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Aerco AM 399B - User Manual

Aerco AM 399B
154 pages
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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

Foreword

Chapter 1: General Information

1.1 Warnings & Cautions

Crucial warnings and cautions for safe installation and operation of the AM Series units.

1.2 Emergency Shutdown

Procedure for safely shutting down the unit in an emergency situation.

Chapter 2: Functional Overview

2.1 Introduction

Overview of the AM Series boilers and water heaters, including models and options.

2.2 Intended Use - Boilers

Details the intended applications for AM Series boilers in central heating systems.

2.3 Intended Use - Water Heaters

Details the intended applications for AM Series water heaters for domestic hot water.

2.4 Intended Use - Water Heaters and Boilers with AMR Option

Describes the intended use of the AMR option for water heaters and boilers.

2.5 AM Series Functional Schematics

Presents functional schematics for AM Series boilers and water heaters.

Chapter 3: Installation - Site

3.1 Choosing the Installation Location

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

3.3 Safety Concerns

Highlights critical safety considerations during installation.

3.5 Clearances for Installation and Servicing

Specifies minimum clearances required for safe installation and servicing.

3.7 Vent and Combustion Air Piping

Details requirements for vent and combustion air piping systems.

3.10 Unpacking and Transporting

Instructions for safely unpacking and transporting the AM units.

Chapter 4: Installation - Piping

4.1 Water Inlet and Outlet Piping

Guidelines for connecting hot water outlet and cold water inlet piping.

4.2 Water Quality

Importance of water quality and recommended parameters for heating systems.

4.3 System Piping Methods - Boilers

Describes system piping methods for boilers in closed-loop systems.

4.4 Freeze Protection

Recommendations for freeze protection using glycol solutions in systems.

4.8 Safety Relief Valve

Information on the safety relief valve requirements and installation.

Chapter 5: Installation - Electrical

5.1.1 Power Supply Cable Connection - Boilers and Water Heaters

Procedure for connecting the electrical line voltage power supply cable.

5.2 Electrical Connections - Boilers Only

Specific electrical connection details for boilers.

5.3 Electrical Connections - Water Heaters Only

Specific electrical connection details for water heaters.

5.4 AMR Rapid Recovery Option Wiring

Electrical connection requirements for the AMR Rapid Recovery option.

Chapter 6: Installation - Venting and Combustion Air Piping

6.1 Combustion Air Contamination Prevention

Ensuring combustion air is free from contaminants for safe operation.

6.2 General Venting and Air Piping Systems

Overview of general venting and air piping system requirements.

6.5.6 Determining Vent Termination Location

Guidelines for selecting the correct vent termination location.

6.5.17 Determining Location of Vertical Termination

Guidelines for locating vertical vent and air terminations.

Chapter 7: Installation - Natural Gas

7.1 Gas Supply Piping

Guidelines for connecting the natural gas supply piping.

7.4 Natural Gas Supply Pressure Requirements

Specifies required natural gas supply pressure parameters.

7.7 Checking and Adjusting the Unit Inlet Gas Supply Pressure

Procedure for checking and adjusting gas supply pressure.

7.9 Conversion from Natural gas to Propane Gas

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

Chapter 8: Unit Start-Up

8.1 Initial Start-Up Requirements

Essential requirements before initiating the unit start-up process.

8.2 General Warnings Concerning the Gas Supply

Critical safety warnings related to the gas supply during start-up.

8.6 Gas Supply Pressure Test

Procedure for testing the gas supply pressure.

8.7 Combustion Calibration

Detailed steps for calibrating combustion parameters for optimal performance.

Chapter 9: Operation

9.2 Freeze Protection

Explanation of the freeze protection function and its operation.

9.5 Startup Procedure - Boilers

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

9.13 Startup Procedure - Water Heaters

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

9.16 Installer Menu

Accessing and adjusting parameters via the installer menu.

9.19 Diagnostics - Lockout (Loc) Errors

Troubleshooting guide for lockout errors and their solutions.

Chapter 10: Maintenance

10.1 Checking for Gas Leaks

Procedure for inspecting gas piping and connections for leaks.

10.4 Ignition and Flame Sensor Inspection

Instructions for inspecting and maintaining ignition and flame sensors.

10.9 Relief Valve Inspection

Guidance on inspecting the safety relief valve for proper function.

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

Steps for cleaning the burner and primary heat exchanger.

10.21 Condensate Trap and Neutralizing Reservoir Maintenance

Maintenance procedures for the condensate trap and neutralizing reservoir.

10.27.1 Wiring Diagram

Detailed wiring diagram for the AM Series units.

Chapter 11: Technical Data

AM Series Boiler and Water Heater Technical Data

Provides technical specifications for AM Series boilers and water heaters.

AM Rapid Recovery Buffer Tank Technical Data

Provides technical specifications for the AMR buffer tank.

Chapter 12: Spare Parts Drawings & Lists

12.1 AM 399;500 Spare Parts Drawings

Exploded view drawings of spare parts for AM 399/500 models.

12.2 AM 399;500 Spare Parts List

List of spare parts for AM 399/500 models with part numbers.

12.3 AM 750;1000 Spare Parts Drawings

Exploded view drawings of spare parts for AM 750/1000 models.

12.4 AM 750;1000 Spare Parts List

List of spare parts for AM 750/1000 models with part numbers.

12.5 AMR Option Spare Parts Drawing

Exploded view drawing of spare parts for the AMR option.

12.6 AM Rapid Recovery (AMR) Option Spare Parts List

List of spare parts for the AMR option.

Appendix A: Control Panel Operation Chart

Summary

Foreword

Chapter 1: General Information

1.1 Warnings & Cautions

Crucial warnings and cautions for safe installation and operation of the AM Series units.

1.2 Emergency Shutdown

Procedure for safely shutting down the unit in an emergency situation.

Chapter 2: Functional Overview

2.1 Introduction

Overview of the AM Series boilers and water heaters, including models and options.

2.2 Intended Use - Boilers

Details the intended applications for AM Series boilers in central heating systems.

2.3 Intended Use - Water Heaters

Details the intended applications for AM Series water heaters for domestic hot water.

2.4 Intended Use - Water Heaters and Boilers with AMR Option

Describes the intended use of the AMR option for water heaters and boilers.

2.5 AM Series Functional Schematics

Presents functional schematics for AM Series boilers and water heaters.

Chapter 3: Installation - Site

3.1 Choosing the Installation Location

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

3.3 Safety Concerns

Highlights critical safety considerations during installation.

3.5 Clearances for Installation and Servicing

Specifies minimum clearances required for safe installation and servicing.

3.7 Vent and Combustion Air Piping

Details requirements for vent and combustion air piping systems.

3.10 Unpacking and Transporting

Instructions for safely unpacking and transporting the AM units.

Chapter 4: Installation - Piping

4.1 Water Inlet and Outlet Piping

Guidelines for connecting hot water outlet and cold water inlet piping.

4.2 Water Quality

Importance of water quality and recommended parameters for heating systems.

4.3 System Piping Methods - Boilers

Describes system piping methods for boilers in closed-loop systems.

4.4 Freeze Protection

Recommendations for freeze protection using glycol solutions in systems.

4.8 Safety Relief Valve

Information on the safety relief valve requirements and installation.

Chapter 5: Installation - Electrical

5.1.1 Power Supply Cable Connection - Boilers and Water Heaters

Procedure for connecting the electrical line voltage power supply cable.

5.2 Electrical Connections - Boilers Only

Specific electrical connection details for boilers.

5.3 Electrical Connections - Water Heaters Only

Specific electrical connection details for water heaters.

5.4 AMR Rapid Recovery Option Wiring

Electrical connection requirements for the AMR Rapid Recovery option.

Chapter 6: Installation - Venting and Combustion Air Piping

6.1 Combustion Air Contamination Prevention

Ensuring combustion air is free from contaminants for safe operation.

6.2 General Venting and Air Piping Systems

Overview of general venting and air piping system requirements.

6.5.6 Determining Vent Termination Location

Guidelines for selecting the correct vent termination location.

6.5.17 Determining Location of Vertical Termination

Guidelines for locating vertical vent and air terminations.

Chapter 7: Installation - Natural Gas

7.1 Gas Supply Piping

Guidelines for connecting the natural gas supply piping.

7.4 Natural Gas Supply Pressure Requirements

Specifies required natural gas supply pressure parameters.

7.7 Checking and Adjusting the Unit Inlet Gas Supply Pressure

Procedure for checking and adjusting gas supply pressure.

7.9 Conversion from Natural gas to Propane Gas

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

Chapter 8: Unit Start-Up

8.1 Initial Start-Up Requirements

Essential requirements before initiating the unit start-up process.

8.2 General Warnings Concerning the Gas Supply

Critical safety warnings related to the gas supply during start-up.

8.6 Gas Supply Pressure Test

Procedure for testing the gas supply pressure.

8.7 Combustion Calibration

Detailed steps for calibrating combustion parameters for optimal performance.

Chapter 9: Operation

9.2 Freeze Protection

Explanation of the freeze protection function and its operation.

9.5 Startup Procedure - Boilers

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

9.13 Startup Procedure - Water Heaters

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

9.16 Installer Menu

Accessing and adjusting parameters via the installer menu.

9.19 Diagnostics - Lockout (Loc) Errors

Troubleshooting guide for lockout errors and their solutions.

Chapter 10: Maintenance

10.1 Checking for Gas Leaks

Procedure for inspecting gas piping and connections for leaks.

10.4 Ignition and Flame Sensor Inspection

Instructions for inspecting and maintaining ignition and flame sensors.

10.9 Relief Valve Inspection

Guidance on inspecting the safety relief valve for proper function.

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

Steps for cleaning the burner and primary heat exchanger.

10.21 Condensate Trap and Neutralizing Reservoir Maintenance

Maintenance procedures for the condensate trap and neutralizing reservoir.

10.27.1 Wiring Diagram

Detailed wiring diagram for the AM Series units.

Chapter 11: Technical Data

AM Series Boiler and Water Heater Technical Data

Provides technical specifications for AM Series boilers and water heaters.

AM Rapid Recovery Buffer Tank Technical Data

Provides technical specifications for the AMR buffer tank.

Chapter 12: Spare Parts Drawings & Lists

12.1 AM 399;500 Spare Parts Drawings

Exploded view drawings of spare parts for AM 399/500 models.

12.2 AM 399;500 Spare Parts List

List of spare parts for AM 399/500 models with part numbers.

12.3 AM 750;1000 Spare Parts Drawings

Exploded view drawings of spare parts for AM 750/1000 models.

12.4 AM 750;1000 Spare Parts List

List of spare parts for AM 750/1000 models with part numbers.

12.5 AMR Option Spare Parts Drawing

Exploded view drawing of spare parts for the AMR option.

12.6 AM Rapid Recovery (AMR) Option Spare Parts List

List of spare parts for the AMR option.

Appendix A: Control Panel Operation Chart

Aerco AM 399B Specifications

General IconGeneral
ModelAM 399B
ManufacturerAerco
CategoryBoiler
Fuel TypeNatural Gas
Input (BTU/h)399, 000
Thermal Efficiency95%
Turndown Ratio20:1
Operating Pressure (psi)160
Water Connections (inches)2
Vent Size (inches)4"

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