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Thermal Solutions AMP 400 - User Manual

Thermal Solutions AMP 400
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PN: 110820-05 Rev. 2, 4/23
Thermal Solutions Products, LLC www.thermalsolutions.com
Phone: 717-239-7642 1175 Manheim Pike, Lancaster, PA 17601 orders@thermalsolutions.com
Boiler Models
AMP 400
AMP 500
AMP 650
AMP 800
AMP 1000L
Model: Serial Number:
Installation Date: System Type:
Heating Contractor: Phone/Email:
Address:
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
399-1000 MBH Hot Water Boiler Indoor/Outdoor
WARNING WARNING
WARNING: If the informaon in these instrucons
is not followed exactly, a re or explosion may
result causing property damage, personal injury
or death.
DANGER DANGER
Do not store or use gasoline or other ammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not
use any phone in your building.
Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instrucons.
If you cannot reach your gas supplier, call
the re department.
Installaon and service must be performed by
a qualified installer, service agency or the gas
supplier.

Table of Contents

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Thermal Solutions AMP 400 Specifications

General IconGeneral
BrandThermal Solutions
ModelAMP 400
CategoryBoiler
LanguageEnglish

Summary

Pre-Installation Safety and Compliance

General Pre-Installation Requirements

Installation Compliance and Clearances

Adherence to codes and minimum clearances for installation.

Combustion and Ventilation Air

Requirements for adequate combustion and ventilation air supply.

Mounting and Installation Environment

Clearances and Installation Types

Serviceability Clearances

Required clearances for servicing the appliance.

Venting General Guidelines

General Venting Requirements

Basic rules for installing the vent system.

Field Venting Installation and Sizing

Field Installation Procedures

Steps for installing vent and combustion air piping.

Venting Options and Air Supply

Venting Termination Guidelines

General Termination Requirements

Rules for vent and air intake termination placement.

Vent Terminal Clearances

Clearance Requirements

Diagram illustrating required spacing around vent terminals.

Direct Vent Terminal Clearances

Clearance Table (Direct Vent)

Specific clearance requirements for direct vent terminals.

Other Vent Terminal Clearances

Clearance Table (Non-Direct Vent)

Clearance requirements for non-direct vent systems.

Vent and Combustion Air Terminations

Termination Installation Details

Procedures for installing vent and air intake terminations.

Multiple Appliance Venting

Multiple Appliance Termination Rules

Guidelines for venting multiple appliances together.

Polypropylene Venting and Room Air

Polypropylene Venting Installation

Guidelines for installing polypropylene vent pipe.

Air Supply and Appliance Venting

Air Supply Requirements for Large Inputs

Air needs for appliances with high total input.

Category IV Venting Requirements

Specific venting system requirements for Category IV appliances.

Massachusetts Venting Requirements

CO Detector and Signage Rules

Specific requirements for MA installations including CO detectors.

Condensate Disposal System

Condensate Trap Assembly

Description and diagram of the condensate trap.

Condensate Neutralization and Pumping

Hydronic Piping Guidelines

Primary;Secondary Piping Configuration

Recommended piping setup for optimal performance.

Relief Valve and Piping Components

Relief Valve Package Installation

Instructions for installing the pressure relief valve assembly.

Water Quality Requirements

Water Quality Parameters

Table of required water quality standards for system.

System Water Chemistry and Inhibitors

Oxygen Contamination Causes and Prevention

Methods to prevent oxygen contamination in the system.

Heat Exchanger Performance and Head Loss

Temperature Rise and Flow Rate Data

Table relating temperature rise to flow rate and head loss.

Gas Piping Installation

Gas Piping Guidelines and Requirements

Conforming to codes and proper sizing for gas piping.

Gas Pressure Switches and Inlet Pressures

Gas Pressure Switch Operation

Function, tripping, and reset of gas pressure switches.

Electrical Installation Requirements

General Electrical Safety and Codes

Compliance with electrical codes and safety precautions.

Appliance Wiring and Pump Connections

Low Voltage and High Voltage Wiring

Connecting control PCBs and field wiring.

Low Voltage Control Connections

Low Voltage PCB Terminal Guide

Diagram illustrating terminals on the low voltage PCB.

Boiler Wiring Schematic

Complete Wire Schematic Diagram

Detailed schematic showing all electrical wiring connections.

Boiler Wire Diagram

Electrical System Wiring Details

System Start-up Procedures

Pre-Start System Checks

Verifying installation and supplies before initial operation.

Initial Appliance Operation

Operating Instructions

Step-by-step guide for starting the appliance.

Combustion Air and Fuel Adjustment

High Fire Adjustment Procedure

Procedure for adjusting O2/CO2 levels at high fire.

Combustion Tuning and Gas Conversion

Low Fire Adjustment and Emissions

Adjusting O2/CO2 at low fire and checking emissions.

System Checks and Safety Device Testing

Safety Device Test Procedures

Methods for testing all safety controls and devices.

Service and Maintenance Safety Information

General and Monthly Maintenance

Igniter and Ionization Electrode Service

Burner and Combustion Chamber Service

Post-Shutdown Procedures and Troubleshooting

Limited Warranty Information

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