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Aerco GF-146-IR Installation, Operation, Maitenance Manual

Gas-fired water heater systems am series
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Installation, Operation, & Maintenance Manual (IOMM)
Selectable Natural Gas or Propane
Modulating and Condensing
Water Heater with Integrated
Buffer Tank
This supplement pertains to the following
AMR Integrated water heater models:
• AM 199R
• AM 250R
• AM 399R
• AM 500R
Applies to all units with serial number of
15000000 and above.
IMPORTANT NOTE!
This is a supplement and MUST
be used in conjunction with the AM
Series main user manual, GF-146,
when installing gas, air, and vent
piping and when operating, and
maintaining AMR Integrated units.
Latest Update: 07/22/2015
Page 1 of 52
PRI - 07/22/15
Integrated Rapid Recovery
PENDING
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
SUPPLEMENT TO
USER MANUAL GF-146
Gas-Fired Water Heater Systems
AM 399R/500R
GF-146-IR
OMM-0106_0A
GF-146-IR

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Summary of Contents for Aerco GF-146-IR

  • Page 1 AMR Integrated units. AM 399R/500R Latest Update: 07/22/2015 Page 1 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288 GF-146-IR...

  • Page 2: Supplement To Am Series User Manual Gf

    The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    CHAPTER 7: INSTALLATION – NATURAL GAS............. 32 CHAPTER 8: UNIT START-UP ..................33 CHAPTER 9: OPERATION ....................34 OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 4 APPENDIX A: CONTROL PANEL OPERATION CHART ........... 49 APPENDIX B: FACTORY MENU ..................50 STANDARD WARRANTY ....................51 STANDARD WARRANTY ....................52 Page 4 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...

  • Page 5: Amr Integrated Water Heaters

    The AMR is great for new construction to save space as well as for replacement of existing equipment; all sizes fit through a standard doorway. As with all AERCO boilers and water heaters, high efficiency and low emissions are hallmark features to provide the best performance for your system.

  • Page 6: Chapter 1: General Information

    CHAPTER 1: GENERAL INFORMATION 1.1 Warnings & Cautions In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers.
  • Page 7 • Incorrect use of this appliance • Inadequate or incorrect service • Inadequate or incorrect maintenance OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 7 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 8 AMR Integrated Water Heaters (Supplement to GF-146) CHAPTER 1: GENERAL INFORMATION OFF. OFF. Page 8 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...

  • Page 9: Emergency Shutdown

    248 CMR 5.08 (2). • Must be installed according to all local codes. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 52 GF-146-IR PRI - 07/22/15...

  • Page 10: Chapter 2: Functional Overview

    Figure 2-1: AMR Integrated water Heater with Front Covers (Left) and Without Covers and Open Panel (Right) (AM 399R / 500R Shown) Page 10 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 11: Intended Use And Functions

    2.3 AMR Integrated Series Functional Schematics 2.3.1 AM 199R / 250R Functional Schematic Figure 2-2: AM 199R / 250R Functional Schematic OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 11 of 52 GF-146-IR PRI - 07/22/15...

  • Page 12: Am 399R / 500R Functional Schematic

    CHAPTER 2: FUNCTIONAL OVERVIEW 2.3.2 AM 399R / 500R Functional Schematic Figure 2-3: AM 399R / 500R Functional Schematic Page 12 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 13: Chapter 3: Installation - Site

    When installed in a room with thin flooring, resonating noises may occur. Install noise reducing parts if required. Do not allow excessive dust to collect on the appliance. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 52 GF-146-IR PRI - 07/22/15...

  • Page 14: Water Heater Installation Location Factors

    • If flooding is possible, elevate the water heater sufficiently to prevent water from reaching the unit; Page 14 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288 GF-146-IR...

  • Page 15: Safety Concerns

    Split vent (two pipes) after 3 feet from the water heater 0 inches (0 mm) Water heater piping ¼ inch (7 mm) OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 15 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 16: Vent And Combustion Air Piping

    Page 16 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 17: Transporting The Water Heater

    4. Install the two factory supplied eyebolts “F” on the upper side of the unit and attach chains or straps to lifting ring/hook “G”. Figure 3-4: Removing the Unit from Wood Pallet (Lifting) OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 17 of 52 GF-146-IR PRI - 07/22/15...

  • Page 18: Amr Integrated Supply And Return Piping Dimensions

    • Models 399 / 500 = 4” Gas Connection 1” Condensate Hose Figure 3-6: AMR Integrated - Installation Connection Dimensions Page 18 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288 GF-146-IR...

  • Page 19: Chapter 4: Installation - Piping

    18” of the ground, and not be combined with any other piping all the way to the point of discharge into a drain. Provide piping that is the same size as the safety relief valve outlet. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 20: Expansion Tank And Makeup Water

    Install an expansion tank. Ensure the expansion tank is properly sized for the boiler volume and the system volume, temperature and pressure. See figures 4-5 and 4-7 for suggested tank location. Page 20 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 21: Recirculator Heating Pump Sizing And Installation

    Figure 4-2: AMR Integrated Series Water Side Head Pressure Loss Graph 4.5.2 Recirculation Pump Selection Table 4-1 shows a selection of recirculation pumps available from AERCO specified for each model and for use with normal and hard water supplies. Table 4-1: Recommended AMR Integrated Recirculation Pumps...

  • Page 22: Recirculator Pump Mechanical Installation

    4) If pump current draw is greater than 2.5A, a pump relay must be installed. This is included with the larger pumps from AERCO. Page 22 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 23: Domestic Hot Water System Piping With Direct Water Heater

    An anti-scald mixing valve is field supplied and is mandatory on the domestic hot water outlet of the water heater. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 23 of 52 GF-146-IR PRI - 07/22/15...

  • Page 24: Scalding

    Figure 4-6: Approximate Time / Temperature Relationships for Scalding Page 24 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 25 AMR Integrated Water Heaters (Supplement to GF-146) CHAPTER 5: INSTALLATION – PIPING Figure 4-7: AMR Integrated - Multi-Unit Installation Piping Example OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 25 of 52 GF-146-IR PRI - 07/22/15...

  • Page 26: Condensate Disposal

    B = Condensate Neutralizer Tank C = Condensate Drain Outlet D = Tank Cover Figure 4-8: Condensate Neutralizer Tank Page 26 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288 GF-146-IR...
  • Page 27 The pump should have an overflow switch to prevent property damage from condensate spillage. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 28: Chapter 5: Installation - Electrical

    To connect the electrical line voltage power supply cable, refer to Figure 5-1. Figure 5-1: Line Voltage Connection Figure 5-2: AMR Integrated Electrical Junction Box Connections Page 28 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 29: Connecting Units In Cascade

    Figure 5-4. A maximum of eight heaters can be connected in a cascade. Refer to the AERCO Cascade Sequencer user manual (GF-146-CS) for information on how to set up and use a cascade system using AM water heaters.

  • Page 30: Vdc Input Connections - 500R Model (Option For 399R)

    This MODBUS interface can be connected to drive the unit from a building management device. Refer to the AM Series MODBUS User Manual (GF-146-MB), which is available from AERCO technical support and the AERCO website (www.aerco.com).

  • Page 31: Chapter 6: Installation - Venting And Combustion Air Piping

    AM Series user manual, GF-146, pertaining to Chapter 6 to prevent a dangerous situation, harm to persons, and damage to equipment. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 31 of 52 GF-146-IR PRI - 07/22/15...

  • Page 32: Chapter 7: Installation - Natural Gas

    AM Series user manual, GF-146, pertaining to Chapter 7 to prevent a dangerous situation, harm to persons, and damage to equipment. Page 32 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 33: Chapter 8: Unit Start-Up

    AM Series user manual, GF-146, pertaining to Chapter 8 to prevent a dangerous situation, harm to persons, and damage to equipment. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 33 of 52 GF-146-IR PRI - 07/22/15...

  • Page 34: Chapter 9: Operation

    AM Series user manual, GF-146, pertaining to Chapter 9 to prevent a dangerous situation, harm to persons, and damage to equipment. Page 34 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR...

  • Page 35: Chapter 10: Maintenance

    AERCO technical support for information about repair or replacement of any parts or components. See Chapter 12 for a diagram and parts list of all AMR option spare parts.

  • Page 36: Buffer Tank Anode Rods

    20% to 3/5” (0.60”) diameter or less. Figure 10-14 shows a comparison of an old anode needing replacement, and a new anode. Contact AERCO Technical Support for replacement anodes. Page 36 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR...

  • Page 37: Chapter 11: Technical Data

    216 / 428 312 / 607 323 / 623 Recovery Rating (100°F rise) Gal/hr DHW delivery (75°F rise) 10.1 12.7 OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...

  • Page 38: Chapter 12: Spare Parts Drawings & Lists

    CHAPTER 12: SPARE PARTS DRAWINGS & LISTS 12.1 AMR Integrated Spare Parts Drawings Figure 12-1: 199R-250R Spare Parts Drawing (1 of 2) Page 38 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR...
  • Page 39 AMR Integrated Water Heaters (Supplement to GF-146) CHAPTER 12 – SPARE PARTS Figure 12-2: AMR Integrated General Assembly Parts drawing (2 of 2) OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 52 GF-146-IR PRI - 07/22/15...
  • Page 40 AMR Integrated Water Heaters (Supplement to GF-146) CHAPTER 12 – SPARE PARTS Figure 12-3: 199R/250R/399R/500R Burner/Fan Spare Parts Drawing Page 40 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...

  • Page 41: 199R/250R Spare Parts List

    61405316 D.125 H.809 COLLECTOR-2 EXCHANGERS FLOAT D40X16X8,6 62111052 D.125 H.809 COLLECTOR-2 EXCHANGERS 61405316 61405348 CONICAL PLUG TAB D.29.2-32,7 OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 42 60504206 60701023 GASKET KERASIL 325R SQ 38X17X2 62632007 GRP SPARK DETECTION SCREW SELFTAPPING 4X10 TC S-TT UNI-8112 60801080 Page 42 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...
  • Page 43 BOILER FAN 135 KW 115V 61901036 2 GASKETS KIT DN65 60701014 62632018 GRP GAS AND BURNER 12/15 LAPS OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 43 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 44 AMR Integrated Water Heaters (Supplement to GF-146) CHAPTER 12 – SPARE PARTS Figure 12-4: 399R-500R Spare Parts Drawing (1 of 2) Page 44 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR...
  • Page 45 See Figure 12-3 for the burner assembly part drawings, as the parts and item numbers are identical for all models of AM series units. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 45 of 52 GF-146-IR PRI - 07/22/15...
  • Page 46 61405348 CONICAL PLUG TAB D.29.2-32,7 62651066 CONDENSATE BLOCKED DRAIN SWITCH 60801106 SCREW 6X25 GALVANIZED 62111051 MAGNETIC SENSOR D5,8X38 Page 46 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...
  • Page 47 60504266 MASTER GAS CABLE UL 885 60406137 SHAPED BRACKET 67X54X36 60702083 OR RING 3137 EPDM 2,62 X 34,60 OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 47 of 52 GF-146-IR PRI - 07/22/15 Ph.: 800-526-0288...
  • Page 48 61901036 BOILER FAN 135 KW 115V 60701014 2 GASKETS KIT DN65 62632018 GRP GAS AND BURNER 12/15 LAPS Page 48 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR Ph.: 800-526-0288...

  • Page 49: Appendix A: Control Panel Operation Chart

    AM Series user manual, GF-146, pertaining to Appendix A to prevent a dangerous situation, harm to persons, and damage to equipment. OMM-0106_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 52 GF-146-IR Ph.: 800-526-0288...

  • Page 50: Appendix B: Factory Menu

    AM Series user manual, GF-146, pertaining to Appendix B to prevent a dangerous situation, harm to persons, and damage to equipment. Page 50 of 52 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0106_0A PRI - 07/22/15 GF-146-IR...

  • Page 51: Standard Warranty

    An Officer of AERCO must do any modifications to this warranty in writing. AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES.

  • Page 52: Standard Warranty

    AERCO shall accept no responsibility if such item has been improperly installed, operated, or maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the item. The use of replacement parts not manufactured or sold by AERCO will void any warranty, express or limited.

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