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INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
399-1000 MBH Hot Water Boiler Indoor/Outdoor
Model:
Installation Date:
Heating Contractor:
Address:
Thermal Solutions Products, LLC
Phone: 717-239-7642
Boiler Models
AMP 400
AMP 500
AMP 650
AMP 800
AMP 1000L
1175 Manheim Pike, Lancaster, PA 17601
WARNING
WARNING: If the information in these instructions
is not followed exactly, a fire or explosion may
result causing property damage, personal injury
or death.
DANGER
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
Serial Number:
System Type:
Phone/Email:
PN: 110820-05
Save this manual for future reference.
WARNING
DANGER
www.thermalsolutions.com
orders@thermalsolutions.com
Rev. 2, 4/23
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Table of Contents
Related Manuals for Thermal Solutions AMP 400
Summary of Contents for Thermal Solutions AMP 400
- Page 1 AMP 650 supplier. AMP 800 AMP 1000L Model: Serial Number: Installation Date: System Type: Heating Contractor: Phone/Email: Address: Thermal Solutions Products, LLC www.thermalsolutions.com Phone: 717-239-7642 1175 Manheim Pike, Lancaster, PA 17601 orders@thermalsolutions.com...
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Page 2: Table Of Contents
Venting Design Requirements Field Installation Room Air for Combustion PVC Venting Venting for Outdoor Installation General Termination Vent and Combustion Air Terminations Multiple Appliance Terminations Terminal Installation Polypropylene Venting Optional Room Air for Combustion Removing Existing Appliance Special Installation Requirements for Massachusetts Condensate trap VIII. Condensate Disposal Condensate Neutralizer Installation AMP 400-1000L I&O Manual... - Page 3 Testing of Controls and Safety Devices General Maintenance XIV. Service and Maintenance Monthly Inspection Annual Inspections and Service Restarting after Prolong Shutdown Troubleshooting APPENDIX A: Tables APPENDIX B: Figures APPENDIX C: Default Light-off and Modulation Rates APPENDIX D: Gas Valve and Pressure Switch Tubing Schematics AMP 400-1000L I&O Manual...
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Page 4: Hazard Definitions
Failure to prevent the gas line from turning could damage correctly installed and are operating properly. the gas train components on the appliance (gas valve, 2. Factory warranty does not apply to units improperly blower, etc.). installed or improperly operated. AMP 400-1000L I&O Manual... -
Page 5: Gas Leakage (If You Detect Or Smell Gas
California to cause cancer and birth defects or Should overheating occur or the gas supply fail to shut other reproductive harm. For more information off, turn off the manual gas control valve to the appli- go to: www. P65Warnings.ca.gov. ance. AMP 400-1000L I&O Manual... -
Page 6: Product Rating, Specifications, And Dimensional Data
Appliance will go into hard lockout if temperature exceeds 200 Table 3: Appliance Connection Sizes AMP Model Dimensions (in.) 1000L Gas Inlet Water Outlet Pipe (FNPT) Water Inlet Pipe (MNPT) Air Intake Vent Outlet Condensate Drain (PVC) Drain Line (FNPT) Electrical Conduit Holes AMP 400-1000L I&O Manual... - Page 7 8 " 8 " 43" 2 " 2 " 8 " 4 " 2 " 4 " 4 " 8 " 8 " 8 " 4 " Front View Rear View 10" Figure 1: AMP 400-500 Dimensions AMP 400-1000L I&O Manual...
- Page 8 8 " 4 " 43" 2 " 8 " 2 " 4 " 26 2 " 4 " 4 " 8 " 8 " 4 " 8 " Front View 10" Back View Figure 2: AMP 650-1000L Dimensions AMP 400-1000L I&O Manual...
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Page 9: Unpacking The Amp
Please read the instructions contained in this manual carefully as they provide important information Rear intake cover regarding the safe installation, use and servicing of this appliance. Figure 3: AMP 400-1000L with Outdoor Trim AMP 400-1000L I&O Manual... -
Page 10: Amp Boiler Component Identification
4" female PVC slip provided for 400-500 models. 15. Gas supply connection 6" aluminum ring provided for 650-1000 models. Connection to appliance gas train. See Table 28 for model specific pipe sizes. 16. Inlet/Return 2" Male NPT inlet water connection to the appliance. AMP 400-1000L I&O Manual... - Page 11 V. AMP Boiler Component Identification (continued) Figure 4: Component Identification AMP 400-1000L I&O Manual...
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Page 12: Pre-Installation And Mounting
Ensure air intake accelerated component failure. pipe termination is away from areas that may Thermal Solutions DOES NOT warrant failures contaminate the combustion air (see Table 4). In caused by mis-sized appliance applications. DO particular, avoid areas near chemical products NOT oversize the appliance to the system. -
Page 13: Appliance Mounting
3 feet from its top. The area under the heat exchanger. overhang must be open on 3 sides. 4. Provide adequate space for condensate piping, Never install directly on carpeted flooring. condensate pump, or neutralizer kit. AMP 400-1000L I&O Manual... -
Page 14: Amp 400-1000L Stacking
VI. Pre-Installation and Mounting (continued) D. AMP 400-1000L Stacking a. Follow all previous instructions for mounting the 1. The AMP 400-1000L models may be installed in a bottom appliance. stacked configuation. b. Use the included screws to secure the brace as a. -
Page 15: Clearances
Intall in couples 4. Clearances for closet or alcove Installation: with at least 24 inches inbetween Front - 24" Sides - 24" Rear - 22" Top - 20" Table 5: AMP 400-1000L Clearances Minimum Front Rear Right Left Clearance (In.) -
Page 16: General Venting Guidelines
Common venting with other manufacturers' ap- to the rating of adjoining floor or ceiling. pliances or different Thermal Solutions models is 5. For flue gas venting, have horizontal runs sloping prohibited. -
Page 17: Field Installation
Combustion Air Total Vent Total Equivalent Length Equivalent Length Notes: 1. Total equivalent length cannot exceed maximum equivalent length shown in Table 6. 2. Combustion air and vent terminations do not count towards total equivalent length. AMP 400-1000L I&O Manual... - Page 18 Note: Flow rates are based on the combustion of natural gas. Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphe- WARNING WARNING nylsulfone) in non-metallic venting systems is prohibited. Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. AMP 400-1000L I&O Manual...
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Page 19: Room Air For Combustion
The outdoor vent system requires field installed support. Do not rely on the vent adapter of the appliance to hold the vent material The outdoor vent kit may be shipped separately from the appliance. AMP 400-1000L I&O Manual... -
Page 20: General Termination
1. It is recommended to use tees for both intake and vent terminations in extra windy locations. NOTICE NOTICE 2. All terminations shall have bird screens. 3. All non-metallic venting exposed to sunlight shall be UV resistant. AMP 400-1000L I&O Manual... - Page 21 Covering non-metallic vent pipe and fittings with through a common conduit or chase so that thermal insulation is prohibited. one roof penetration may be made. Maintain recommended separations of terminations after penetration. Figure 8: Vent Terminal Clearances AMP 400-1000L I&O Manual...
- Page 22 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearance shall prevail. AMP 400-1000L I&O Manual...
- Page 23 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code If locally adopted installation codes specify clearances different than those illustrated, then the most stringent clearance shall prevail. AMP 400-1000L I&O Manual...
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Page 24: Vent And Combustion Air Terminations
Do not use a barometric damper or draft hood culation. Recirculation of flue gas products into with this appliance. the combustion air supply can cause damage to property or the appliance. AMP 400-1000L I&O Manual... - Page 25 Do not use Louvers for direct vent systems One appliance per gooseneck termination Vent and intake piping must not share the same gooseneck All terminations should have Bird/Rodent Screens Do not use rain caps, Rain will drain through boot tee or condensate drain AMP 400-1000L I&O Manual...
- Page 26 To avoid/ minimize frost damage, extend the distance from building surfaces to vent termination end and increase the horizontal distance between adjacent vent terminations AMP 400-1000L I&O Manual...
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Page 27: Multiple Appliance Terminations
1/2 in. x 1/2 in. (13 mm x 13 mm) Alteration of the appliance vent connection is mesh. prohibited. 4. Adhere to the minimum and maximum wall thickness specified by the manufacturer of the wall penetration assembly. AMP 400-1000L I&O Manual... - Page 28 4. For roof terminations, install vent terminal Above Snow Line downstream of prevailing winds relative to intake terminal. 5. It is recommended to use tee terminations with a vertical run in extra windy areas. Figure 12: Multiple Appliance Direct Vent Termination AMP 400-1000L I&O Manual...
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Page 29: Polypropylene Venting
Avoid combustion air contaminants in the boiler venting system. room. Permanently remove any contaminants found in the boiler room. If contaminants cannot be removed, do not use room air for combustion. AMP 400-1000L I&O Manual... - Page 30 DO NOT use chimney for Combus- tion air intake. DO NOT insulate polypropylene vent pipes. Excessive heat could cause premature vent pipe failure. Figure 13: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake AMP 400-1000L I&O Manual...
- Page 31 A flue gas vent or a vent connector shall not be tions in this manual installed inside either a duct or a shaft used for Thermal Solutions takes no responsibility for vent return air, hot air, ventilating air, or combustion systems that create issues and or affect the per- air.
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Page 32: Removing Existing Appliance
Propane Installation Code, CAN/CSA B149.1. Resizing of any portion of the common venting system, should be done in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/ or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. AMP 400-1000L I&O Manual... -
Page 33: Special Installation Requirements For Massachusetts
5. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. AMP 400-1000L I&O Manual... -
Page 34: Condensate Disposal
Use continuous Teflon, high temperature silicone tubing, or other tubing material compatible with flue gas condensate for condensate piping. c. Do not route or terminate the condensate drain line in areas subject to freezing temperatures. AMP 400-1000L I&O Manual... - Page 35 2. If a common sump is used, individual drain lines 107860-09 107886-10 should be constructed, using material listed above, such that one drain cannot back feed into another 107860-09 107886-10 drain. 1000L 107860-06 107886-06 3. Do not manifold condensate and vent drains together. AMP 400-1000L I&O Manual...
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Page 36: Hydronic Piping
1. Primary/Secondary piping is the recommended can lead to appliance failure. Thermal Solutions’ piping configuration. Isolate the appliance from Standard Warranty does not cover problems the system using closely spaced tees (12 inches or caused by contamination of supply water. - Page 37 5 pipe diameters from T & P Gauge the flow switch. 2" pipe nipple, close 2" X 2" X 1" reducing tee 3/4" pipe nipple, close 1" x 3/4" Hex Bushing Pressure relief Valve AMP 400-1000L I&O Manual...
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Page 38: Standard Piping Components
Flow control valves are used to prevent gravity expansion tank can generally be reused. If the circulation in circulator zone systems through zones expansion tank must be replaced, consult the that are not calling for heat. expansion tank manufacturer’s literature for proper sizing. AMP 400-1000L I&O Manual... -
Page 39: Water Quality
Chlorine and Chloride have different levels of corrosion needed. effects on stainless steel. It is recommended for chlorine (Cl2) levels to be below 5ppm and chloride (Cl ) levels to be below 150 ppm for 316 stainless steel. AMP 400-1000L I&O Manual... -
Page 40: Oxygen Contamination
NOTICE NOTICE 3. There are many possible causes of oxygen Thermal Solutions' Standard Warranty does not cover contamination such as: boiler failure caused by oxygen contamination of boiler a. Addition of excessive make-up water as a result water or scale build-up. -
Page 41: Temperature Rise And Heat Exchanger Head Loss
Required Flow = Output×1000/(500×ΔT), where flow rate is in GPM, output is in MBH, and ΔT is in 0F, Outputs are shown in Table 1. This Boiler has a temperature rise (delta) limit of 55 °F AMP 400-1000L I&O Manual... -
Page 42: Water Piping Diagrams
3. Some piping components cannot be supported by the piping. Refer to the man- CAUTION CAUTION ufacturers' installation instructions. 4. It is the installer's responsibility to select piping configurations that provide the proper flow rates and performance. AMP 400-1000L I&O Manual... - Page 43 3. Some piping components cannot be supported by the piping. Refer to the man- CAUTION CAUTION ufacturers' installation instructions. 4. It is the installer's responsibility to select piping configurations that provide the proper flow rates and performance. 5. Erosion could occur if common piping is undersized. AMP 400-1000L I&O Manual...
- Page 44 3. Some piping components cannot be supported by the piping. Refer to the man- CAUTION CAUTION ufacturers' installation instructions. 4. It is the installer's responsibility to select piping configurations that provide the proper flow rates and performance. 5. Erosion could occur if common piping is undersized. AMP 400-1000L I&O Manual...
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Page 45: Gas Piping
7. To protect the gas valve when testing over 1/2 psig (3.4 kPa), the appliance and its individual shutoff Figure 19: The AMP 400-1000L Gas Connection valve must be disconnected from gas supply piping. For testing at 1/2 psig (3.4 kPa) or less, isolate the appliance from gas supply piping by closing the manual shutoff valve on the appliance. - Page 46 0.824 22.9 11.4 ½ 1.049 29.1 14.6 ¾ 1.38 38.3 19.1 1.61 44.7 22.4 11.2 1¼ 2.067 57.4 28.7 14.4 11.5 10.3 1½ 2.469 68.5 34.3 17.1 13.7 12.3 3.068 85.2 42.6 21.3 17.1 15.3 2½ AMP 400-1000L I&O Manual...
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Page 47: Gas Pressure Switches
Low Gas Inlet Size (In. W.C.) (In. W.C.) Pressure Switch Pressure Switch (In.) Model (In. W.C.) (In. W.C.) Natural Propane Natural Propane Natural: 3 LP: 7 1000L Factory default high and low gas pressure switch setpoint. AMP 400-1000L I&O Manual... -
Page 48: Electrical
1. 1. Route all field connections through conduits into Route all field connections through conduits into rors can cause improper and dangerous operation. the rear control box. the rear control box. Verify Proper operation after servicing. AMP 400-1000L I&O Manual... -
Page 49: System And Circulation Pump Wiring
AIR DAMPER 6.3A, SLOW BLOW (IF USING 5mm X 20mm FUSE ROOM AIR) * For indirect water heating with boiler models. Use Primary Pump for direct water heating with water heater models. Figure 21: 120 VAC Connections PCB AMP 400-1000L I&O Manual... - Page 50 XII. Electrical (continued) Figure 22: Low Voltage Connections PCB AMP 400-1000L I&O Manual...
- Page 51 COMBUSTION AIR DAMPER AND PROVING SWITCH ARE REQUIRED IF USING ROOM AIR FOR COMBUSTION WITH MOTORIZED DAMPER(S) OR LOUVER(S). ENERGY MANAGEMENT SYSTEM WIRING CAN BE DONE WITH RJ45 PLUGS OR USING SCREW TERMINALS A, B AND C LABELED 'EMS (DELTA ONLY)'. Figure 23: AMP 400-1000L Wire Schematic AMP 400-1000L I&O Manual...
- Page 52 Pump L Pump N System Pump LWCO P3-12 L2-1 L2-3 P3-2 24V Transformer Figure 24: AMP 400-1000L Wire Diagram 24V Fuse, F3 Size 400: 1.6A Slow Blow 24V Transformer Control Panel Size 500-1000: 2.4A fast acting Ground Screw P8-8 L3-1 L3-2...
- Page 53 Peer-to-Peer and EMS J8-8 Outlet/ J8-9 Supply Sensor J8-10 J9-4 Flue Gas J9-5 Sensor J9-6 J10-7 Outdoor P8-11 J10-8 Sensor P8-3 J8-11 Header/ Tank P8-9 Sensor J8-6 Remote P8-1 4-20mA J9-1 P8-2 J9-2 Sensor P8-10 Wire Diagram (continued) AMP 400-1000L I&O Manual...
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Page 54: System Start-Up
Concert Control is required personal injury or death. to restart. If ignition is not achieved in three consecutive attempts, contact factory or a qualified heating service technician. AMP 400-1000L I&O Manual... - Page 55 3. Tourner la chaudière externe manuelle poignée en clapet à gaz dans le performed. 3. Turn the external boiler manual gas valve handle clockwise sens des aiguilles d'une montre pour fermer l'offre de gaz. to close gas supply. 101607-03 Figure 25: Operating Instructions AMP 400-1000L I&O Manual...
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Page 56: Combustion Air/Fuel Adjustment
VALVE COIL (V2) INLET GAS PRESSURE TAP (P1) WITH INTERNAL SCREW OUTLET GAS PRESSURE TAP (P2) WITH INTERNAL SCREW GAS INLET THROTTLE SCREW OFFSET SCREW VALVE COIL (V1) (ADJUSTMENT NOT NORMALLY REQUIRED) Figure 27: AMP 400 Gas Valve Adjustment AMP 400-1000L I&O Manual... -
Page 57: Field Conversion Of Gas Type
111545-02 111544-02 6. Fill out the gas conversion labels included with the 111545-03 111544-03 appliance (Order part number 110301-01 if not 111545-04 111544-04 included). Follow the instructions included with the 1000L 111545-05 111544-05 label for placement. AMP 400-1000L I&O Manual... -
Page 58: Pump Control
Low Water Level. reset button. down the main burner. Reduce the water flow rate with Water Flow Adjust manual valve to normal a manual shutoff valve until the Low Water Flow Switch position. appliance shuts down. AMP 400-1000L I&O Manual... -
Page 59: Service And Maintenance
• If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist. • Ingestion: Do NOT induce vomiting. Drink plenty of water. Seek immediate medical attention. AMP 400-1000L I&O Manual... -
Page 60: General Maintenance
Verify proper operation after servicing. NOTICE NOTICE To reduce lime scale buildup and prolong the life of the appliance, closely monitor pH, chloride, total dissolved solids, and water hardness levels. See Table 20. AMP 400-1000L I&O Manual... - Page 61 Never jump out or bypass any safety or operating control or component. Interior of the venting system must be inspected and clean before the initial startup and should be inspected periodically for any obstructions. AMP 400-1000L I&O Manual...
- Page 62 Slide the control box out. ii. Do not spray burner, combustion chamber divider, or burner door insulations. e. The burner door, blower, and mixer assembly can be pulled out of the appliance jacket as shown in Figure 30. AMP 400-1000L I&O Manual...
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Page 63: Restarting After Prolong Shutdown
Control manual on how to navigate the Limit String Status screen which shows an active safety limit status and for an in-depth guide to all the possible lockouts as well as recommended corrective actions to restore operation. AMP 400-1000L I&O Manual... -
Page 64: Appendix A: Tables
Table 14: Direct Vent Terminal Clearances Table 15: Other than Direct Vent Terminal Clearances Table 16: Table of Acceptable Terminations Table 17: Condensate Neutralizer Kit VIII. Condensate Disposal Table 18: Outlet Piping Parts IX. Hydronic Piping Table 20: Water Quality Requirements Table 19: Absolute Water Flow Rates Table 21: Corrosion/Scale Inhibitors and Removal Agents Table 22: Water Treatment Types Table 23: Flow Rates for Glycol Systems Table 24: Temperature rise, flow rate, and head loss X. Water Piping Diagrams Table 25: Maximum capacity of schedule 40 black pipe in CFH* XI. Gas Piping Table 26: Equivalent Lengths of Standard Pipe Fittings & Valves (ft) Table 27: Specific Gravity Correction Factors Table 28: Inlet Gas Pressures and Pipe Size Table 29: Electrical Ratings XII. Electrical Table 30: Combustion O Levels XIII. System Start-up Table 31: Approximate Throttle Screw Position for Gas Types Table 32: Gas Conversion Kits Table 33: Safety Device Test XIV. Service and Maintenance AMP 400-1000L I&O Manual... -
Page 65: Appendix B: Figures
Figure 11: Flat Roof Vent Terminations Figure 10: Slopped Roof Termination Figure 12: Multiple Appliance Direct Vent Termination Figure 13: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake Figure 14: Condensate Drain Assembly VIII. Condensate Disposal Figure 15: Relief Valve Package Assembly IX. Hydronic Piping Figure 16: Single Boiler, Primary/Secondary Piping X. Water Piping Diagrams Figure 17: Multiple Boiler, Primary/Secondary with Common Header Piping Figure 18: Single Boiler with Indirect Domestic Water Heater Figure 19: The AMP 400-1000L Gas Connection XI. Gas Piping Figure 20: High/Low Gas Pressure Switch Figure 21: 120 VAC Connections PCB XII. Electrical Figure 22: Low Voltage Connections PCB Figure 23: AMP 400-1000L Wire Schematic Figure 24: AMP 400-1000L Wire Diagram Figure 25: Operating Instructions XIII. System Start-up Figure 27: AMP 400 Gas Valve Adjustment Figure 26: AMP 500-1000L Gas Valve Adjustment Figure 28: Igniter Electrode Assembly XIV. Service and Maintenance Figure 29: Ionization Electrode (Flame Rod) Figure 30: Burner Door Opening AMP 400-1000L I&O Manual... -
Page 66: Appendix C: Default Light-Off And Modulation Rates
Maximum Light-off (RPM) 3600 2600 2600 2200 2600 2000 2600 Minimum Light-off (RPM) 3000 1900 2200 1700 2200 1700 2200 Factory Default RPM NOTE: To maintain rate in maximum vent length application, contact factory for assistance. AMP 400-1000L I&O Manual... -
Page 67: Appendix D: Gas Valve And Pressure Switch Tubing Schematics
APPENDIX D: Gas Valve and Pressure Switch Tubing Schematics AMP 400-1000L I&O Manual... - Page 68 APPENDIX D: Gas Valve and Pressure Switch Tubing Schematics (continued) REV: DATE: DWN: ENG: APPD: APPD: FIRST USE MATERIAL PART NUMBER TITLE AMP 400-1000L I&O Manual PROPERTY OF...
- Page 69 If a claim is made under this warranty during the “No Charge” period from the date of shipment, Thermal Solutions will, at its option, repair or replace the pressure vessel (not including labor).
- Page 70 Thermal Solutions Product, LLC Lancaster, PA 17604-3244 Phone: 717-239-7642 orders@thermalsolutions.com www.thermalsolutions.com...