Watts Aerco AM Series Operation & Maintenance Manual
Natural gas and propane gas modulating condensing pool heating system
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Also See for Aerco AM Series:
- Quick installation manual (7 pages) ,
- Operation & maintenance manual (170 pages)
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Operation & Maintenance Manual
AM Series Pool Heater
Natural Gas and Propane Gas
Modulating Condensing Pool
Heating System
•
AM 399P
•
AM 500P
•
AM 750P
•
AM 1000P
Other documents for this product include:
TAG-0072 GF-146-E Electrical Power Guide
TAG-0073 GF-146-G Gas Supply Guide
TAG-0074 GF-146-P Piping Application Guide
TAG-0075 GF-146-V Venting Guide
IMPORTANT!
This manual MUST be used in conjunction with User
Manual GF-146 for the startup, operation, and
maintenance of the AM Series Boiler used in the pool
heating system.
.
Disclaimer
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. AERCO International is
not liable for errors appearing in this manual, not for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials
OMM-0111_B: • GF-146-P • 10/29/2019
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Table of Contents
Related Manuals for Watts Aerco AM Series
Summary of Contents for Watts Aerco AM Series
- Page 1 Operation & Maintenance Manual AM Series Pool Heater Natural Gas and Propane Gas Modulating Condensing Pool Heating System • AM 399P • AM 500P • AM 750P • AM 1000P Other documents for this product include: TAG-0072 GF-146-E Electrical Power Guide TAG-0073 GF-146-G Gas Supply Guide TAG-0074 GF-146-P Piping Application Guide TAG-0075 GF-146-V Venting Guide...
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Page 2: Table Of Contents
AM Series Pool Heater User Manual TABLE OF CONTENTS Table of Contents FOREWORD ........................4 SECTION 1: GENERAL INFORMATION ................5 1.1 WARNINGS & CAUTIONS ........................... 5 1.2 EMERGENCY SHUTDOWN ........................8 SECTION 2: FUNCTION & SPECIFICATIONS ..............9 2.1 INTRODUCTION ............................9 2.2 SPECIFICATIONS ............................ - Page 3 AM Series Pool Heater User Manual TABLE OF CONTENTS 6.10.2 Gas Conversion Instructions ..........................35 SECTION 7: INSTALLATION - ELECTRICAL ..............36 7.1 ELECTRICAL CONNECTIONS – BOILER ....................36 7.1.1 Power Supply Cable Connection ........................... 36 7.1.2 Connecting Units in Cascade ..........................38 7.1.3 0-10 VDC Input Connections..........................
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Page 4: Foreword
AM Series Pool Heater User Manual FORWARD FOREWORD The Advanced Modular (AM) Series P o o l H e a t i n g s y s t e m represents the latest in high efficiency pool heating applications. The AM Series Pool Heaters are comprised of an AERCO AM Series boiler, shell and tube heat exchanger, pump, expansion tank, air vent, and fittings for makeup water connections, all factory configured and installed on a skid. -
Page 5: General Information
AM Series Pool Heater User Manual CHAPTER 1: GENERAL INFORMATION SECTION 1: GENERAL INFORMATION 1.1 Warnings & Cautions NOTE: This manual provides installation instructions for the AM Series Pool Heaters, but does NOT provide information for venting, system start-up, operation, or maintenance of the boiler used in the system. - Page 6 AM Series Pool Heater User Manual CHAPTER 1: GENERAL INFORMATION NOTE: When calling or writing about the AM Series Pool Heating system, have the unit model and serial number as seen on the unit rating plate located on the boiler. CAUTION! Do not use petroleum-based cleaning or sealing compounds in the boiler system.
- Page 7 AM Series Pool Heater User Manual CHAPTER 1: GENERAL INFORMATION OFF. OFF. OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 7 of 47...
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Page 8: Emergency Shutdown
AM Series Pool Heater User Manual CHAPTER 1: GENERAL INFORMATION 1.2 Emergency Shutdown If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit. NOTE: The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel. -
Page 9: Function & Specifications
AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS SECTION 2: FUNCTION & SPECIFICATIONS 2.1 INTRODUCTION REFERENCE NOTE: This manual provides installation instructions for the AM Series Pool Heaters, but not documentation for all features, such as venting, start-up, operation, or maintenance of the boiler used in the system. -
Page 10: Specifications
AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS 2.2 Specifications 2.2.1 Boiler - Burner Modules, Efficiency, Flow Rate, and Water Connections Each AM Series pool heating system includes a boiler featuring from 2 to 4 thermal modules, depending on model, performing total turn down ratios without loss of combustion efficiency as shown in the table below. - Page 11 AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS Figure 2-3a: AM 399P/500P Pool Heater Connection Dimensions NOTE: These drawings and/or dimensions are subject to change. Please refer to latest drawings revisions on the AERCO website. OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support •...
- Page 12 AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS Figure 2-3b: AM 750P/1000P Pool Heater Connection Dimensions NOTE: These drawings and/or dimensions are subject to change. Please refer to latest drawings revisions on the AERCO website. OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support •...
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Page 13: Boiler Controls
AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS 2.3 Boiler Controls AM Series pool heater units must be controlled in one of two ways: either through an external AERCO controller, or be controlled through a Building Automation System (BAS). The boiler is comprised of an internal controller coordinating individual thermal module controllers linked as slaves, and these controls are fully field adjustable while the boiler is in operation by either the external controller or the BAS. -
Page 14: Controls Interoperability
AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS 2.4 Controls Interoperability The communications module utilizes the MODBUS open protocol to interface with third party Building Automation Systems (BAS). The controls interface with BACnet, Lonworks, and N2, shall utilize an optional AERCO Communications Gateway to act as a MODBUS interface/translator between the BAS the communications. - Page 15 AM Series Pool Heater User Manual CHAPTER 2: FUNCTION & SPECIFICATIONS (This Page Is Intentionally Blank) OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 15 of 47...
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Page 16: Installation - Site
AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE SECTION 3: INSTALLATION – SITE 3.1 Choosing the Installation Location This section describes the general installation considerations for the AM Series Pool Heaters. WARNING! Provisions for combustion air and ventilation of the boiler room are always required, regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside (room air for combustion). -
Page 17: Boiler And Water Heater Installation Location Factors
AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE 3.2 Boiler and Water Heater Installation Location Factors When locating the boiler or water heater, the following factors must be considered: • location of vent/air intakes; • connection to the gas supply; •... - Page 18 AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE Or per piping of 24” Heat Exchanger 32” FRONT REAR 12” 24” TOP VIEW 20” SIDE VIEW Figure 3-1a: Recommended Minimum Service Clearances (AM 399 / AM 500) 24” 12”...
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Page 19: Clearances To Combustible Material
AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE NOTE: Service clearances are minimum required clearances for ease of access, but larger service clearances are always preferred. 3.6 Clearances to Combustible Material This unit may be installed directly onto a floor of combustible material with the following clearances: Table 3-1: Unit Installation Clearance Dimensions Component... - Page 20 AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE Transporting an AM Series Pool Heating System 1. Remove the two (2) 3/8-16 hex cap screws, washers, and nuts attaching the front of the assembly skid to the wooden pallet, and then remove the same hardware at the rear of the unit.
- Page 21 AM Series Pool Heater User Manual SECTION 3: INSTALLATION - SITE (This Page Is Intentionally Blank) OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 21 of 47...
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Page 22: Installation - Vent And Air
AM Series Pool Heater User Manual SECTION 4: INSTALLATION – VENT AND AIR SECTION 4: INSTALLATION – VENT AND AIR WARNING! This section provides necessary, but only general, information and requirements regarding flue venting and combustion air piping installation for this system. The installer must refer to Section 6 of the AM Series User Manual, GF-146, for very important information and instructions regarding the installation of the venting and combustion air piping, or risk creating a dangerous situation. - Page 23 AM Series Pool Heater User Manual SECTION 4: INSTALLATION – VENT AND AIR (This Page Is Intentionally Blank) OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 23 of 47...
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Page 24: Installation - Piping
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING SECTION 5: INSTALLATION – PIPING 5.1 Boiler Water Inlet and Outlet Piping When connecting the hot water outlet and cold water inlet to building piping, first make sure the threads are thoroughly clean. -
Page 25: Freeze Protection
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING 5.4 Freeze Protection Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. -
Page 26: Safety Relief Valve
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING 5.5 Safety Relief Valve AM units come equipped with a safety relief valve on each factory installed module. Boilers are supplied with 50 PSI pressure relief valves. If a higher or lower rated PRV is required it must be field supplied and installed. -
Page 27: Condensate Disposal
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING 5.6 Condensate Disposal WARNING! The condensate trap (Fig. 5-2, item “B”) MUST be filled with water or combustion gases will enter the room. The condensate neutralizer tank must be installed into the unit exactly as shown in Figure 5-2. -
Page 28: Pool Water Piping Requirements
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING E = Condensate Drain Pipe F = Floor Drain or Drain Pan Figure 5-3: Condensate Tank Draining A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. -
Page 29: Piping Methods - Full Flow Or Bypass Flow
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING 5.9 Piping Methods - Full Flow or Bypass Flow There are two recommended piping configurations for heating pool water, Full Flow and Bypass Flow. Both are described in the following subsections. 5.9.1 Full Flow Piping Method A full flow system is recommended if the total system flow of the swimming pool or spa system is within five gallons per minute of the recommended system water flow as shown in the table below. -
Page 30: Bypass Flow Piping Method
AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING 5.9.2 Bypass Flow Piping Method A bypass flow system is recommended under one or more of the following conditions: • If the total system flow is greater than the amount required by the indirect heat exchanger. •... - Page 31 AM Series Pool Heater User Manual SECTION 5: INSTALLATION – PIPING OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 31 of 47...
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Page 32: Installation - Natural Gas
AM Series Pool Heater User Manual SECTION 6: INSTALLATION - NATURAL GAS SECTION 6: INSTALLATION – NATURAL GAS 6.1 Gas Supply Piping Check that the type and the pressure of the gas supplied correspond with those required for the heater as stated on the rating plate. Never use a gas different than that stated on the heater rating plate. -
Page 33: Connection Of Gas Supply Piping
AM Series Pool Heater User Manual SECTION 6: INSTALLATION - NATURAL GAS 6.3 Connection of Gas Supply Piping Connect the gas supply to the unit as follows: Connecting the Gas Supply to the Unit 1. Refer to Figure 6-1 for connections necessary to pipe gas to the unit. a) Install ground joint union for servicing, when required. -
Page 34: Natural Gas Pipe Sizing
AM Series Pool Heater User Manual SECTION 6: INSTALLATION - NATURAL GAS The unit is shipped ready to fire on natural gas. Check appliance rating plate to determine which fuel the appliance is set for. If set to natural gas, it may be converted to propane gas following instructions in Section 7.9 of AM Series User Manual GF-146. -
Page 35: Checking And Adjusting The Unit Inlet Gas Supply Pressure
AM Series Pool Heater User Manual SECTION 6: INSTALLATION - NATURAL GAS o Minimum 3” W.C. with gas flowing (verify during high fire). NOTE: Ensure that the high gas pressure regulator is at least 6 to 10 feet upstream of the appliance. 6.8 Checking and Adjusting the Unit Inlet Gas Supply Pressure DO NOT adjust or attempt to measure gas valve outlet pressure. -
Page 36: Installation - Electrical
AM Series Pool Heater User Manual SECTION 7: INSTALLATION – ELECTRICAL SECTION 7: INSTALLATION - ELECTRICAL 7.1 Electrical Connections – Boiler 7.1.1 Power Supply Cable Connection Provide and install a fused disconnect or service switch (15 amp recommended) as required by prevailing codes. - Page 37 AM Series Pool Heater User Manual SECTION 7: INSTALLATION – ELECTRICAL Figure 7-2: Pool Heater Boiler Electrical Connections OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 37 of 47...
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Page 38: Connecting Units In Cascade
AM Series Pool Heater User Manual SECTION 7: INSTALLATION – ELECTRICAL 7.1.2 Connecting Units in Cascade The cascade function is reserved for future implementation. 7.1.3 0-10 VDC Input Connections The AM Series models 500, 750 and 1000 are factory supplied with a Communications Module (the 399 model can be equipped with one as an option). -
Page 39: Electrical Connections - Boilers Only
AM Series Pool Heater User Manual SECTION 7: INSTALLATION – ELECTRICAL 7.2 Electrical Connections – Boilers Only 7.2.1 Pool Flow Switch Connections The flow switch is field supplied and installed on the pool water piping downstream of filter (pump discharge side) and before the inlet of heat exchanger (see Figures 5-5a and 5-5b). When this switch senses a flow of cold pool water to the heat exchanger, the AM boiler is enabled. -
Page 40: Pool Water High Limit Switch Connections
AM Series Pool Heater User Manual SECTION 8: UNIT STARTUP 7.2.2 Pool Water High Limit Switch Connections The pool water high limit switch is field supplied and installed downstream of heat exchanger in the supply hot pool water piping (see Figure 5-5a and 5-5b). When this switch senses a pool water temperature above the allowed maximum, the AM boiler is shut down. -
Page 41: Section 11: Boiler Technical Data
AM Series Pool Heater User Manual SECTION 8: UNIT STARTUP SECTION 11: BOILER TECHNICAL DATA REFERENCE NOTE: For all information regarding the technical data of the boiler, refer to Section 12 of the AM Series User Manual, GF-146. SECTION 12: BOILER PARTS DRAWINGS & LISTS REFERENCE NOTE: For all information regarding the detailed spare parts and lists for the boiler, refer to Section 13 of the AM Series User Manual, GF-146. -
Page 42: Section 13: System Part Drawings And Lists
AM Series Pool Heater User Manual WARRANTY SECTION 13: SYSTEM PART DRAWINGS AND LISTS 13.1 AM 399P/500P Pool Heating System Parts Drawing and List Equipment List Models: AM399P-016 AM500P-016 Item Part Description Base AM399B/AM500B Boiler 0066605 Expansion Tank 99124 Pump 63063 Relay* Starter... - Page 43 AM Series Pool Heater User Manual WARRANTY Equipment List Models: AM399P-075 AM500P-075 Item Part Description Base AM399B/AM500B Boiler 0066605 Expansion Tank 99126 Pump 63190 Relay* Starter 16050265-001 Pool Heat Exchanger 92081-2.5 Circuit Setter Thermal Unit 121700 Low Water Cutoff 0386425 Press Reducing Valve 61053 Water Return Temperature Sensor...
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Page 44: Am 750P/1000P Pool Heating System Parts Drawing And List
AM Series Pool Heater User Manual WARRANTY 13.2 AM 750P/1000P Pool Heating System Parts Drawing and List Equipment List Models: AM750P-016 AM1000P-016 Item Part Description Base AM750B/AM1000B Boiler 0066605 Expansion Tank 99124 Pump 63063 Relay* Starter 28567 Pool Heat Exchanger 92081-2.5 Circuit Setter Thermal Unit... - Page 45 AM Series Pool Heater User Manual WARRANTY Equipment List Models: AM750P-075 AM1000P-075 Item Part Description Base AM750B/AM1000B Boiler 0066605 Expansion Tank 99126 Pump 63190 Relay* Starter 28567 Pool Heat Exchanger 92081-2.5 Circuit Setter Thermal Unit 121700 Low Water Cutoff 0386425 Press Reducing Valve 61053 Water Return Temperature Sensor...
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Page 46: Am Series Pool Heater Warranty
AM Series Pool Heater User Manual WARRANTY AM SERIES POOL HEATER WARRANTY: The pressure vessel/heat exchanger of the boiler carries a non-prorated 7 year warranty against failure due to condensate corrosion, thermal stress, mechanical defects or workmanship. All other boiler components carry an 18-month warranty against failure due to defective materials or workmanship. - Page 47 AM Series Pool Heater User Manual Change Log: DATE DESCRIPTION CHANGED BY 11/29/2018 Rev A: Initial release. Rev B: Parts List Update (Section 13.2); 10/29/2019 Linley Thobourne Wiring Update (Section 7) © AERCO International, Inc., 2018 OMM-0111_B: • GF-146-P • 10/29/2019 Technical Support •...