terminations on a roof.

6.5.22 Determining Location of Vertical Concentric Vent Termination

Guidelines for locating vertical concentric vent terminations.

CHAPTER 7: INSTALLATION - NATURAL GAS

7.1 Gas Supply Piping

Requirements for checking gas type and pressure for unit installation.

7.4 Natural Gas Supply Pressure Requirements

Required natural gas supply pressure at the gas valve inlet.

7.6 Propane Gas Supply Pressure Requirements

Required propane gas supply pressure at the gas valve inlet.

7.7 Checking and Adjusting the Unit Inlet Gas Supply Pressure

Procedure for checking and adjusting the unit inlet gas supply pressure.

7.9 Conversion from Natural gas to Propane Gas

Procedures for converting the unit from natural gas to propane gas.

Gas Rating Conversion of Master Burner 1

Steps to convert Master Burner 1 for gas rating.

Gas Rating Conversion of Burners 2, 3, and 4

Steps to convert Burners 2, 3, and 4 for gas rating after Master Burner.

CHAPTER 8: UNIT START-UP

8.1 INITIAL START-UP REQUIREMENTS

Initial start-up requirements and user instructions for the heater.

8.2 General Warnings Concerning the Gas Supply

Checks to perform concerning the gas supply before initial unit start-up.

8.2.2 Gas Type Conversion

Procedure for converting the heater's gas type if needed.

8.4 Boiler Startup Procedure

Step-by-step procedure for starting up AM Series boilers.

8.5 Water Heater Startup Procedure

Step-by-step procedure for starting up AM Series water heaters.

8.6 Gas Supply Pressure Test

Procedure for testing the gas supply pressure to the unit.

8.7 Combustion Calibration

Procedure for performing combustion calibration and checking CO2/O2 ranges.

8.8 Lost Ignition Procedure

Procedure to follow if the burner fails to stay lit during ignition.

8.10 Heating System Pressure Test

Procedure for testing heating system pressure and restoring correct pressure.

CHAPTER 9: OPERATION

9.5 Startup Procedure - Boilers

Step-by-step procedure for starting up AM Series boilers.

9.13 Startup Procedure - Water Heaters

Step-by-step procedure for starting up AM Series water heaters.

9.19 Diagnostics - Lockout (Loc) Errors

Troubleshooting lockout errors, including error codes and solutions.

9.20 Diagnostics - Blocking (Err) Errors

Troubleshooting blocking errors, including error codes and solutions.

9.21 Blocked Flue Pressure Switch

Safety feature that shuts down the unit when the flue vent pipe is blocked.

CHAPTER 10: MAINTENANCE

10.15 Cleaning the Burner and Primary Heat Exchanger (Flue;Gas Side)

Procedure for cleaning the burner and the flue gas side of the heat exchanger.

10.16 Inspecting and Replacing the Heat Exchanger Thermal Insulation

How to inspect and replace thermal insulation in heat exchanger modules.

10.17 Inspecting and Replacing the Burner Thermal Insulation

How to inspect and replace thermal insulation on the burner module.

10.19 Ignition and Flame Detection Sensor Electrode Positioning

Correct positioning of ignition and flame detection sensor electrodes for burner function.

10.21 Condensate Trap and Neutralizing Reservoir Maintenance

Maintenance of the condensate trap and neutralizing reservoir, including pH monitoring.

10.22 Control Board Replacement

Instructions for replacing the Burner 1 (Master) control board.

Summary

CHAPTER 1: GENERAL INFORMATION

1.1 Warnings & Cautions

Installation requirements, safety warnings, and unit cautions.

FOR YOUR SAFETY READ BEFORE OPERATING

Safety instructions for appliance operation, including gas leak response.

1.2 Emergency Shutdown

Procedure for emergency shutdown and location of manual gas shutoff valve.

CHAPTER 2: FUNCTIONAL OVERVIEW

2.2 Intended Use - Boilers

Intended application of AM Series boilers in central heating systems.

2.3 Intended Use - Water Heaters

Intended application of AM Series water heaters for domestic hot water.

CHAPTER 3: INSTALLATION - SITE

3.1 Choosing the Installation Location

General considerations for selecting the proper installation site for AM Series units.

3.2 Boiler and Water Heater Installation Location Factors

Factors to consider when choosing the installation location for boilers and water heaters.

3.3 Safety Concerns

Important safety considerations regarding the installation area of the unit.

3.7 Vent and Combustion Air Piping

Requirements for the special vent system and combustion air piping.

3.8 Prevention of Combustion Air Contamination

Measures to prevent contamination of combustion air for proper unit operation.

CHAPTER 4: INSTALLATION - PIPING

4.2 Water Quality

Guidelines for water quality to prevent damage and ensure proper operation.

4.4 Freeze Protection

Methods for freeze protection using glycol solutions and related warnings.

4.8 Safety Relief Valve

Information on safety relief valves, their installation, and requirements.

4.12 Domestic Hot Water System Piping with Direct Water Heater - Water Heaters

Recommended piping for AM Series water heaters with direct water heater setup.

4.13 Scalding - Water Heaters

Information on scald hazards and protective measures for water heaters.

4.14 Condensate Disposal

Procedures and requirements for condensate disposal from the unit.

CHAPTER 5: INSTALLATION - ELECTRICAL

5.2.3 Indirect Water Heater Connection - Boilers

Steps for connecting an indirect water heater to the boiler.

CHAPTER 6: INSTALL - VENT & COMBUSTION AIR PIPING

6.1 Combustion Air Contamination Prevention

Measures to prevent contamination of combustion air and avoid unit damage.

6.2 General Venting and Air Piping Systems

General requirements for pressurized venting and air piping systems.

6.4 General Venting and Combustion Air Piping Installation

General guidelines for installing vent and air piping and ensuring airtightness.

6.5.6 Determining Vent Termination Location

Guidelines for selecting the proper location for vent termination.

6.5.8 Combustion Air and Ventilation Openings

Requirements for providing outdoor combustion air through openings.

6.5.17 Determining Location of Vertical Termination

Guidelines for locating vertical vent and air terminations on a roof.

6.5.22 Determining Location of Vertical Concentric Vent Termination

Guidelines for locating vertical concentric vent terminations.

CHAPTER 7: INSTALLATION - NATURAL GAS

7.1 Gas Supply Piping

Requirements for checking gas type and pressure for unit installation.

7.4 Natural Gas Supply Pressure Requirements

Required natural gas supply pressure at the gas valve inlet.

7.6 Propane Gas Supply Pressure Requirements

Required propane gas supply pressure at the gas valve inlet.

7.7 Checking and Adjusting the Unit Inlet Gas Supply Pressure

Procedure for checking and adjusting the unit inlet gas supply pressure.

7.9 Conversion from Natural gas to Propane Gas

Procedures for converting the unit from natural gas to propane gas.

Gas Rating Conversion of Master Burner 1

Steps to convert Master Burner 1 for gas rating.

Gas Rating Conversion of Burners 2, 3, and 4

Steps to convert Burners 2, 3, and 4 for gas rating after Master Burner.

CHAPTER 8: UNIT START-UP

8.1 INITIAL START-UP REQUIREMENTS

Initial start-up requirements and user instructions for the heater.

8.2 General Warnings Concerning the Gas Supply

Checks to perform concerning the gas supply before initial unit start-up.

8.2.2 Gas Type Conversion

Procedure for converting the heater's gas type if needed.

8.4 Boiler Startup Procedure

Step-by-step procedure for starting up AM Series boilers.

8.5 Water Heater Startup Procedure

Step-by-step procedure for starting up AM Series water heaters.

8.6 Gas Supply Pressure Test

Procedure for testing the gas supply pressure to the unit.

8.7 Combustion Calibration

Procedure for performing combustion calibration and checking CO2/O2 ranges.

8.8 Lost Ignition Procedure

Procedure to follow if the burner fails to stay lit during ignition.

8.10 Heating System Pressure Test

Procedure for testing heating system pressure and restoring correct pressure.

CHAPTER 9: OPERATION

9.5 Startup Procedure - Boilers

Step-by-step procedure for starting up AM Series boilers.

9.13 Startup Procedure - Water Heaters

Step-by-step procedure for starting up AM Series water heaters.

9.19 Diagnostics - Lockout (Loc) Errors

Troubleshooting lockout errors, including error codes and solutions.

9.20 Diagnostics - Blocking (Err) Errors

Troubleshooting blocking errors, including error codes and solutions.

9.21 Blocked Flue Pressure Switch

Safety feature that shuts down the unit when the flue vent pipe is blocked.

CHAPTER 10: MAINTENANCE

10.15 Cleaning the Burner and Primary Heat Exchanger (Flue;Gas Side)

Procedure for cleaning the burner and the flue gas side of the heat exchanger.

10.16 Inspecting and Replacing the Heat Exchanger Thermal Insulation

How to inspect and replace thermal insulation in heat exchanger modules.

10.17 Inspecting and Replacing the Burner Thermal Insulation

How to inspect and replace thermal insulation on the burner module.

10.19 Ignition and Flame Detection Sensor Electrode Positioning

Correct positioning of ignition and flame detection sensor electrodes for burner function.

10.21 Condensate Trap and Neutralizing Reservoir Maintenance

Maintenance of the condensate trap and neutralizing reservoir, including pH monitoring.

10.22 Control Board Replacement

Instructions for replacing the Burner 1 (Master) control board.

Aerco AM 1000B Specifications

General IconGeneral
BrandAerco
ModelAM 1000B
CategoryBoiler
LanguageEnglish

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