Aerco AM Series Application Manual
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Aerco AM Series Application Manual

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Natural Gas or Propane
Modulating & Condensing
Boilers and Water Heaters
Applies to the following models:
Boilers
•
AM 399B
•
AM 500B
•
AM 750B
•
AM 1000B
Water Heaters
•
AM 399W
•
AM 500W
•
AM 750W
•
AM 1000W
04/08/2014
Page 1 of 30
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
PIPING APPLICATION GUIDE
Pending
Pending
399 / 500 / 750 / 1000
Gas-Fired Boilers and Water Heaters
AM 399 Single-Installation Piping Example
GF-146-P
TAG-0074_0B
PR1 04/08/2014

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  • Page 1 • AM 399W • AM 500W • AM 750W • AM 1000W AM 399 Single-Installation Piping Example Pending 04/08/2014 Page 1 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • 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. AERCO International is not liable for errors appearing in this manual, nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of these materials.

  • Page 3: Table Of Contents

    PRIMARY-SECONDARY PIPING ..............19 4.2. SYSTEM FILLING AND DRAINING ............... 19 4.3. CONDENSATE DRAIN ................... 19 PIPING DIAGRAMS ................. 21 Page 3 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

  • Page 4: Mandatory Requirements

    For boiler replacement installations, cleaning of the whole system is required before connecting the boiler (See Section 2.3 for Flushing, Treatment, and Cleansing tips and guidelines). Failure to clean a system will limit it from the full benefits offered by the high efficiency AM Series. •...
  • Page 5 Each relief valve must have its own discharge piping all the way to the point of discharge, and must never be manifolded, attached to, or combined with any other piping. Page 5 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

  • Page 6: Boiler Quality And Maintenance

    2.1.3. Treating Water to Prevent Freezing When using anti-freeze solutions, their compatibility with the AM Series 316 (Ti) heat exchanger and other components of the heating system must be determined prior to use. If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed upstream of the fill/makeup valve.
  • Page 7 Water treatment is also advisable in the following cases: o Very large heating systems o High quantities of replenished water due to leakages or maintenance work Page 7 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

  • Page 8: System Flushing, Treatment, And Cleansing

    Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent infusion of containments, including sludge, into the boiler. Section 2.3 provides recommendations for flushing, cleaning, and treating the water used in the AM Series system. IMPORTANT! Cleaning solution and inhibitors used must be compatible with heat exchanger material.

  • Page 9: Water Quality Maintenance And Boiler Warranty

    – actual pressure drops will vary depending on actual piping layout and strainer size/type used. Page 9 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 10 Water Flow (GPM) @ Min. ∆T of 25°F 29.4 36.8 55.2 73.6 Water Pressure Drop (Ft. of Hd.) at Max. Flow 41.5 Page 10 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

  • Page 11: Primary Pump

    NOTE Select the pump flow rate so that the boiler water outlet temperature is 190°F (87.8°C) or below. Page 11 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 12 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 2: Water Side Pressure Loss Chart Figure 3: Water Velocity Flow Chart Page 12 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 13 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 4: AM BOILER: Electrical Connections Page 13 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 14 Figure 5: Water Heater Electrical Junction Box Connections (with Small Storage Tank) Figure 6: Water Heater Electrical Junction Box Connections (with Large Storage Tank) Page 14 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

  • Page 15: Strainers

    TAG-0074 0B 2.5. STRAINERS AERCO requires the installation of a Y strainer to keep dirt out of the system and boiler. The strainer should be installed in the return piping with isolation valves to allow for cleaning as necessary. The Y strainer shall have a 20 mesh or finer strainer.

  • Page 16: Air Venting Of The Heating System (Boilers Only)

    2.7. AIR VENTING OF THE HEATING SYSTEM The AM Series units come standard with automatic air vents on each of the headers on the rear of the unit (see Figure 6a and 6b). These vents are for the unit only and not the entire heating system. An effective air vent for air removal for the entire heating system must be installed in the highest point of the system piping.
  • Page 17 SENSOR WATER SUPPLY (OUTLET) CONNECTION HEADERS WATER RETURN (INLET) CONNECTION DRAINING VALVES Figure 6b: AM 750/1000 Rear Panel Connections Page 17 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 18 If a low water cutoff (LWCO) is preferred (Figure 8), one may be installed in place of, or in addition to, the flow switch. This is available as an accessory from AERCO. When installing such a device, you must consult and abide by all local codes and regulations in force.

  • Page 19: Connections

    3/8 in./ft. (30 mm/m). In order to prevent ice from forming, the condensate piping must be well insulated. Figure 9: Typical Condensate Drain Installation Page 19 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 20 Application Guide TAG-0074 0B The AM Series of boilers and water heaters come equipped with a condensate trap and neutralizer tank (see Figure 10). It is crucial that these be filled with water to prevent combustion gases from entering the room and/or gases flowing backwards through the condensate line. A corrugated tube is provided to pipe neutralized condensate to a drain.

  • Page 21: Piping Diagrams

    13" W.C.) 7) All drawings are of typical installations. Local codes and authorities should be consulted. Page 21 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 22 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 11: AM 399/500 Single Unit Installation Page 22 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 23 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 12: AM Series 399/500 Single Unit Installation with DHW Installed Page 23 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 24 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 13: AM Series 399/500 Multiple Unit Installation Page 24 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 25 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 14: AM Series 399/500 Multiple unit Installation With DHW Installed Page 25 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 26 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 15: AM 750/1000 Single Unit Installation Page 26 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 27 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 16: AM Series 750/1000 Single Unit Installation with DHW Installed Page 27 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 28 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 17: AM Series 750/1000 Multiple Unit Installation Page 28 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 29 AM Series Piping GF-146-P Application Guide TAG-0074 0B Figure 18: AM Series 750/1000 Multiple unit Installation With DHW Installed Page 29 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...
  • Page 30 TAG-0074 0B Change Log Date Description Changed By 04/08/2014 Rev 0A: Release Curtis Harvey © AERCO International, Inc., 2014 www.aerco.com Page 30 of 30 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/08/2014...

This manual is also suitable for:

Am 399bAm 500bAm 750bAm 1000b

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