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Aerco AM-R Series Installation And Maintenance Instructions Manual

Gas-fired condensing water heater
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AERCO INTERNATIONAL, Inc., 100 Oritani Dr., Blauvelt, NY 10913 USA
Installation and maintenance instructions
gas-fired condensing water heater series
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE HEATER
Instruction
AM - R
62403631 R03
No.
WARNING!!! This manual must only be
used by a qualified heating installer /
service technician. Read all instruc-
tions, including this manual, before
installing. Perform steps in the order
given. Failure to comply could result
in severe personal injury, death, or
substantial property damage.
Save this manual for future reference.
A
S
M
E

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  • Page 1 Instruction 62403631 R03 AERCO INTERNATIONAL, Inc., 100 Oritani Dr., Blauvelt, NY 10913 USA Installation and maintenance instructions gas-fired condensing water heater series AM - R WARNING!!! This manual must only be used by a qualified heating installer / service technician. Read all instruc- tions, including this manual, before installing.

  • Page 2: Safety Instructions

    SAFETY INSTRUCTIONS WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
  • Page 3 SAFETY INSTRUCTIONS...
  • Page 4 SAFETY INSTRUCTIONS AVERTISSMENT: Assurez vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort - Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inflammables à...
  • Page 5 SAFETY INSTRUCTIONS...
  • Page 6 SAFETY INSTRUCTIONS NOTICE! Local approval of the flue WARNING!!! WARNING!!! system and the condensate Flue gas/air connection to the public sewer Installer: Read all instructions, intake: You are only permitted system may be required. including this manual, before to operate this appliance with installing.
  • Page 7 SAFETY INSTRUCTIONS WARNING!!! WARNING!!! ATTENTION!!! En cas de When Only use the surchauffe ou si l’alimentation servicing heater, to avoid severe heater in the combinations and de gaz ne peut être coupée, burns, allow heater to cool with the accessories and spares ne pas couper ni débranch before performing maintenance.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SAFETY INSTRUCTIONS ...............................2 TABLE OF CONTENTS ................................8 1 - CODE REQUIREMENTS ..............................11 1.1 - Regulations and guidelines ............................11 2 - GENERAL INFORMATION ..............................13 2.1 - Key to symbols used ..............................13 2.2 - Manufactured by ..............................13 2.3 - Description of models: .............................13 2.4 - Accessories included ...............................13 3 - MAIN COMPONENTS ..............................14...
  • Page 9 TABLE OF CONTENTS 12.6.2 - PVC/CPVC air intake connection ......................53 12.6.3 - PVC/CPVC vent connection ........................53 12.7 - Stainless steel vent piping materials ........................54 12.7.1 - Stainless steel air intake connection ......................54 12.7.2 - Stainless steel vent connection ........................ 55 12.8 - Polypropylene vent piping materials ........................
  • Page 10 TABLE OF CONTENTS 16.1 - Check water pressure ............................84 16.2 - Overview ................................84 16.3 - Displays .................................84 16.4 - Start-up procedure ..............................84 16.5 - Supply water temperature adjustment ........................84 16.6 - Delays, alarms and protective actions ........................85 16.7 - Circulator pump protection .............................85 16.8 - Heater’s Freeze protection .............................85 16.9 - Display in energy saver mode ..........................85 16.10 - “Users’...

  • Page 11: Code Requirements

    1 - CODE REQUIREMENTS 1.1 - Regulations and guidelines - The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to: - the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and or CAN/ CSA B149.1, Natural Gas and Propane Installation Code.

  • Page 12: Commonwealth Of Massachusetts

    1 - CODE REQUIREMENTS 1.2- Commonwealth time of completion of installation, the system components; and owner shall have a period of thirty 2. A complete parts list for the venting of Massachusetts (30) days to comply with the above system design or venting system. requirements;...

  • Page 13: General Information

    2.2 - Manufactured CAUTION!!! Failure to symbols used observe this indication may compromise the smooth running of the appliance AERCO INTERNATIONAL., INC, WARNING!!! or cause serious damage 100 Oritani Drive, Blauvelt, Failure to to individuals, animals or NY 10913, USA follow these indications can property.

  • Page 14: Main Components

    3 - MAIN COMPONENTS 020021.01.004 1 - Air / gas mixing device 10 - Burner unit return connection 2 - Gas valve 11 - Support arrangement 3 - Air intake silencer 13 - Water pressure sensor (present on Burner 1 only) 4 - High limit temperature safety switch (UL 353 listed) 14 - Spark generator 5 - Burner unit supply temperature sensor (par.
  • Page 15 3 - MAIN COMPONENTS 020009.01.005_a 33 31 020021.01.005 19 - Burner surface 27 - Left ignition electrode 20 - Burner unit condesate discharge 28 - Right ignition electrode 21 - Detection electrode 30 - Gasket 22 - Thermal insulation 31 - Flapper valve 23 - Sight glass 32 - Flapper magnet 24 - Raccord fan-burner...
  • Page 16 3 - MAIN COMPONENTS 020021.01.001 1 - Leveling feet 16 - 885IF board (optional) 2 - Drain valve 17 - Flue exhaust connection 3 - Tank sensor well 18 - Electrical terminals 4 - Electronic anode 19 - Electrical control board 5 - 32 gal storage tank with 2”...
  • Page 17 3 - MAIN COMPONENTS 020021.01.002 26 - Top cover 27 - Main electrical switch 28 - Fan protection cover 29 - High limit flue gas temperature fuse (Red color connector) 30 - Flue gas temperature sensor (Blue color connector) (1006) 31 - Water Return connection 32 - Flue gas exhaust manifold 33 - Condensate blocked drain switch...
  • Page 18 3 - MAIN COMPONENTS 020021.01.003 34 - Gas connection 35 - P-T safety relief valve 36 - P-T gauge 37 - Condensate drain 38 - Plug (connection for field supplied safety relief valve) 39 - Hot water supply connection 40 - Cold water inlet connection 41 - DHW Circulator pump 42 - 3/4”...
  • Page 19 3 - MAIN COMPONENTS 18 19 18 19 020022.01.001 1 - Leveling feet 14 - Electrical cable passages 2 - Drain valve 15 - Air filter 3 - Tank sensor well 16 - 885IF board (optional) 4 - Electronic anode 17 - Flue exhaust connection 5 - 32 gal storage tank with 2”...
  • Page 20 3 - MAIN COMPONENTS BURNER 2 (Slave) BURNER 1 (Master) 020022.01.002 26 - Top cover 27 - Main electrical switch 28 - Fan protection cover 29 - High limit flue gas temperature fuse (Red color connector) 30 - Flue gas temperature sensor (Blue color connector) (1006) 31 - Water Return connection 32 - Flue gas exhaust manifold 33 - Condensate blocked drain switch...
  • Page 21 3 - MAIN COMPONENTS 020022.01.003 34 - Gas connection 35 - P-T safety relief valve 36 - P-T gauge 37 - Condensate drain 38 - Plug (connection for field supplied safety relief valve) 39 - Hot water supply connection 40 - Cold water inlet connection 41 - DHW Circulator pump 42 - 3/4”...

  • Page 22: Function Overview

    4 - FUNCTION OVERVIEW Key to figures 4-1: 1 - Air inlet 2 - Flue exhaust 3 - P-T Safety relief valve 4 - P-T gauge 5 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - CRV Stainless steel heat exchanger 9 - Water pressure sensor 10 - Flue gas temperature sensor...
  • Page 23 4 - FUNCTION OVERVIEW Key to figures 4-2: 1 - Air inlet 2 - Flue exhaust 3 - P-T Safety relief valve 4 - P-T gauge 5 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - CRV Stainless steel heat exchanger 9 - Water pressure sensor 10 - Flue gas temperature sensor...

  • Page 24: Intended Use And Functions

    4 - FUNCTION OVERVIEW 4.1 - Intended use and functions 4.1.1 Intended use and functions The water heater version, is designed to warm domestic water (potable) for civil uses. Any other use is prohibited. The water heater can be installed with a Direct Venting system or with a one pipe vent system and getting combustion air from room.

  • Page 25: Installation - Location

    5 - INSTALLATION - Location 5.1 - Choosing the Maintain minimum specified clearances WARNING!!! for adequate operation. All installations LIQUEFIED installation location must allow sufficient space for servicing PETROLEUM (L.P.) PROPANE the vent connections, water pipe GAS-FIRED HEATER LOCATION connections, piping and other auxiliary REQUIRES SPECIAL WARNING!!! equipment, as well as the appliance.
  • Page 26 5 - INSTALLATION - Location The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation. 1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room (see Fig.
  • Page 27 5 - INSTALLATION - Location 3. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm per kW).
  • Page 28 5 - INSTALLATION - Location MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM * Outside Air from Inside Air from 2 openings Directly from 2 Ducts Delivered from * Outside Air from Model Outdoor Outdoors 1 Opening Directly from Number Outdoors, in Bottom Bottom...

  • Page 29: Prevent Combustion Air Contamination

    5 - INSTALLATION - Location 5.1.1 - Prevent 5.1.2 - Location of water WARNING!!! combustion air heater Under no circumstances should the contamination When locating the water heater the equipment room ever be under following factors must be considered: Do not terminate vent/air in locations negative pressure.

  • Page 30: Residential Garage Installation

    5 - INSTALLATION - Location 5.2 - Residential 5.4 - Clearances WARNING!!! Do not garage installation for installation and attempt to install the heater Take the following precautions when servicing using any other venting / installing the heater in a residential air intake methods than as Figure 5-6 shows the minimum clearances garage.
  • Page 31 5 - INSTALLATION - Location Figure 5-6 Recommended minimum clearance distances for proper installation and servicing for models 199 to 500 (G1 = Center of gravity for 199 and 250 model G2 = Center of gravity for 399 and 500 model)

  • Page 32: Installation - Mounting The Heater

    6 - INSTALLATION - Mounting the heater 6.1 - Transporting the heater WARNING!!! Always lift and carry the heater with a hand truck or special equipment. Failure to comply with this provision could result in severe personal injury, death or substantial property damage.
  • Page 33 6 - INSTALLATION - Mounting the heater 4. Access to the uplift brackett “A” (Figure 6-3) on the upper side of the heater (see Figure 6-3); 5. Using a proper equipment (check the weight of the unit in Section 18), and lift the unit from the wood pallet and move it to the installation location;...

  • Page 34: Dimensions

    6 - INSTALLATION - Mounting the heater 6.3 - Dimensions Figure 6-6 list all dimensions of each heater model. MODEL WATER SUPPLY WATER RETURN AIR INTAKE FLUE EXHAUST COONECTION CONNECTION CONNECTION CONNECTION CONNECTION CONNECTION 1”1/4 1”1/4 3” 3” 1” 1”1/4 1”1/4 1”1/4 3”...

  • Page 35: Installation - Water Side Head Loss Of The Heater

    7 - INSTALLATION - Water side head loss of the heater RIC 01-2015 0,98 0,66 0,33 1000 2000 3000 4000 5000 6000 17,6 26,4 Figure 7-1 Water side head loss of the heater...

  • Page 36: Installation - Water Connections

    8 - INSTALLATION - Water connections 8.1 - Water heaters 8. Anti-scald mixing valve: Field Low water cutoff device supplied. Install an anti-scald On a water heater installed above water connections mixing valve as shown on figure radiation level, some states and local 8-5.

  • Page 37: Temperature And Pressure Relief Valve

    8 - INSTALLATION - AGUADENS water connections 8.2.2 - Temperature and pressure Relief valve This water heater is supplied with a Safety Temperature and Pressure Relief valve which discharge connection must be piped in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, to prevent scalding in the event of a discharge.

  • Page 38: Expansion Tank

    8 - INSTALLATION - Water connections 8.3 - Scalding 8.4 - How to install 8.2.3 - Expansion Tank If a water heater is installed in a This water heater can deliver scalding the circulator pump closed water supply system, such temperature water at any faucet in the as one having a backflow preventer This water heater must be fitted with a...
  • Page 39 8 - INSTALLATION - Water connections CAUTION!!! CAUTION!!! CAUTION!!! Since the pump Water with a Water with a wires conduct 120 Vac, they hardness of less than 5 grains hardness of more than 19 gr/gal must never run through conduits per gallon will usually have a pH can cause damage to the heat containing 24 Vac power wires...
  • Page 40 8 - INSTALLATION - AGUADENS water connections CAUTION!!! This is a concept drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the designer are appropriate, in order to properly size, Gas Inlet configure and design that system and...

  • Page 41: Installation - Condensate Disposal

    9 - INSTALLATION - Condensate disposal 9.1 - Condensate CAUTION!!! The condensate disposal discharge line must be of materials approved by the authority having jurisdiction. In WARNING!!! the absence of other authority, PVC and CPVC pipe must condensate trap is the same comply with ASTM D1785 or condensate neutralizer box D2845.
  • Page 42 9 - INSTALLATION - Condensate disposal A = Pipe connected to the heaters’ flue exhaust system B = Condensate neutralizer box C = Condensate drain pipe D = Cover of the box E = PH test port 020010.01.029 Figure 9-1 Condensate neutralizer box (see also Figures 3-3 through 3-6, Item “8”) A = Condensate drain pipe B = Floor drain or drain pan (Below this point there must be a trap capable of preventing the return of sewer gas)

  • Page 43: Installation - Electrical Connections

    10 - INSTALLATION - Electrical connections 10.1 - Electrical NOTICE! Wiring must be N.E.C. CAUTION!!! The heater is not Class 1. Use only type 105°C wire or connections: provided with any protection equivalent. against lightening strikes. overview Installation must comply with: 10.1.1 - Connecting the 1.
  • Page 44 10 - INSTALLATION - Electrical connections Figure 10-2 Electrical customer connection Figure 10-3 Electrical customer connection for pump brand Wilo model Stratos Z1,25X3-35...

  • Page 45: Connecting The Heater In Cascade

    10 - INSTALLATION - Electrical connections 10.2 - Connecting CAUTION!!! For this appliance the following terminals are “NOT the heater in APPLICABE” (See Figures 10-2 and 10-3): cascade Terminal “12” - Tank Sensor - (NOT APPLICABLE) Terminal “13” - Tank Sensor - (NOT APPLICABLE) Heaters can be installed in cascade Terminal “14”...

  • Page 46: Installation - Removing Of An Heater From A Common Venting System

    11 - INSTALLATION - Removing of an heater from a common venting system 11.1 - Removing of (d) Place in operation the appliance (c) Dans la mesure du possible, being inspected. Follow the lighting fermer toutes les portes et les an heater from a instructions.

  • Page 47: Installation - Category Iv: Vent And Combustion Air

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.1 - CATEGORY WARNING!!! NOTICE! The exhaust pipe must Use of IV: Positive be pitched a minimum of a 1/4 inch cellular core PVC and CPVC per foot back to the heater (to allow pressure or Radel for venting system is drainage of condensate).
  • Page 48 12 - INSTALLATION - CATEGORY IV: Vent and combustion air Figure 12-1 Side wall two Figure 12-2 Vertical two pipes Figure 12-3 Side wall air pipes (Direct venting). (Direct Venting). intake, vertical vent (Direct venting). Figure 12-6 Side wall (or vertical in a roof) one pipe venting, combustion air from Figure 12-5 Side wall...

  • Page 49: Minimum / Maximum Allowable Combustion Air And Vent Piping Lengths

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.3 - Minimum / 12.4 - Install vent of venting materials or failure to follow vent pipe and fittings Maximum allowable and combustion air manufacturer’s instructions can result in personal injury, death combustion air and piping or property damage.
  • Page 50 12 - INSTALLATION - CATEGORY IV: Vent and combustion air Approved vent manufacturers and items Item Family of Manufacturer/ Applicable Manufactur. the Material supplier to models Part Number 3” Concentric roof or wall terminal IPEX (System 636) 199, 250 196006 4”...

  • Page 51: Air Inlet Pipe Materials

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.5 - Air inlet pipe 12.5.1 - Sealing of PVC, CPVC or ABS air inlet materials: pipe The PVC, CPVC, or ABS air inlet pipe WARNING!!! should be cleaned and sealed with the The air pipe manufacturer’s recommended inlet pipe(s) must be sealed.

  • Page 52: Pvc/Cpvc Vent Piping Materials

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.6 - PVC/CPVC b. Apply a liberal even coat of WARNING!!! VITON-BASED RTV high All vent vent piping temperature silicone (or pipes must be glued, properly equivalent) to the the pipe end materials supported, and the exhaust approximately 1/2”...

  • Page 53: Pvc/Cpvc Air Intake Connection

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.6.2 - PVC/CPVC air outside. Vent piping must be supported CAUTION!!! per the National Building Code, Section intake connection Apply a liberal 305, Table 305.4 or as local codes even coat of VITON-BASED dictate.

  • Page 54: Stainless Steel Vent Piping Materials

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.7 - Stainless 12.7.1 - Stainless steel air NOTICE! Installation must comply with local requirements and with the intake connection steel vent piping National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for materials Combustion Air Intake Canadian installations.

  • Page 55: Stainless Steel Vent Connection

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.7.2 - Stainless steel b. Apply a liberal even coat of CAUTION!!! VITON-BASED RTV high vent connection Apply a liberal temperature silicone (or even coat of VITON-BASED equivalent) to the adapter “R” RTV high temperature silicone Vent connection (Figure approximately 2”...

  • Page 56: Polypropylene Vent Piping Materials

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.8 - Polypropylene WARNING!!! Improper vent piping materials installation of Polypropylene systems may result in injury or death. WARNING!!! Use only the materials listed in Figures WARNING!!! 12-7 and 12-8 for vent pipe, Use only and fittings.

  • Page 57: Polypropylene Air Intake Connection

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.8.1 - Polypropylene air 12.8.2 - Polypropylene CAUTION!!! intake connection vent connection Apply a liberal even coat of VITON-BASED Combustion Air Intake connection Vent connection (Figure 12-13 item RTV high temperature silicone (see Figure 12-13 Item “M”) is used “C”) is used to provide a passageway (or equivalent) to the internal...

  • Page 58: Single Pipe Vent (Not Sealed Combustion)

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.9 - Single pipe NOTICE! Vent pipe system shall WARNING!!! be installed in a way to prevent Use only vent (not sealed accumulation of condensate. the materials, vent systems, and combustion) terminations listed in Figures 12-7 and 12-8.

  • Page 59: Determine Location

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.9.1 - Determine location 4. Maintain clearances as expected by “Venting of Equipment,” of the Locate the vent termination using the National Fuel Gas Code, ANSI following guidelines: Z223.1/NFPA 54, or “Venting Systems 1.

  • Page 60: Sidewall Termination - Two Pipes

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.10 - Sidewall 12.10.2 - Determine location termination - Two Locate the vent/air terminations using pipes the following guidelines: 1. The total length of piping for vent or air must not exceed the limits given 12.10.1 - Vent/air in the Section 12.3.
  • Page 61 12 - INSTALLATION - CATEGORY IV: Vent and combustion air 3. The air piping must terminate in a down-turned elbow as shown in Figures 12-15 and 12-16. This arrangement avoids recirculation of flue products into the combustion air stream. 4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in Figures 12-15 and 12-16.

  • Page 62: Prepare Wall Penetrations

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.10.3 - Prepare wall penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

  • Page 63: Sidewall Termination - Concentric Vent

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.11 - Sidewall termination – Concentric vent 12.11.1 - Description and usage The termination kit must terminate outside the structure and must be installed as shown in Figure 12-19. The required concentric termination kit as well as combustion air and vent pipe materials are listed in Figures 12-7 and 12-8.

  • Page 64: Multiventing Sidewall Terminations

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.11.3 - Multiventing sidewall terminations When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 12-21.

  • Page 65: Vertical Termination - Two Pipes

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.12 - Vertical 12.12.1 - Determine 12.12.2 - Prepare roof location penetrations termination - Two Locate the vent/air terminations using 1. Air pipe penetration: cut a hole for pipes the following guidelines: the air pipe.

  • Page 66: Multiple Vent/Air Terminations

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.12.4 - Multiple vent/air terminations 1. When terminating multiple heaters, Air intake Air intake Vent Vent terminate each vent/air connection as shown in Figures 12-23 and 12- vertically from vent outlet to WARNING!!! any air inlet Terminate all...

  • Page 67: Vertical Termination - Concentric Vent

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.13 - Vertical 12.13.3 - Vertical 4. Cut one (1) hole into the structure to install the termination kit. termination installation termination – 5. Install the Concentric vent kit following the concentric kit Concentric vent 1.

  • Page 68: Multiventing Vertical Terminations

    12 - INSTALLATION - CATEGORY IV: Vent and combustion air 12.13.4 - Multiventing vertical terminations When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see Figure 12-27). WARNING!!! NEVER common vent or breach vent this appliance to avoid possibility of severe personal injury, death, or substantial...

  • Page 69: Installation - Category Ii: Vent And Combustion Air

    13 - INSTALLATION - CATEGORY II: Vent and combustion air 13.1 - CATEGORY II: Negative pressure condensing An appliance that operates with a non-positive vent static pressure with a vent gas temperature that may cause excessive condensate production in the vent. 13.2 - CATEGORY II: Adapter and increaser...

  • Page 70: Condensing Vent Option: Category Ii

    13 - INSTALLATION - CATEGORY II: Vent and combustion air 13.3 - Condensing vent option: CATEGORY II: Vertical vent with combustion air from equipment room The flue outlet terminates on the rooftop. The termination point for the flue products must follow the vertical vent termination clearance EQUIPMENT requirements on section 12.12.
  • Page 71 13 - INSTALLATION - CATEGORY II: Vent and combustion air Vent/Air vertical Common venting Consult a vent designer to determine the diameter of the common vent installation with sidewall CATEGORY II: pipe required for combined vent Flues of multiple water heaters may combustion air inlet installation.

  • Page 72: Installation - Gas Supply

    14 - INSTALLATION - Gas supply 14.1 - Gas supply WARNING!!! WARNING!!! Do not Never use piping attempt to support the weight of an open flame to test for gas the piping with the heater or its leaks. Always use an approved accessories.

  • Page 73: Pipe Sizing For Natural Gas

    14 - INSTALLATION - Gas supply 14.2 - Pipe sizing 14.3 - Propane Gas Propane supply pressure requirements: for natural gas 1. Adjust propane supply regulator WARNING!!! provided by the gas supplier for These heaters 13”W.C. maximum pressure. Refer to Figure 14-2 for pipe length are typically shipped ready 2.

  • Page 74: Check Inlet Gas Supply Pressure

    14 - INSTALLATION - Gas supply 14.4 - Check CAUTION!!! Never force the inlet gas supply pressure connection screw or the gas valve will be damaged! pressure WARNING!!! Never use an WARNING!!! open flame to check for gas DO NOT leaks, or a fire or an explosion adjust or attempt to measure could result causing severe...

  • Page 75: Convert A Heater Model 199 Or 250 From Natural Gas To Propane Gas Or Viceversa

    14 - INSTALLATION - Gas supply 14.6 - Convert a requirements of the provincial authorities having jurisdition heater model 199 and in accordance with the or 250 from Natural requirements of the CAN-B149.1 and CAN1-B149.2 installation Gas to Propane gas code.
  • Page 76 14 - INSTALLATION - Gas supply 13 - turn the power on to the heater; equipment to ensure proper reading and accuracy. Failure 14 - turn completely counter clockwise to comply with this requirement the screw “E” of Figure 14-6; could result in severe personal 15 - Checking gas supply pressure...

  • Page 77: Convert A Heater Model 399 Or 500 From Natural Gas To Propane Gas Or Viceversa

    14 - INSTALLATION - Gas supply 14.7 - Convert a Contents: The conversion kit (supplied with the heater model 399 heater) is composed of the following elements, which are necessary for the or 500 from Natural gas change: Gas to Propane gas - a label rating stating the new gas setting;...

  • Page 78: Start-Up

    15 - START-UP 15.1 - Operating 15.2 - General Before starting the heater, the following warnings concerning must be done. gas supply 15.1.1 - User instructions When starting up the heater for the first The user must be correctly instructed time the following must be checked: by the installer, on how to operate the ...

  • Page 79: Confirming The Heater's Gas Type

    15 - START-UP 15.3 - Confirming the 15.5 - Start-up 15.6 - Ignition control 1. Open the manual gas shut off valve heater’s gas type testing (Figure 14-1). The type of gas and the gas supply After placing the heater in operation, the 2.

  • Page 80: Gas Supply Pressure Checking

    15 - START-UP 15.7 - Gas supply 4. connect a manometer with 9. check the manometer to make sure graduations of at least 0.1 in.W.C. the gas supply pressure does not pressure checking (0.25 mbar) to the inlet gas port drop below 3 in.W.C.

  • Page 81: Checking And Adjusting Co2 Levels

    15 - START-UP 15.8 - Checking and 15.8.2 - Checking CO2 6. compare the CO2 reading with the high fire range given in Figure 14-7, level on units model 399 adjusting CO2 levels making sure to use the range for the and 500 gas type in use.

  • Page 82: Check The Capacity Input

    15 - START-UP c. wait 2 to 3 minutes for the CO2 to consideration that for the Burner 2 the measured flow in ft3/hr by stabilize; 2500). 2202 you have to use parameter d. insert the probe of a calibrated 4.

  • Page 83: Use

    16 - USE 020010.01.023 A - Key to reduce the supply water temperature; B - Multifunctional key: reset any lockouts; access to user and installer menu. C - Key to increase the supply water temperature; D - Flame icon, is present when the flame is present; E - Radiator icon.

  • Page 84: Check Water Pressure

    16 - USE 16.1 - Check water 16.4 - Start-up 16.5 - Supply pressure procedure water temperature If the pressure inside the water circuit 1. Open the manual gas shutoff valve; adjustment falls below the minimum pressure for 2. switch on electric power to the The water heater provides hot water at the system, the appliance switches heater;...

  • Page 85: Delays, Alarms And Protective Actions

    16 - USE 16.6 - Delays, 16.8 - Heater’s alarms and Freeze protection protective actions CAUTION!!! For the freeze To protect the life of the appliance, protection function to work, the improve comfort, and maximize energy heater must remain connected savings, the following timings have to the electrical and gas been incorporated into the control...

  • Page 86: Users' Menu

    16 - USE 16.10 - “Users’ will start showing parameters from 1 (Master)” are applicable for that burner only. If you want to see the 1000 menu” . Press keys same parameters for other burners scroll all parameters inside this menu. you have to connect the display to Pressing RESET key for 2 seconds, All parameters into this “Users’...

  • Page 87: Installer's Menu

    16 - USE 16.11 - “Installer’s To access the “Installers’ Menu” (see also Section 20 to better understand than 5 seconds until the icon menu” the several menus) proceed as stops to be displayed. follows: CAUTION!!! Changing these 1. press and hold together buttons NOTICE! If no key is pressed for parameters could cause more than 60 seconds, the control...

  • Page 88: Diagnostic

    16 - USE 2027 Night setback temperature °F 2 to 90 2040 2041 2042 Burner 1 anti cycling: time 10 to 900 2043 Burner 1 anti cycling: differential temperature °F 0 to 36 2062 DHW post pump time (N/A) 10 to 255 2063 DHW max priority time (N/A) 1 to 60...

  • Page 89: Diagnostic: Lockouts "Loc

    16 - USE 16.13 - Diagnostic:  the corresponding burner icon ( Lockouts “Loc” ‚ ) if failing, will blink. To reset the lockout press the RESET key, the display will show the Lockout To RESET a lockout on units model number, you can try to reset the 199 and 250, simply press RESET lockout by pushing the RESET key...
  • Page 90 16 - USE Loc 18 Internal software error Replace the power control board Loc 19 Internal software error Replace the power control board Loc 20 Flame lost three times Control: that the ionisation current is at a value over 60 (see If the ionisation current is not over 60, the CO2 must be checked (see parameter 1008) chapter 15.8) and restore the correct value.

  • Page 91: Diagnostic: Blocking Errors "Err

    16 - USE 16.14 - Diagnostic: icon and the corresponding burner  ‚ Blocking errors icon ( ) if failing will blink. To see the blocking error code, press the “Err” RESET key and display will show the blocking error code. Press and hold Blocking errors are generated by a the RESET key to go back into normal permanent fault.

  • Page 92: Flue Blocked Pressure Switch

    16 - USE Err 86 Flue sensor shorted Check if temperature sensor match section 17.10 If temperature sensor do not match section 17.10, it must be replaced. Err 87 Reset button error Too many reset button pushing in 60 sec Err 93 Appliance selection error Check the list of 3000 parameters (Section 21)

  • Page 93: Maintenance

    17 - MAINTENANCE 17.1 - Care and Installer should discuss contents of WARNING!!! Section 16 (User’s section) with the Servicing, maintenance user. inspection and adjustment A trained and qualified service This section must be brought to the must be done by a trained technician should perform the inspection attention of the user by the installer so technician in accordance with...

  • Page 94: Address Reported Problems

    17 - MAINTENANCE from meter to appliance including WARNING!!! all pipes and fittings and heater Never store connection. Use liquid soap solution combustible materials, gasoline for all gas testing. or any product containing flammable vapors and liquids WARNING!!! in the vicinity of the heater. Do not check Failure to comply with this for gas leaks with an open...

  • Page 95: Check Ignition And Flame Sense Electrodes

    17 - MAINTENANCE 17.1.10 - Check flame WARNING!!! signal If gas flow occurs, close the manual gas 1. Start unit and perform the shutoff valve and troubleshoot procedure of Section 15.8 to check the system to determine why the flame signal. there is gas flow when the gas 2.

  • Page 96: Check Heater Area

    17 - MAINTENANCE 17.1.12 - Check heater 17.1.14 - Check vent piping area 1. Visually inspect the vent outlet termination to be sure it is WARNING!!! unobstructed. Visually inspect the To prevent entire length of the flue gas vent potential of severe personal piping for any signs of blockage, injury, death, or substantial leakage, or deterioration of the...

  • Page 97: Shut Heater Down

    17 - MAINTENANCE 17.1.18 - Shut heater If the red led is ON or both leds are OFF, this means that the anode is not down working, after checking the correct 1. Follow “To Turn Off Gas to connection of the same, proceed as Appliance”...

  • Page 98: Removing The Casing

    17 - MAINTENANCE 17.2 - Removing the 7. pull back from left side the door “D” 8. pull up the fan cover “H”; casing Now you can gain access to all In order to remove the casing, follow components inside heater. the steps below while refering to Figure 17-2: To gain access to the junction box:...

  • Page 99: Cleaning The Burner And Primary Heat Exchanger, Flue Gas Side

    17 - MAINTENANCE 17.3 - Cleaning the burner and primary 020009.01.012 heat exchanger, flue gas side Burner and primary heat exchanger must be checked every year and cleaned if ther’is presence of debris or products of the combustion. To correctly clean the burner and the flue gas side of the heat exchanger follow the steps below: WARNING!!!
  • Page 100 17 - MAINTENANCE 11. unscrew the four nuts “B” in Figure 17-7; 12. remove the entire fan - burner assembly, detail “C” in Figure 17-7; 13. use a cylindrical brush with plastic bristles to clean the inside of the combustion chamber, detail “H”...
  • Page 101 17 - MAINTENANCE 020009.01.011 Figure 17-7 Remove the fan burner assembly GASKET 020009.01.032 HEAT EXCHANGER DOOR CAUTION!!! If gasket is damaged DO NOT reuse, the heat exchanger door must be replaced. NOTICE ! Gasket is intended for sealing combustion. If damaged DO NOT reuse, the heat exchanger door must be replaced.

  • Page 102: Thermal Insulations

    17 - MAINTENANCE 17.3.1 - Thermal insulations Thermal insulations must be checked every year and replaced if they are cracked or damaged. See Figures below where the thermal insulations (items “C” and “E”) are showned already disassembled from heat A = Fixing screw exchanger and burner.

  • Page 103: Correct Positioning Of The Ignition And Flame Detection Electrodes

    17 - MAINTENANCE 17.4 - Correct positioning of the ignition and flame detection electrodes For the heater to work properly the electrodes must be positioned as shown in Figure 17-8. NOTICE! To insure correct functioning of heater the distances listed above shall be verified very carefully also using a hand caliper.

  • Page 104: Condensate Trap And Neutralizing Box Maintenance And Cleaning

    17 - MAINTENANCE 17.6 - Condensate trap and neutralizing box maintenance and cleaning The condensate trap and neutralizing box must be checked every year and cleaned if required. Follow the steps below to properly inspect, recharge or substitute condensate neutralizing box and media: Monitor the level of the neutralization media in the box periodically.

  • Page 105: Connection Of The Display To Other Burners

    17 - MAINTENANCE 17.7 - Connection of the display to other burners On multi-burner units models 399 and 500, display of Figure 16-1, is always connected directly to “Burner 1 (Master)”. All parameters readed in the display (see Sections 16.10, 16.11 and 21), addressed to “Burner Burner 2 1 (Master)”...

  • Page 106: How To Move A Control Board

    17 - MAINTENANCE 17.8 - How to move 3. disconnect plug “B” (plug coming 13. turn the electrical power on to the from display) from plug “A” (plug unit; a control board coming from “Burner 1 (Master)”); 14. gain access to the Factory menu, 4.

  • Page 107: Draining The Water From The Heater

    17 - MAINTENANCE 17.9 - Draining the water from the heater To drain the water from the unit, follow the steps below: 1. turn the power off to the heater; 2. close the manual gas shutoff valve, Figure 14-1; 3. wait until the water temperature decreas below 104°F (40°C);...

  • Page 108: 199 And 250 Models Wiring Diagram

    17 - MAINTENANCE 17.11 - 199 and 250 models wiring diagram For the legend see section 17.12. WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!
  • Page 109 17 - MAINTENANCE ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien est terminé.

  • Page 110: 399 And 500 Models Wiring Diagram

    17 - MAINTENANCE 17.12 - 399 and WARNING!!! Label all wires prior to disconnection when servicing 500 models wiring controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can diagram cause extensive property damage, severe personal injury or death!
  • Page 111 17 - MAINTENANCE ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien est terminé. Continue...
  • Page 112 17 - MAINTENANCE...
  • Page 113 17 - MAINTENANCE Legend to electrical schemes: 6 - High limit supply temperature switch 7 - Supply temperature sensor 9 - Flue gas temperature sensor 10 - High limit flue gas temperature fuse 11 - Control board Fuse - F1 5x20 3A 13 - Ignition electrodes 14 - Spark generator 15 - Return temperature sensor...

  • Page 114: Technical Data

    18 - TECHNICAL DATA Heater MODEL Category of discharge chimney II and IV II and IV Maximum heat input Btu/hr 199,500 250,000 Minimum heat input Btu/hr 50,000 50,000 Turndown ratio Number of burners Gas flow rate (Natural gas) ft3/hr 199.5 Gas flow rate (LP gas) ft3/hr Min / Max gas pressure (Nat.
  • Page 115 18 - TECHNICAL DATA Heater MODEL Category of discharge chimney II and IV II and IV Maximum heat input Btu/hr 399,000 500,000 Minimum heat input Btu/hr 50,000 50,000 Turndown ratio 10:1 Number of burners Gas flow rate (Natural gas) ft3/hr Gas flow rate (LP gas) ft3/hr Min / Max gas pressure (Nat.

  • Page 116: Spare Parts

    19 - SPARE PARTS Spare parts...
  • Page 117 19 - SPARE PARTS 199 and 250 Spare parts for models: DESCRIPTION AM 199R AM 250R WARNING!!! Only use the heater in combinations and with the spare parts listed in this manual. Failure to do so can cause severe personal injury or death.
  • Page 118 19 - SPARE PARTS 199 and 250 USER S INSTRUCTION INSTALLER S INSTRUCTION NEUTRALISING LIMESTONE 020021.03.001...
  • Page 119 19 - SPARE PARTS 199 and 250 020021.03.002...
  • Page 120 19 - SPARE PARTS 199 and 250 020021.03.003...
  • Page 121 AM 199R-500R USER INSTRUCTIONS AERCO 62403631 AM 199R-500R INSTALLER INSTRUCTIONS AERCO 62630212 NAT-LP CONV KIT 199-1000 AERCO 62630213 LP-NAT CONV KIT 199 AND 399 AERCO 62630214 LP-NAT CONV KIT 2505007501000 AERCO 62801022 NEUTRALISING LIMESTONE 10 KG 62801023 CONDENSE ACIDITY NEUTRALIZER UNTIL 280 KW BOX...
  • Page 122 19 - SPARE PARTS 199 and 250 DESCRIPTION MOD. AM 199R AM 250R CODE DESCRIPTION 62651066 CONDENSATE BLOCKED DRAIN SWITCH 60801106 SCREW 6X25 GALVANIZED 62111051 MAGNETIC SENSOR D5,8X38 62610093 COMPLETE PLASTIC FRONT COVER BLACK 62610096 COMPLETE PLASTIC FRONT COVER GREY 60322021 CORRUGATED TUBE DIAM 28 L 1250 61405320...
  • Page 123 19 - SPARE PARTS 199 and 250 DESCRIPTION MOD. AM 199R AM 250R CODE DESCRIPTION 62632007 GRP DETECTION ELECTRODE 60801080 SCREW SELFTAPPING 4X10 TC S-TT UNI-8112 60504266 MASTER GAS CABLE UL 885 60406137 SHAPED BRACKET 67X54X36 60702083 OR RING 3137 EPDM 2,62 X 34,60 61405300 CONDENSATION DISCHARGE PIPE D.46.7 60801138...
  • Page 124 19 - SPARE PARTS 399 and 500 Spare parts for models: DESCRIPTION AM 399R AM 500R WARNING!!! Only use the heater in combinations and with the spare parts listed in this manual. Failure to do so can cause severe personal injury or death.
  • Page 125 19 - SPARE PARTS 399 and 500 17 18 17 18 USER S INSTRUCTION INSTALLER S INSTRUCTION NEUTRALISING LIMESTONE 020022.03.001...
  • Page 126 19 - SPARE PARTS 399 to 500 59 58 020022.03.002...
  • Page 127 19 - SPARE PARTS 399 to 500 020021.03.004...
  • Page 128 AM 199R-500R USER INSTRUCTIONS AERCO 62403631 AM 199R-500R INSTALLER INSTRUCTIONS AERCO 62630212 NAT-LP CONV KIT 199-1000 AERCO 62630213 LP-NAT CONV KIT 199 AND 399 AERCO 62630214 LP-NAT CONV KIT 2505007501000 AERCO 62801022 NEUTRALISING LIMESTONE 10 KG 62801023 CONDENSE ACIDITY NEUTRALIZER UNTIL 280 KW BOX...
  • Page 129 19 - SPARE PARTS 399 and 500 DESCRIPTION MOD. AM 399R AM 500R CODE DESCRIPTION 62651066 CONDENSATE BLOCKED DRAIN SWITCH 60801106 SCREW 6X25 GALVANIZED 62111051 MAGNETIC SENSOR D5,8X38 62610093 COMPLETE PLASTIC FRONT COVER BLACK 62610096 COMPLETE PLASTIC FRONT COVER GREY 60322021 CORRUGATED TUBE DIAM 28 L 1250 61405320...
  • Page 130 19 - SPARE PARTS 399 and 500 DESCRIPTION MOD. AM 399R AM 500R CODE DESCRIPTION 62632007 GRP DETECTION ELECTRODE 60801080 SCREW SELFTAPPING 4X10 TC S-TT UNI-8112 60504266 MASTER GAS CABLE UL 885 60406137 SHAPED BRACKET 67X54X36 60702083 OR RING 3137 EPDM 2,62 X 34,60 61405300 CONDENSATION DISCHARGE PIPE D.46.7 60801138...

  • Page 131: Read Out Flow Chart

    20 - READ OUT FLOW CHART Gain access to installers’ Changing menu (see Section of the 16.11) parameters’ value Gain access to users’ menu (see Section 16.10) Parameters shown during Installers’ normal operations menu (See Section parameters 16.12) (see Section 16.11) User’s menu parameters...

  • Page 132: Factory Menu

    21 - FACTORY MENU CAUTION!!! WARNING!!! WARNING!!! On multiburner Changing Pay attention units (399 and 500) display these parameters could cause when entering the Factory is always connected to the the heater and the system to Menu, changes may cause the Burner 1 (Master).
  • Page 133 21 - FACTORY MENU The heater’s micro-processor makes this menu of parameters available to the qualified technician for the setting of the appliance. To enter this menu operate as follow: 1. turn the main electrical supply Off; 2. press and hold, in the same time, RESET key and key;...

  • Page 134: Sequence Of Operation For Water Heater

    22 - SEQUENCE OF OPERATION for WATER HEATER Sequence of Supply or DHW Burners continue operations temp. increases to operate Is the DHW temp. Burners continue Turn the electrical power on near setpoint? to operate Fan proof After 1 minute ignition speed Lock 12 Err 64...
  • Page 136 AERCO declines every responsibility for the possible inaccuracies if owed to errors of transcript or press. Also, AERCO reserves the right to bring those changes that will hold necessary to its own products or profits, without jeopardizing its essential characteristics.

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