Aerco esteem User Manual
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Aerco esteem User Manual

Natural gas or propane gas modulating & condensing hot water boiler
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GF-135
OMM-0089_0A
Installation, Operation & Maintenance Manual (IOMM)
USER MANUAL
Natural Gas or Propane Gas
Modulating & Condensing Hot
Water Boiler:
Installation, Operation and Maintenance
GAS FIRED BOILER
06/19/2014
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 1 of 188
OMM-0089_0A
Ph.: 800-526-0288
MC1 06/19/14

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  • Page 1 USER MANUAL Natural Gas or Propane Gas Modulating & Condensing Hot Water Boiler: Installation, Operation and Maintenance GAS FIRED BOILER 06/19/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 2 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

    5.8.1 Diaphragm Expansion Tank ........................34 5.8.2 Closed-Type Expansion Tank ........................34 5.9 CIRCULATOR ..............................34 5.10 SIZING PRIMARY PIPING ..........................34 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 4 10.7 HEATING EZ SETUP ..........................71 10.7.1 Select CH Demand (Default: Switch & Outdoor Reset) ................71 10.7.2 CH1 Setpoint (Default: 180°F [82°C]) ......................72 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 5 12.3 OPERATING INSTRUCTIONS (READ BEFORE OPERATING BOILER) ..............91 12.3.1 Troubleshooting Start-Up Problems ......................93 12.4 INSPECTION OF THE ESTEEM BOILER AND SYSTEM ..................93 12.4.1 Boiler Piping inspection ..........................93 12.4.2 Vent Piping and Combustion Air Piping inspection .................. 93 AERCO International, Inc.
  • Page 6 18.3 CH and DHW SETTINGS MENU ........................ 121 18.3.1 Heating Operation (Default: Enabled) ....................121 18.3.2 Demand Type (Default: Switch & Outdoor Reset) .................. 122 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 7 18.7.5 Cascade Installation – Line Voltage Wiring Connections ................ 150 18.8 CASCADE AUTODETECTION MENU ...................... 151 18.8.1 Cascade Operation – Lockouts ....................... 151 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 7 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 8 18.10.4 SYS CH2 Parameter ........................173 APENNDIX A: PART AND DIMENSIONAL DRAWINGS ............... 175 APENNDIX B: CIRCULATOR PRESSURE LOSS CHARTS ..............183 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 9: Chapter 1: Safety Precautions

    • High electrical voltages are used in this equipment, therefore the cover on the unit’s power box must be installed at all times, except during maintenance and servicing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 10: Emergency Shutdown

    AERCO International. 1.2 EMERGENCY SHUTDOWN Turn the service switch on the Esteem 399 Low NOx control panel to “OFF” AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 11: Prolonged Shutdown

    Chapter 12 of this manual be performed, to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream from the unit.
  • Page 12 248 CMR 5.08(2)(a)1 through 4. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 13 [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 13 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 14 Esteem 399 Low NOx Boiler Chapter 1 Installation, Operation & Maintenance Manual Safety Precautions OMM-0089_0A (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 15: Chapter 2: Installation

    Ensure the boiler location allows the combustion air/vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends. Ensure the area chosen for the installation of the Esteem 399 is free of any combustible materials, gasoline and other flammable liquids.

  • Page 16: Boiler Replacement

    Installation OMM-0089_0A The Esteem 399 Low NOx should be installed in a location so that any water leaking from the boiler or piping connections or relief valve will not cause damage to the area surrounding the unit or any lower floors in the structure.

  • Page 17: Residential Garage Installations

    National Fuel Gas Code NFPA 54…Latest Edition. 2.5 RESIDENTIAL GARAGE INSTALLATIONS When installing the Esteem boiler in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken: • Mount the unit a minimum 18 inches [458 mm] above the floor level of the garage.
  • Page 18 GF-135 Esteem 399 Low NOx Boiler Chapter 2 Installation, Operation & Maintenance Manual Installation OMM-0089_0A (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 19: Chapter 3: Combustion Air And Venting

    COMBUSTION AIR AND VENTING 3.1 COMBUSTION AIR CONTAMINATION WARNING! If the Esteem boiler combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air...

  • Page 20: Areas Likely To Contain Contaminating Products

    12 inches from the floor of the space. For installations where the Esteem 399 Low NOx shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to all the equipment.

  • Page 21: Ventilation And Combustion Air Requirements - Category Iv

    This practice also promotes higher system efficiency. In installations where the Esteem boiler shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil), the space must be provided with adequate air openings to provide ventilation and combustion air to all the equipment.

  • Page 22: Indoor Combustion Air

    2 sq. in./1000 Btu/hr. of total input rating of all gas utilization equipment. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 23: Outdoor Combustion Air

    1 sq. in./3000 Btu/hr. of the total input rating of all equipment located in the enclosures, • Not less than the sum of the areas of all vent connectors in the space. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 23 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 24: Option 2: Two Permanent Openings To Outside

    1 sq. in./2000 Btu/hr. of total input rating of all equipment in the enclosure. See Figure 3-4. Figure 3-4: All Combustion Air from Outdoors Through Horizontal Ducts AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 25: Combination Of Indoor And Outdoor Combustion Air

    The Esteem boiler requires a Category IV venting system, which is designed for pressurized venting and condensate. The Esteem boiler is certified per ANSI Z21.13 as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance uses uncontaminated indoor or outdoor air (surrounding the appliance) for combustion.

  • Page 26: Removal Of An Existing Boiler From A Common Vent System

    3.8 REMOVAL OF AN EXISTING BOILER FROM A COMMON VENT SYSTEM WARNING! Do not install the esteem unit into a common vent with other gas or oil appliances. This may cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
  • Page 27 Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 27 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 28 Esteem 399 Low NOx Boiler Chapter 3 Installation, Operation & Maintenance Manual Comb. Air & Venting OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 29: Chapter 4: Unit Preparation

    4.2 WALL MOUNTING INSTALLATION The Esteem boiler should be wall mounted using the bracket provided with the boiler. The Esteem boiler is not designed for floor installation. If floor installation is required an optional floor stand is available through AERCO International.

  • Page 30: Stud Wall Installation

    • To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the Esteem 399 Low NOx boiler Wall Frame kit. • When using the wall frame to mount the boiler reference the kit installation instructions and ensure the frame is securely fastened to the wall.

  • Page 31: Chapter 5: Boiler Piping

    • The Esteem 399 Low NOx boiler is supplied with a 80 psi pressure relief valve and must be piped using the PRV connection as shown in Figure 5-1. •...

  • Page 32: Boiler Air Vent

    If the hygroscopic cap is not fully tightened, water may leak from the cap. Simply tighten the cap securely. 5.4 LOW WATER CUTOFF DEVICE • The Esteem boiler is equipped with a factory installed pressure switch type Low Water Cut Off device. • The minimum operating system pressure allowable with this device is 10 psig.

  • Page 33: Additional Limit Control

    5.8 EXPANSION TANK AND MAKEUP WATER Ensure the expansion tank is properly sized for the boiler volume 7 gallons [26 L] for Esteem 399 Low NOx boiler and the system volume and temperature. WARNING!

  • Page 34: Diaphragm Expansion Tank

    To wire the DHW circulator to the boiler control module, see Chapter 9, External Wiring. 5.12 SYSTEM PIPING - ZONE CIRCULATORS Connect the Esteem boiler to the system piping as shown in Figure 5-5 when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating as well as the boiler circulator.

  • Page 35: System Piping - Zone Valves

    5.13 SYSTEM PIPING - ZONE VALVES Connect the Esteem boiler to the system piping as shown in Figure 5-6 when zoning with zone valves. The primary / secondary piping ensures that the boiler loop has sufficient flow. 5.14 SYSTEM PIPING - THROUGH BOILER...

  • Page 36: System Piping-Special Applications

    The boiler system piping shown must be a “closed” system to avoid any contamination and potential failure of any components in the system. Figure 5-2: Piping Diagram Component Legend AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 37 (1” of pipe per 5 feet of piping) toward expansion tank. Figure 5-4: Near Boiler Piping – Closed Type Expansion Tank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 37 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 38 Smart. Figure 5-6: System Piping – Zoning with Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 39 Figure 5-8: System Piping – Single Zone System with Single System/Boiler Circulator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 39 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 40 Esteem 399 Low NOx Boiler Chapter 5 Installation, Operation & Maintenance Manual Boiler Piping OMM-0089_0A Figure 5-9: System Piping – Multiple Esteem Boiler Piping – Secondary/Primary AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 41 13 = High Temp. Limit Control 4 = Isolation Valve 8 = Air Separator 5 = Zone Valve 9 = Automatic Air Vent AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 41 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 42 Esteem 399 Low NOx Boiler Chapter 5 Installation, Operation & Maintenance Manual Boiler Piping OMM-0089_0A (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 43: Chapter 6: Installing Vent, Air Intakes, And Drain

    6.1 INSTALLING VENT AND COMBUSTION AIR INTAKE WARNING! The Esteem 399 Low NOx boiler must be vented and supplied with combustion air as instructed in the Esteem boiler Vent Application Guide (GF-125V or GF-125CV), which is included in the boiler installation envelope. Once installation is complete, inspect the vent and combustion air system thoroughly to ensure systems are airtight and comply with the instructions given in the venting guide and are within all requirements of applicable codes.
  • Page 44 The pump should be equipped with an overflow switch to prevent property damage from potential condensate spillage. The Esteem boiler will typically produce a condensate that is considered slightly acidic with a pH content below 3.0. Install a neutralizing filter if required by authority having jurisdiction.

  • Page 45: Chapter 7: Gas Piping

    2. Install a manual shutoff valve in the gas supply piping as shown in Figure 7-1. For Canadian installations the main shutoff valve must be tagged and identified by the installer. 3. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the Esteem boiler gas train as shown in Figure 7-1.

  • Page 46: Natural Gas

    7.2.1 Pipe Sizing - Natural Gas Refer to Table 7-1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated Esteem 399 Low NOx boiler input (divide by 1,000 to obtain cubic feet per hour).

  • Page 47: Natural Gas Supply Pressure Requirements

    NOTE The natural gas orifice for the Esteem 399 Low NOx boiler is 0.339” (8.6 mm). 7.3 PROPANE GAS 7.3.1 Pipe Sizing – Propane Gas Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator.

  • Page 48: Propane Gas Supply Pressure Requirements

    7-2. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage. NOTE The propane orifice required for the Esteem 399 Low NOx boiler is 0.264” (6.7 mm). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 49 (RED PLASTIC SLEEVE) INLET PRESSURE PORT Figure 7-2: Gas Valve and Component Locations (With Gas Valve Shown Separated From the Blower Assembly) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 49 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 50 GF-135 Esteem 399 Low NOx Boiler Chapter 7 Installation, Operation & Maintenance Manual Gas Piping OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 51: Chapter 8: Internal Wiring

    If original wiring as supplied with the unit must be replaced, use only Type T 90ºC wire or equivalent as a minimum. • The Esteem boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70—latest edition and / or the Canadian Electrical Code Part 1, CSA C22.1, Electrical Code.

  • Page 52: Line Voltage Fuses Location

    2.5A 32,33,34 CH1 Pump/Diverter Valve 8.0A 35,36,37 Power Supply 2.5A 38,39,40 Alarm Fuse Locations Figure 8-2: Line Voltage Fuse Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 53 Esteem 399 Low NOx Boiler Chapter 8 Installation, Operation & Maintenance Manual Internal Wiring OMM-0089_0A Figure 8-3: Esteem Boiler Internal Wiring Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 53 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 54 GF-135 Esteem 399 Low NOx Boiler Chapter 8 Installation, Operation & Maintenance Manual Internal Wiring OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 55: Chapter 9: External Wiring

    If local codes or conditions require an additional service switch, the installer must install a fused disconnect for 15 amp (minimum) service switch. 06/04/13 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 55 of 158...

  • Page 56: Circulator Wiring

    2. Connect the CH circulator to the line voltage terminal strip on the wiring panel below the Esteem control module, as shown in Figure 8-3. The CH circulator is enabled during a CH 1 or CH 2 call. This circulator is used to supply heat to the central/space heating loop.

  • Page 57: Alarm Wiring

    OMM-0089_0A 9.4 ALARM WIRING The alarm contact closes whenever the Esteem is in a soft or hard lockout. This dry contact can be connected to an external monitoring system or other indicator to alert the operator that the Esteem is locked out.

  • Page 58: Outdoor Sensor Wiring

    Additional boiler limits (High Limit, LWCO, etc.) can be wired into either the Manual Reset Limit or Auto Reset Limit terminals of the Esteem. These limit connections will provide a “hard” lockout requiring a manual reset of the Esteem or a “soft” lockout in which the Esteem will automatically reset when the limit resets.

  • Page 59: Cascade Wiring

    The EZ-SETUP controller includes the ability to communicate with building management systems (BMS) through a Modbus interface. Consult Section 10, Basic Controller Operation, for more information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 59 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 60 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring OMM-0089_0A Figure 9-1: Multiple Zone Field Wiring Using Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 61 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring OMM-0089_0A Figure 9-2: Multiple Zone Field Wiring Using Zone Circulators 06/04/13 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 61 of 158...
  • Page 62 Installation, Operation & Maintenance Manual External Wiring OMM-0089_0A Figure 9-3: Esteem 399 Wiring - Zoning with Zone Circulators Figure 9-4: Esteem 399 Wiring - Zoning with Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 63 External Wiring OMM-0089_0A Figure 9-5: Esteem 399 Wiring – Multiple Zone Valve with Single System/Boiler Circulator Figure 9-6: Esteem 399 Wiring – Single Zone System with Single System/Boiler Circulation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 64 GF-135 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 65: Chapter 10: Basic Ez-Set Controller Operation

    10.1 EZ-SET CONTROLLER INTRODUCTION The Esteem Boiler Management System is designed to be flexible yet easy to use. controller monitors and controls the Esteem boiler to operate as efficiently as possible. The controller monitors the boiler supply, return and flue gas temperatures and operates the igniter, gas valve and blower and uses this information to modulate the boiler’s firing rate to maintain the...

  • Page 66: Controller Navigation

    Home Screen when selected. The Previous Screen ( icon at the bottom of each screen returns to the previous screen when selected. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 67 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual EZ-SET Controller OMM-0089_0A Figure 10-3: Controller Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 67 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 68: Home Screen

    The Home Screen presents status information in a very user friendly way so that the current state of the boiler can be quickly accessed. The status line displays the current operating state of the Esteem boiler. See Table 10-1, for a list of all status line messages.
  • Page 69 External Demand An external modulation call has been received. The Esteem is responding to a call from the master Esteem boiler in a Slave Operation cascade system. The burner or circulators have manually been enabled in the Installer Manual Operation Menu.

  • Page 70: Main Menu

    Menus can be entered by highlighting the desired icon and pressing the OK button. Figure 10-5: EZ-SETUP Controller Main Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 71: Ez Setup

    The EZ Setup menus provide a simple way to quickly customize the controller for each installation. EZ Setup prompts the user to make selections which allows the Esteem 399 boiler to be setup very quickly without searching through long lists of settings and manually making adjustments.

  • Page 72: Ch1 Setpoint (Default: 180°F [82°C])

    OK button to store the setting. Figure 10-8: Select CH1 Reset Curve Menu (Same as CH2 Reset Curve Menu) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 73: Set Warm Weather Shutdown Temperature (Default: Off)

    Warm Weather Shutdown prompts the installer to enter an optional outdoor temperature at which to disable the central heating function. The Esteem will continue to respond to a domestic hot water call or a 0-10VModulation Signal when the outdoor temperature exceeds the Warm Weather Shutdown Temperature setting.

  • Page 74: Domestic Hot Water Ez Setup

    • Sensor: This option requires the use of Indirect Water Heater Sensor 69107. The Esteem will monitor the DHW storage temperature and generate a domestic hot water call when the temperature drops below the DHW Storage Setpoint by 6ºF [3ºC].

  • Page 75: Dhw Storage Setpoint (Default: 140°F [60°C])

    Press the LEFT or RIGHT buttons to adjust the DHW Priority Timeout then press the OK button to store the setting. Figure 10-13: DHW Priority Timeout Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 75 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 76: Ez Setup Reset

    Press the UP or DOWN buttons to select then press the OK button to store the setting. Figure 10-15: Display EZ Setup (Temperature Units Select) Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 77: Ch/Dhw Operation

    CH / DHW Operation provides a simple way to disable either the central heating or domestic hot water functions of the Esteem. Operation can be enabled and disabled by selecting the central heating or domestic hot water icon then pressing the OK button to toggle between enabled and disabled.
  • Page 78 Displays the number of central heating ignitions since the unit CH Ignitions was installed. This counter increases in increments of twenty. Displays the number of hours the Esteem has run for a central CH Runtime heating call since the unit was installed.

  • Page 79: Boiler Information Logging

    • Boiler Flue Temperature • Outdoor Temperature • DHW Storage Temperature • External Modulation Signal Figure 10-18: Boiler Information Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 79 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 80: Lockout History

    Boiler Supply Temperature • Boiler Return Temperature • Boiler Flue Temperature • Outdoor Temperature • System Temperature Figure 10-20: Lockout Details Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 81 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual EZ-SET Controller OMM-0089_0A Figure 10-21: Lockout Screen Information AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 81 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 82 Return > Supply Return temperature is higher than supply temperature. External Limit Open An external manual reset limit has opened. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 83 Communication with other boilers has been lost. Communication between boiler display and control module Controller Bus Error has been lost. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 83 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 84 GF-135 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual Basic Controller OMM-0089_0A (This page intentionally blank) Page 84 of 158 06/04/13 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...

  • Page 85: Chapter 11: Start-Up Preparation

    Maintain the boiler water pH between 6.0 and 8.0. Check using litmus paper or contact a water treatment company for a chemical analysis. If the pH does not meet this requirement, do not operate the Esteem or leave the unit filled until the condition is corrected.

  • Page 86: Check And Test Antifreeze

    Determine the antifreeze fluid quantity using the system water content volume and following the antifreeze manufacturer instructions. The water volume of the Esteem 399 Low NOx boiler is approximately 7 gallons [26 L]. Remember to include the volume of the expansion tank.

  • Page 87: Cleaning Of New Boiler/System

    11.3 CHECK LOW WATER CUT-OFF DEVICE The Esteem boiler is provided with a factory installed LWCO device that measures system pressure of more than 10 psi. Remove the front jacket panel and check for continuity across the low water cut-off device wire terminals.

  • Page 88: Check For Gas Leaks

    Use an isolation relay to prevent voltage from the external circuit entering the Esteem control panel. 6. Reconnect the external thermostat wires to the low voltage terminal strip. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 89: Inspection Of Condensate Drain Assembly

    Failure to ensure trap is filled with water could result in severe personal injury or death. 3. Re-Install the plug into the condensate drain assembly. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 90 GF-135 Esteem 399 Low NOx Boiler Chapter 11 Installation, Operation & Maintenance Manual Start-Up Preparation OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 91: Chapter 12: Start-Up Procedures

    Chapter 18 for initial installation and in-depth operation of the Boiler Management System. • Verify the Esteem 399 and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler (see Appendix A).
  • Page 92 TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to its lowest setting. 2. Turn off switch on Esteem control panel, and any downstream electrical service switches. 3. Close the external manual gas valve clock-wise to OFF position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 93: Troubleshooting Start-Up Problems

    Start-Up Procedures OMM-0089_0A 12.3.1 Troubleshooting Start-Up Problems If the Esteem boiler does not start correctly, follow the procedures below to troubleshoot the problem. Troubleshooting Start-Up Problems 1. Check for loose electrical connections, blown fuses, (on control module and in terminals) or an open service switch.

  • Page 94: Omm-0089_0A

    Press the RIGHT button to highlight the Manual Operation icon then press the OK button. OK Button Installer Button Figure 12-1: Installer Button (L) & Manual Operation Menu (R) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 95 The combustion levels should be measured at high firing rate. If the combustion levels are outside the range given in Table 12-1 for the firing rate, shut the boiler down and contact AERCO Technical Support. Failure to comply with this requirement could result in severe personal injury, death, or substantial property damage.

  • Page 96: Measure And Verify Input Rating - Natural Gas Only

    Section 12.3.4 of this chapter. 2. Operate the unit for approximately 10 minutes. 3. Turn off all gas appliances within the building, except the Esteem boiler. 4. At the gas meter, record the time required to use one cubic foot of gas.

  • Page 97: High Temperature Limit Testing

    15. Press the DOWN button twice to highlight the Home Screen icon then press the OK button. 16. Press the OK button to reset the lockout and return the unit to service. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 98 GF-135 Esteem 399 Low NOx Boiler Chapter 12 Installation, Operation & Maintenance Manual Start-Up Procedures OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 99: Chapter 13: Outdoor Reset Control

    This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr. or greater. • This boiler is equipped with a tankless coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 100: Outdoor Temperature Sensor Installation

    5. Avoid mounting the enclosure in areas subjected to excessive moisture. 6. Once an area on the exterior wall has been determined, follow the manufacturer’s mounting instructions included with the outdoor sensor. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 101: Outdoor Temperature Sensor Wiring

    1. Cut a small slit in the seal gasket and route 18 AWG 2-wire cable or similar wire cable through the seal gasket into the enclosure. 2. Route the sensor wire back to the Esteem boiler, ensuring the wires are not run parallel to telephone or power cables.
  • Page 102 Esteem 399 Low NOx Boiler Chapter 13 Installation, Operation & Maintenance Manual Outdoor Reset Control OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 103: Chapter 14: External Modulating Control

    This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr. or greater. • This boiler is equipped with a tankless coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 103 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 104 Antilegionella Function Disabled Boiler Settings Factory Default EZ Setup Reset Installer Reset  Lockout Temperature 210°F [99°C]  Modbus Address 0=BCST AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 105: Chapter 15: Check-Out Procedures

    Measured the rate of input on Natural Gas as outlined in Section 12.3.5. Completed high temperature limit testing per Section 12.4.6. Checked the incoming gas pressure to the Esteem to ensure a minimum pressure of 5” W.C. during flow conditions to all gas appliances and a maximum pressure of 13”w.c during non-flow conditions for Natural and Propane.
  • Page 106 Esteem 399 Low NOx Boiler Chapter 15 Installation, Operation & Maintenance Manual Check Out Procedures OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 107: Chapter 16: Maintenance Schedule

    Check vent piping. • Check combustion air inlet piping. • Check the pressure relief valve. • Check the condensate drain system. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 107 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 108 Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the Esteem boiler or in system components, resulting in severe personal injury, death or substantial property damage.

  • Page 109: Chapter 17: Maintenance Procedures

    17.2 SURROUNDING AREA INSPECTION Verify that the area surrounding the Esteem boiler is free of combustible / flammable materials or flammable vapors or liquids. Remove immediately if found. Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed section 3.2 of Chapter 3 of this manual.

  • Page 110: System Piping Inspection

    Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired can result in severe personal injury or death. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 111: Boiler System Inspection

    The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 111 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 112: Ignition Electrode Inspection

    Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range. • Complete the checkout procedures as referenced in this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 113: Burner Flame Inspection And Troubleshooting

    Check gas piping for any leaks as outlined in Section 11.4 and Section 12.3.3 and repair if necessary. Place the unit back into service. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 113 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 114: Flame Signal Inspection

    3. If the flue gas temperature is more than 54°F [30°C] above the supply water temperature, shut the boiler down and follow the heat exchanger cleaning procedure described in the next section. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 115: Heat Exchanger Cleaning

    Remind the owner of the importance to call a licensed contractor should the unit or system exhibit any unusual behavior. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 115 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 116: Handling Previously Fired Combustion Chamber Insulation

    Discard used insulation in an air tight plastic bag. NIOSH Stated First Aid: • Eye/Skin: Immediately irrigate • Breathing: Clean fresh air AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 117: Chapter 18: Ez-Setup Controller Operation And Settings

    When the EZ-SETUP controller is first turned on, the HOME screen is displayed (Figure 18-1). Figure 18-1: HOME Screen Display In order for the technician installing the Esteem boiler to properly configure and use the controller, an access code must first be entered.

  • Page 118: Using The Installer Menu

    18.2 USING THE INSTALLER MENU After entering INSTALLER access code, the INSTALLER menu is displayed (Figure 18-4). Figure 18-4: INSTALLER Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 119: Manual Operation Menu

    Selections in the Manual operation Menu enable the burner and circulators to be manually enabled for testing. See Section 18.9. The INSTALLER Menu structure is diagrammed on the next page (Figure 18-5). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 119 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 120 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-5: INSTALLER Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 121: Ch And Dhw Settings Menu

    Disabled: The boiler will NOT respond to a central heating call. The heating operation disabled icon is displayed on the home screen when central heating operation has been disabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 121 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 122: Demand Type (Default: Switch & Outdoor Reset)

    0-10V Modulation Signal: This option allows the boiler firing rate to be controlled by an external control system with a 0-10 VDC signal. ======================================================================= AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 123: Omm-0089_0A

    Setpoint option is chosen in CH Demand. Press the LEFT or RIGHT buttons to adjust the CH1 Maximum Setpoint then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 123 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 124: Ch1 Minimum Setpoint (Default: 120°F [49°C])

    Setpoint option is chosen in CH Demand. Press the LEFT or RIGHT buttons to adjust the Reset Curve Warmest Day then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 125: Ch2 Circuit (Default: Enabled)

    CH Demand. Press the LEFT or RIGHT buttons to adjust the CH2 Minimum Setpoint then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 125 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 126: Warm Weather Shutdown (Default: Off)

    Warm Weather Shutdown allows the installer to enter an optional out-door temperature at which to disable the central heating function. The Esteem will continue to respond to a domestic hot water call or a 0-10V Modulation Signal when the outdoor temperature exceeds the Warm Weather Shutdown Temperature setting.

  • Page 127: Ch Post Pump Time (Default: 1 Minute)

    Press the LEFT or RIGHT buttons to adjust the CH Post Pump Time then press the OK button to store the setting. ======================================================================= AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 127 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 128: Freeze Protection (Default: Enabled)

    Subjecting the boiler to freezing conditions could lead to freezing of the condensate, and the possibility of causing serious injury or death. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 129: Frost Protection Setpoint (Default: -22°F [-30°C])

    CH setpoint will return to the highest CH1 or CH2setpoint. Press the LEFT or RIGHT buttons to adjust the Parallel Shift Value then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 129 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 130: Ch Call Blocking (Default: 1 Minute)

    UP or DOWN buttons to select the desired System Pump operation then press the OK button to store the setting. The System Pump options are: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 131 CH2 – The system pump will only be enabled for a CH2 central heating call. The CH(1) pump will only be enabled for a CH1 central heating call. Figure 18-25 illustrates a system zoned with zone circulators requiring this setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 131 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 132 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-23: System Piping with System Pump = CH1/CH2/DHW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 133 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-24: System Piping with System Pump = CH1/CH2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 133 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 134 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-25: System Piping with System Pump = CH2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 135: Dhw Settings Menu

    Press the UP or DOWN buttons to scroll through additional CH Settings. See the following for a description of each of these settings. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 135 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 136: Dhw Operation (Default: Enabled)

    Disabled: The boiler will not respond to a domestic hot water call. The domestic hot water operation disabled icon is displayed on the home screen when domestic hot water operation has been disabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 137: Demand Type (Default: Switch)

    Sensor: This option requires the use of Indirect Water Heater Sensor 69107, which is included with every Esteem boiler. The Esteem will monitor the DHW storage temperature and generate a domestic hot water call when the temperature drops below the DHW Storage Setpoint - DHW On Differential.

  • Page 138: Dhw On Differential (Default: 6°F [3°C])

    Failure to comply could result in severe personal injury, death, or substantial property damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 139: Dhw Storage Adder (Default: 46°F [25°C])

    Press the LEFT or RIGHT buttons to adjust the DHW Post Pump Time then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 139 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 140: Dhw Priority Timeout (Default: Off)

    DHW priority is set to disabled. The use of a mixing device on the lower temperature zones may be required to protect the lower temperature zones from damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 141: Dhw Call Blocking (Default: 0 Minutes)

    Press the LEFT or RIGHT buttons to adjust the DHW To CH Call Blocking time then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 141 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 142: Antilegionella Function (Default: Disabled)

    DHW demand. The use of an Indirect Water Heater Sensor ensures that the domestic hot water is heated to 140°f [60°c] at least once per week. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 143: Boiler Settings Menu

    102°F [39°C]. • 210°F [99°C]: A High Boiler Temperature lockout (E3) will occur when the boiler temperature reaches 210°F [99°C]. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 143 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 144: Modbus Address (Default: 0=Bcst)

    Reset All Settings allows the installer to reset all CH, DHW, and Cascade settings back to the original factory defaults. Follow the onscreen instructions to reset all settings back to the original factory defaults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 145: Boiler Settings

    CH or DHW Boilers Automatic Rotation Enabled  CH Proportional Gain  CH Integral Gain  DHW Proportional Gain  DHW Integral Gain AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 145 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 146: Cascade Menu And Operating Information

    OMM-0089_0A 18.7 CASCADE MENU AND OPERATING INFORMATION The Esteem Boiler Management System includes a Cascade function which allows multiple boilers to operate together without the need for an external controller. One boiler will be selected as the Master and will be wired to accept all the low voltage control signals. The other boilers will be designated as Slaves and will only have a communication cable connecting them to the other boilers in the Cascade System.
  • Page 147 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-43: Cascade Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 147 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 148: Cascade Installation - System Piping

    15 and 16 of the Master boiler. a) Direct Immersion b) Dry Well Figure 18-44: System Sensor Internal Installation Types AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 149: Cascade Installation - Cascade Communication Cable

    System, not just the Cascade Master. • Modbus Wiring: A building management system (BMS) connection must be wired into the Cascade Master. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 149 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 150: Cascade Installation - Line Voltage Wiring Connections

    The total combined amp draw of the CH (1), DHW, and auxiliary Boiler circulators must not exceed 3 amps at any time for the Esteem boiler. Use an isolation relay to lower the total combined amp draw if exceeding these limits.

  • Page 151: Cascade Autodetection Menu

    Master boiler. The Master boiler Lockout Screen will also indicate which boiler in the Cascade System is locked out. Figure 18-46: Cascade Lockout Displays AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 151 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 152 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-47: Standard Primary Secondary Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 153 Controller Operation OMM-0089_0A NOTE Reference Figure 18-47 on previous page for cascade piping. Figure 18-48: Standard Primary Secondary Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 153 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 154 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-49: Standard Reverse Return Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 155 Controller Operation OMM-0089_0A NOTE Reference Figure 18-49 on previous page for cascade piping. Figure 18-50: Standard Reverse Return Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 155 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 156 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A Figure 18-51: Split Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 157 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A NOTE Reference Figure 18- 51 on previous page for cascade piping. Figure 18-52: Split Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 157 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 158: Cascade Information Menu

    Displays the total number of boilers in the Cascade System. Cascade Firing Rate Displays the current firing rate of the entire Cascade System. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 159: Cascade Settings Menu

    Cascade setting changes must be made on the cascade Master. Cascade auto detection must be performed after making any changes to a cascade Setting before the change will take effect. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 159 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 160: Stage Delay (Default: 60 Seconds)

    Figure 18-57: Minimum Firing Rate Menu Press the LEFT or RIGHT buttons to adjust the Minimum Firing Rate then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 161: Boiler Enabling Algorithm

    1 + 1 x 30% = 60% Once the first Esteem firing rate reaches 60%, the second Esteem can be enabled. Both will then fire at the minimum 30% firing rate so that the overall output from the Cascade System remains the same.

  • Page 162: Ch Or Dhw Boilers (Default: 0)

    All CH or DHW Boilers will respond to a domestic hot water call. It is important that the domestic load is capable of transferring all of the heat generated to prevent excessive boiler cycling. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 163: Automatic Rotation (Default: Enabled)

    Switch option is chosen in CH Demand or every 24 hours when a Constant option is chosen in CH Demand. • Disabled: The lead boiler is always the Master boiler followed by each Slave boiler AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 163 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 164: Ch Proportional Gain (Default: 7)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of CH Proportional Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 165: Ch Integral Gain (Default: 245)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of CH Integral Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 165 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 166: Dhw Proportional Gain (Default: 7)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of DHW Proportional Gain could lead to temperature fluctuations and erratic cascade operation. ======================================================================== AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 167: Dhw Integral Gain (Default: 245)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of DHW Integral Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 167 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 168: Modbus Address (Default: 0 = Bcst)

    LEFT or RIGHT buttons to change the Modbus Address then press the OK button to store the setting. Figure 18-65: DHW Integral Gain Menu ======================================================================== AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 169: Modbus Interface

    Value = Maximum Firing Rate %. This Maximum 513 (0x201) 0x06 LB:U8 register becomes active when 255is Firing Rate 0x10 written to register 512 (0x0200) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 169 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 170 Value = Firing Rate %. Firing Rate Value = °C. 776 (0x0308) 0x04 Boiler Setpoint LB:U8 Invalid Value = 32768 (0x8000). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 171: Manual Operation

    DHW circulator. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 171 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 172: Ch Ch1 Parameter

    Figure 18-69: Manual Operation Menu with DHW Selected NOTE The auxiliary Boiler circulator is also powered when the DHW circulator is manually enabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 188 OMM-0089_0A Ph.: 800-526-0288...

  • Page 173: Sys Ch2 Parameter

    Press the OK button again while the SYSCH2 icon is highlighted to shut down the System circulator. Figure 18-70: Manual Operation Menu with SYS CH2 Selected AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 173 of 188 OMM-0089_0A Ph.: 800-526-0288...
  • Page 174 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 175: Apenndix A: Part And Dimensional Drawings

    Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions OMM-0089_0A APENNDIX A: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 175 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 176 Side Jacket Panel (Left or Right) 37124 Top Jacket Panel 37125 Top Jacket Access Panel 33113 Wall Mounting Bracket with Hardware 38038 Combustion Air Deflector AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 177 LWCO Pressure Device 22123 Condensate Drain Assembly 22124 Boiler Piping - Return Assembly 22125 Boiler Piping - Supply Assembly 41035 Polypropylene Pan AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 177 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 178 43081 Venturi 58094 Igniter and Cable with Gasket 58028 Sight Glass Assembly (Glass, Gasket and Bracket) 22126 Gas Valve Piping AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 179 65171 Control Module 5A Fuse (Not Shown) 65172 Circulator 2.5A Fuses (Not Shown) 65173 In-Line Voltage 8A Fuse (Not Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 179 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 180 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions OMM-0089_0A Figure A-5: Esteem 399 – Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 181 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions OMM-0089_0A Figure A-6: Esteem 399 – Side View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 181 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 182 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions OMM-0089_0A (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 183: Apenndix B: Circulator Pressure Loss Charts

    Esteem 399 Low NOx Boiler Appendix B Installation, Operation & Maintenance Manual Pressure Loss Charts OMM-0089_0A APENNDIX B: CIRCULATOR PRESSURE LOSS CHARTS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 183 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 184 Installation, Operation & Maintenance Manual Pressure Loss Charts OMM-0089_0A Figure B-1: Esteem 399 – Grundfos Circulator Pressure Drop Comparison Chart Figure B-2: Esteem 399 – Tacos Circulator Pressure Drop Comparison Chart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 185 GF-135 Esteem 399 Low NOx Boiler Installation, Operation & Maintenance Manual OMM-0089_0A NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 185 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...
  • Page 186 Changed By 04/28/2014 Rev 97: Pre-Release Review Curtis Harvey 06/19/2014 Rev A: Released Curtis Harvey © AERCO International, Inc., 2013 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 188 OMM-0089_0A Ph.: 800-526-0288 MC1 06/19/14...

  • Page 187: General Installation

    STARTUP RECORD FOR ESTEEM 399 Low NOx BOILER Please complete one (1) form for each unit at the site and return to AERCO for warranty validation within 30 days of start-up. For your convenience, this information can be faxed to (845) 580-8090 or sent via US mail to: AERCO International, Inc., 100 Oritani Drive, Blauvelt, NY 10913.

  • Page 188: Boiler Installation

    Venting How many elbows are in the ducting? ____ Is the vent sealed with RTV? Is the vent pitched back toward the boiler (1/4" per ft. length) per the AERCO Venting Guide? Venting material used is: AL29-4C Other (please specify):...

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