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Aerco Esteem 399 Installation, Operation & Maintenance Manual

Low nox boiler
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GF-135
Esteem 399 Low NOx Boiler
Installation, Operation & Maintenance Manual
USER MANUAL
Natural Gas or Propane Gas
Modulating & Condensing Hot
Water Boiler:
Installation, Operation and Maintenance
GAS FIRED BOILER
02/05/2019
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
OMM-0089_0B
Page 1 of 188
02/05/2019

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  • Page 1 Installation, Operation & Maintenance Manual USER MANUAL Natural Gas or Propane Gas Modulating & Condensing Hot Water Boiler: Installation, Operation and Maintenance GAS FIRED BOILER 02/05/2019 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 1 of 188 02/05/2019...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    5.9 CIRCULATOR ..............................34 5.10 SIZING PRIMARY PIPING ..........................34 5.11 DOMESTIC HOT WATER SYSTEM PIPING ......................34 5.12 SYSTEM PIPING - ZONE CIRCULATORS ......................34 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 3 of 188 02/05/2019...
  • Page 4 10.7.2 CH1 Setpoint (Default: 180°F [82°C]) ......................72 10.7.3 CH2 Setpoint (Default: 140°F [60°C]) ......................72 10.7.4 Select CH1 Reset Curve (Default: Finned Tube Baseboard) ..............72 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 4 of 188...
  • Page 5 12.4.3 Gas Piping Inspection ..........................94 12.4.4 Flame Pattern and Combustion Verification .................... 94 12.4.5 Measure and Verify Input Rating - Natural Gas Only ................96 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 5 of 188...
  • Page 6 18.3.4 CH1 Maximum Setpoint (Default: 180°F [82°C]) ..................123 18.3.5 CH1 Minimum Setpoint (Default: 120°F [49°C]) ..................124 18.3.6 Reset Curve Coldest Day (Default: 0°F [-18°C]) ..................124 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 6 of 188...
  • Page 7 MENU ......................158 18.9.1 System Temperature Logging ......................... 158 18.9.2 Cascade Settings Menu ........................159 18.9.3 Stage Delay (Default: 60 Seconds) ......................160 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 7 of 188 02/05/2019...
  • Page 8 DHW Parameter ........................... 172 18.10.4 SYS CH2 Parameter ........................173 APENNDIX A: PART AND DIMENSIONAL DRAWINGS ............... 175 APENNDIX B: CIRCULATOR PRESSURE LOSS CHARTS ..............183 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 8 of 188 02/05/2019...

  • Page 9: Chapter 1: Safety Precautions

    • High electrical voltages are used in this equipment, therefore the cover on the unit’s power box must be installed at all times, except during maintenance and servicing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 9 of 188...
  • Page 10 Please have the unit’s model number and the serial number from the rating label, on the backside of the control panel when inquiring about service or troubleshooting. AERCO International accepts no liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by AERCO International.

  • Page 11: Emergency Shutdown

    Chapter 12 of this manual be performed, to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream from the unit.
  • Page 12 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 12 of 188...
  • Page 13 [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 13 of 188...
  • Page 14 GF-135 Esteem 399 Low NOx Boiler Chapter 1 Installation, Operation & Maintenance Manual Safety Precautions (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 14 of 188 02/05/2019...

  • Page 15: Chapter 2: Installation

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

  • Page 16: Boiler Replacement

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

  • Page 17: Residential Garage Installations

    46ºF or less. See “Chapter 5 Boiler Piping” for primary/secondary piping examples. See Section 11.1.6 for antifreeze guidelines. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 17 of 188 02/05/2019...
  • Page 18 GF-135 Esteem 399 Low NOx Boiler Chapter 2 Installation, Operation & Maintenance Manual Installation (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 18 of 188 02/05/2019...

  • Page 19: Chapter 3: Combustion Air And Venting

    • Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms • Adhesives used to fasten building products and other similar products AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 19 of 188 02/05/2019...

  • Page 20: Areas Likely To Contain Contaminating Products

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

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

    .40 ACH. For infiltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas Code for additional guidance. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 21 of 188 02/05/2019...

  • Page 22: Indoor Combustion Air

    2 sq. in./1000 Btu/hr. of total input rating of all gas utilization equipment. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 22 of 188...

  • Page 23: Outdoor Combustion Air

    1 sq. in./3000 Btu/hr. of the total input rating of all equipment located in the enclosures, • Not less than the sum of the areas of all vent connectors in the space. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 23 of 188...

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

    1 sq. in./2000 Btu/hr. of total input rating of all equipment in the enclosure. See Figure 3-4. Figure 3-4: All Combustion Air from Outdoors Through Horizontal Ducts AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 24 of 188...

  • Page 25: Combination Of Indoor And Outdoor Combustion Air

    Install combustion air and vent pipe as detailed in the Esteem boiler Vent Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for addition vent installation instructions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 25 of 188 02/05/2019...

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

    Part II of the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation codes. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 26 of 188...
  • Page 27 Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 27 of 188 02/05/2019...
  • Page 28 GF-135 Esteem 399 Low NOx Boiler Chapter 3 Installation, Operation & Maintenance Manual Combustion Air/Venting (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 28 of 188 02/05/2019...

  • Page 29: Chapter 4: Unit Preparation

    UNIT PREPARATION 4.1 HANDLING INSTRUCTIONS The Esteem 399 Low NOx boiler is generally easier to handle and maneuver once removed from the shipping carton. To remove the shipping carton, follow these instructions: Removing the Esteem Boiler from the Shipping Carton...

  • Page 30: Stud Wall Installation

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

  • Page 31: Chapter 5: Boiler Piping

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

  • Page 32: Boiler Air Vent

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 32 of 188...

  • Page 33: Additional Limit Control

    Eventual boiler heat exchanger failure can result due to this excessive makeup water addition. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 33 of 188...

  • Page 34: Diaphragm Expansion Tank

    Connect the Esteem boiler to the system piping as shown in Figure 5-5 when zoning with zone circulators. The installer must provide a separate circulator for each zone of space heating as well as the boiler circulator. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 34 of 188 02/05/2019...

  • Page 35: System Piping - Zone Valves

    Figure 5-8 illustrates a single zone utilizing the boiler circulator as the system circulator. 5.15 SYSTEM PIPING - RADIANT HEATING The heat exchanger design of the Esteem 399 Low NOx boiler allows operation in a condensing mode. This feature requires no return water temperature regulation in radiant heating applications.

  • Page 36: System Piping-Special Applications

    The boiler system piping shown must be a “closed” system to avoid any contamination and potential failure of any components in the system. Figure 5-2: Piping Diagram Component Legend AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 36 of 188 02/05/2019...
  • Page 37 Pitch horizontal piping upwards (1” of pipe per 5 feet of piping) toward expansion tank. Figure 5-4: Near Boiler Piping – Closed Type Expansion Tank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 37 of 188 02/05/2019...
  • Page 38 Smart. Figure 5-6: System Piping – Zoning with Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 38 of 188 02/05/2019...
  • Page 39 Smart. pressure drop and provide adequate flow through the boiler system. Figure 5-8: System Piping – Single Zone System with Single System/Boiler Circulator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 39 of 188 02/05/2019...
  • Page 40 Esteem 399 Low NOx Boiler Chapter 5 Installation, Operation & Maintenance Manual Boiler Piping Figure 5-9: System Piping – Multiple Esteem Boiler Piping – Secondary/Primary AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 40 of 188 02/05/2019...
  • Page 41 13 = High Temp. Limit Control 4 = Isolation Valve 8 = Air Separator 5 = Zone Valve 9 = Automatic Air Vent AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 41 of 188 02/05/2019...
  • Page 42 GF-135 Esteem 399 Low NOx Boiler Chapter 5 Installation, Operation & Maintenance Manual Boiler Piping (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 42 of 188 02/05/2019...

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

    6.1 INSTALLING VENT AND COMBUSTION AIR INTAKE WARNING! The Esteem 399 Low NOx boiler must be vented and supplied with combustion air as instructed in the Esteem boiler Vent Application Guide (GF-125V or GF-125CV), which is included in the boiler installation envelope. Once installation is complete, inspect the vent and combustion air system thoroughly to ensure systems are airtight and comply with the instructions given in the venting guide and are within all requirements of applicable codes.
  • Page 44 If the condensate is subjected to freezing or becomes obstructed, it can leak, resulting in potential water damage to the boiler and surrounding area. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 44 of 188 02/05/2019...

  • Page 45: Chapter 7: Gas Piping

    7. Close the manual shutoff valve during any pressure test with less than 13” W.C.. 8. Disconnect the Esteem boiler and its gas valve from the gas supply piping during any pressure test greater than 13” W.C.. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 45 of 188...

  • Page 46: Natural Gas

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

  • Page 47: Natural Gas Supply Pressure Requirements

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

  • Page 48: Propane Gas Supply Pressure Requirements

    7-2. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage. NOTE The propane orifice required for the Esteem 399 Low NOx boiler is 0.264” (6.7 mm). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 49 THROTTLE SCREW (RED PLASTIC SLEEVE) INLET PRESSURE PORT Figure 7-2: Gas Valve and Component Locations (With Gas Valve Shown Separated From the Blower Assembly) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 49 of 188 02/05/2019...
  • Page 50 GF-135 Esteem 399 Low NOx Boiler Chapter 7 Installation, Operation & Maintenance Manual Gas Piping (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 50 of 188 02/05/2019...

  • Page 51: Chapter 8: Internal Wiring

    8.2.1 EZ-SETUP Controller Module Fuses Location The control module contains two (2) internal replaceable 5A fuses, as shown in Figure 8-1. Figure 8-1: Control Module Fuse Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 51 of 188...

  • Page 52: Line Voltage Fuses Location

    DHW Pump / Diverter Valve 2.5A 32,33,34 CH1 Pump/Diverter Valve 8.0A 35,36,37 Power Supply 2.5A 38,39,40 Alarm Fuse Locations Figure 8-2: Line Voltage Fuse Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 52 of 188 02/05/2019...
  • Page 53 GF-135 Esteem 399 Low NOx Boiler Chapter 8 Installation, Operation & Maintenance Manual Internal Wiring Figure 8-3: Esteem Boiler Internal Wiring Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 53 of 188 02/05/2019...
  • Page 54 GF-135 Esteem 399 Low NOx Boiler Chapter 8 Installation, Operation & Maintenance Manual Internal Wiring (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 54 of 188 02/05/2019...

  • Page 55: Chapter 9: External Wiring

    If local codes or conditions require an additional service switch, the installer must install a fused disconnect for 15 amp (minimum) service switch. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 55 of 188 02/05/2019...

  • Page 56: Circulator Wiring

    CH1 or CH2 call with the factory default settings. This circulator is typically used to circulate water in the secondary CH loop when zoning with zone valves. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 56 of 188...

  • Page 57: Alarm Wiring

    Set to match the electrical power requirements of the connected device when wired to zone relays or other devices. Refer to the relay manufacturer’s specifications and the thermostat instructions for additional information on anticipator setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 57 of 188...

  • Page 58: Outdoor Sensor Wiring

    Connect the system temperature sensor to the low voltage terminal strip on the wiring panel below the Esteem control module, as shown in Figure 8-3. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 58 of 188...

  • Page 59: Cascade Wiring

    The EZ-SETUP controller includes the ability to communicate with building management systems (BMS) through a Modbus interface. Consult Section 10, Basic Controller Operation, for more information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 59 of 188...
  • Page 60 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring Figure 9-1: Multiple Zone Field Wiring Using Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 60 of 188 02/05/2019...
  • Page 61 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring Figure 9-2: Multiple Zone Field Wiring Using Zone Circulators AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 61 of 188 02/05/2019...
  • Page 62 Chapter 9 Installation, Operation & Maintenance Manual External Wiring Figure 9-3: Esteem 399 Wiring - Zoning with Zone Circulators Figure 9-4: Esteem 399 Wiring - Zoning with Zone Valves AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 63 Installation, Operation & Maintenance Manual External Wiring Figure 9-5: Esteem 399 Wiring – Multiple Zone Valve with Single System/Boiler Circulator Figure 9-6: Esteem 399 Wiring – Single Zone System with Single System/Boiler Circulation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 64 GF-135 Esteem 399 Low NOx Boiler Chapter 9 Installation, Operation & Maintenance Manual External Wiring (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 64 of 188 02/05/2019...

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

    These advanced features are adjustable in the Installer Menu after entering an access code. Installer Button Navigation Buttons Menu Display Pressure Gauge ON/OFF Switch Figure 10-1: EZ-SET Controller Front Panel Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 65 of 188 02/05/2019...

  • Page 66: Controller Navigation

    Home Screen when selected. The Previous Screen ( icon at the bottom of each screen returns to the previous screen when selected. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...
  • Page 67 GF-135 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual EZ-SET Controller Figure 10-3: Controller Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 67 of 188 02/05/2019...

  • Page 68: Home Screen

    DOWN button while holding in the OK button and LEFT arrow. All buttons must be released and the procedure performed again to switch between increasing and decreasing contrast. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...
  • Page 69 45ºF [25ºC]. Lockout Description The lockout which currently has the Esteem shut down is displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 69 of 188 02/05/2019...

  • Page 70: Main Menu

    Menus can be entered by highlighting the desired icon and pressing the OK button. Figure 10-5: EZ-SETUP Controller Main Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 70 of 188...

  • Page 71: Ez Setup

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

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

    OK button to store the setting. Figure 10-8: Select CH1 Reset Curve Menu (Same as CH2 Reset Curve Menu) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 72 of 188...

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

    ) is displayed on the home screen when the outdoor temperature reaches the Warm Weather Shutdown Temperature. Figure 10-9: Set Warm Weather Shutdown Temperature Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 73 of 188...

  • Page 74: Domestic Hot Water Ez Setup

    LEFT or RIGHT buttons to adjust the Boiler DHW Setpoint then press the OK button to store the setting. Figure 10-11: Boiler DHW Setpoint Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 74 of 188...

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

    Press the LEFT or RIGHT buttons to adjust the DHW Priority Timeout then press the OK button to store the setting. Figure 10-13: DHW Priority Timeout Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 75 of 188...

  • Page 76: Ez Setup Reset

    Press the UP or DOWN buttons to select then press the OK button to store the setting. Figure 10-15: Display EZ Setup (Temperature Units Select) Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 76 of 188...

  • Page 77: Dhw Operation

    Press the UP or DOWN buttons to scroll through additional information items. See Table 10-3 on the next page for a list of all information items. Figure 10-17: Boiler Information Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 77 of 188...
  • Page 78 Displays the number of hours the Esteem has run for a DHW Runtime domestic hot water call since the unit was installed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 78 of 188 02/05/2019...

  • Page 79: Boiler Information Logging

    Boiler Return Temperature • Boiler Flue Temperature • Outdoor Temperature • DHW Storage Temperature • External Modulation Signal Figure 10-18: Boiler Information Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 79 of 188 02/05/2019...

  • Page 80: Lockout History

    • Boiler Supply Temperature • Boiler Return Temperature • Boiler Flue Temperature • Outdoor Temperature • System Temperature Figure 10-20: Lockout Details Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 80 of 188 02/05/2019...
  • Page 81 GF-135 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual EZ-SET Controller Figure 10-21: Lockout Screen Information AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 81 of 188 02/05/2019...
  • Page 82 Return > Supply Return temperature is higher than supply temperature. External Limit Open An external manual reset limit has opened. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 82 of 188 02/05/2019...
  • Page 83 Cascade Bus Error Communication with other boilers has been lost. Communication between boiler display and control module Controller Bus Error has been lost. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 83 of 188 02/05/2019...
  • Page 84 GF-135 Esteem 399 Low NOx Boiler Chapter 10 Installation, Operation & Maintenance Manual EZ-SET Controller (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 84 of 188 02/05/2019...

  • Page 85: Chapter 11: Start-Up Preparation

    For areas with unusually hard water (hardness above 7 grains) consult a water treatment company. 11.1.3 Chlorinated Water Do not use the Esteem 399 to heat a swimming pool or spa directly. Maintain the chlorine level of the water at levels considered safe for drinking. 11.1.4 Flush Boiler to Remove Sediment The installer must flush the boiler system to remove any sediment to allow proper operation of the Esteem 399.

  • Page 86: Check And Test Antifreeze

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

  • Page 87: Cleaning Of New Boiler/System

    The contacts should be closed when system pressure is greater than 10 psi. See Figure A-2 in Appendix A for location of the LWCO (Item 6). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 87 of 188...

  • Page 88: Check For Gas Leaks

    Use an isolation relay to prevent voltage from the external circuit entering the Esteem control panel. 6. Reconnect the external thermostat wires to the low voltage terminal strip. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 88 of 188...

  • Page 89: Inspection Of Condensate Drain Assembly

    Failure to ensure trap is filled with water could result in severe personal injury or death. 3. Re-Install the plug into the condensate drain assembly. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 89 of 188...
  • Page 90 GF-135 Esteem 399 Low NOx Boiler Chapter 11 Installation, Operation & Maintenance Manual Start-Up Preparation (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 90 of 188 02/05/2019...

  • Page 91: Chapter 12: Start-Up Procedures

    Chapter 18 for initial installation and in-depth operation of the Boiler Management System. • Verify the Esteem 399 and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler (see Appendix A).
  • Page 92 10. If the unit will not operate with a call for heat and the system piping is not hot, follow the instructions “To Turn Off Gas to Appliance”, below and call your service technician or gas supplier. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 92 of 188...

  • Page 93: Troubleshooting Start-Up Problems

    Venting system must be sealed gas-tight to prevent flue gas spillage and potential carbon monoxide emissions, which will result in severe personal injury or death. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 93 of 188...

  • Page 94: Gas Piping Inspection

    Press the RIGHT button to highlight the Manual Operation icon then press the OK button. OK Button Installer Button Figure 12-1: Installer Button (L) & Manual Operation Menu (R) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 94 of 188 02/05/2019...
  • Page 95 The combustion levels should be measured at high firing rate. If the combustion levels are outside the range given in Table 12-1 for the firing rate, shut the boiler down and contact AERCO Technical Support. Failure to comply with this requirement could result in severe personal injury, death, or substantial property damage.

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

    3600 x 1000 / number of second recorded for one cubic foot of gas = BTU/H. 6. The BTU/H calculated should approximate the input rating listed on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

  • Page 97: High Temperature Limit Testing

    15. Press the DOWN button twice to highlight the Home Screen icon then press the OK button. 16. Press the OK button to reset the lockout and return the unit to service. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 97 of 188 02/05/2019...
  • Page 98 GF-135 Esteem 399 Low NOx Boiler Chapter 12 Installation, Operation & Maintenance Manual Start-Up Procedures (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 98 of 188 02/05/2019...

  • Page 99: Chapter 13: Outdoor Reset Control

    This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr. or greater. • This boiler is equipped with a tankless coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 99 of 188 02/05/2019...

  • Page 100: Outdoor Temperature Sensor Installation

    5. Avoid mounting the enclosure in areas subjected to excessive moisture. 6. Once an area on the exterior wall has been determined, follow the manufacturer’s mounting instructions included with the outdoor sensor. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 100 of 188...

  • Page 101: Outdoor Temperature Sensor Wiring

    3. Connect the sensor wires to the outdoor sensor terminals on the low voltage terminal strip located inside the boiler enclosure (see boiler wiring diagram, Figure 8-3). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 101 of 188...
  • Page 102 GF-135 Esteem 399 Low NOx Boiler Chapter 13 Installation, Operation & Maintenance Manual Outdoor Reset Control (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 102 of 188 02/05/2019...

  • Page 103: Chapter 14: External Modulating Control

    This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr. or greater. • This boiler is equipped with a tankless coil. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 103 of 188 02/05/2019...
  • Page 104 1 minute  Antilegionella Function Disabled Boiler Settings Factory Default EZ Setup Reset Installer Reset  Lockout Temperature 210°F [99°C]  Modbus Address 0=BCST AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 104 of 188 02/05/2019...

  • Page 105: Chapter 15: Check-Out Procedures

    Ensured that multiple boiler cycles were observed functioning correctly. Ensured that all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 105 of 188...
  • Page 106 GF-135 Esteem 399 Low NOx Boiler Chapter 15 Installation, Operation & Maintenance Manual Check Out Procedures (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 106 of 188 02/05/2019...

  • Page 107: Chapter 16: Maintenance Schedule

    Check vent piping. • Check combustion air inlet piping. • Check the pressure relief valve. • Check the condensate drain system. Every Six (6) Months: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 107 of 188 02/05/2019...
  • Page 108 Esteem boiler or in system components, resulting in severe personal injury, death or substantial property damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 108 of 188...

  • Page 109: Chapter 17: Maintenance Procedures

    WARNING! Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 109 of 188 02/05/2019...

  • Page 110: System Piping Inspection

    Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired can result in severe personal injury or death. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 110 of 188...

  • Page 111: Boiler System Inspection

    The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 111 of 188...

  • Page 112: Ignition Electrode Inspection

    Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range. • Complete the checkout procedures as referenced in this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 112 of 188 02/05/2019...

  • Page 113: Burner Flame Inspection And Troubleshooting

    Check gas piping for any leaks as outlined in Section 11.4 and Section 12.3.3 and repair if necessary. Place the unit back into service. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 113 of 188...

  • Page 114: Flame Signal Inspection

    3. If the flue gas temperature is more than 54°F [30°C] above the supply water temperature, shut the boiler down and follow the heat exchanger cleaning procedure described in the next section. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 114 of 188...

  • Page 115: Heat Exchanger Cleaning

    Ensure the owner understands the importance to perform the maintenance schedule specified in this manual. Remind the owner of the importance to call a licensed contractor should the unit or system exhibit any unusual behavior. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 115 of 188 02/05/2019...

  • Page 116: Handling Previously Fired Combustion Chamber Insulation

    • Discard used insulation in an air tight plastic bag. NIOSH Stated First Aid: • Eye/Skin: Immediately irrigate • Breathing: Clean fresh air AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 116 of 188 02/05/2019...

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

    Installer Button Figure 18-2: EZ-SETUP Controller Front Panel and Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 117 of 188 02/05/2019...

  • Page 118: Using The Installer Menu

    18.2 USING THE INSTALLER MENU After entering INSTALLER access code, the INSTALLER menu is displayed (Figure 18-4). Figure 18-4: INSTALLER Menu AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 118 of 188 02/05/2019...
  • Page 119 Selections in the Manual operation Menu enable the burner and circulators to be manually enabled for testing. See Section 18.9. The INSTALLER Menu structure is diagrammed on the next page (Figure 18-5). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 119 of 188...
  • Page 120 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-5: INSTALLER Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 120 of 188 02/05/2019...

  • Page 121: And Dhw Settings Menu

    Disabled: The boiler will NOT respond to a central heating call. The heating operation disabled icon is displayed on the home screen when central heating operation has been disabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 121 of 188 02/05/2019...

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

    0-10V Modulation Signal: This option allows the boiler firing rate to be controlled by an external control system with a 0-10 VDC signal. ======================================================================= AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 122 of 188...

  • Page 123: Absolute Max Ch Setpoint (Default: 188°F [87°C])

    Setpoint option is chosen in CH Demand. Press the LEFT or RIGHT buttons to adjust the CH1 Maximum Setpoint then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

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

    Setpoint option is chosen in CH Demand. Press the LEFT or RIGHT buttons to adjust the Reset Curve Warmest Day then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

  • Page 125: Ch2 Circuit (Default: Enabled)

    CH Demand. Press the LEFT or RIGHT buttons to adjust the CH2 Minimum Setpoint then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 125 of 188...

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

    Disabled: The central heating circulators will only be enabled during a central heating call. Table 18-1: Circulator Operation with Pump Circulation = Enabled CH2 Pump/System Pump Auxiliary Boiler Pump DHW Pump CH (1) Pump AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 126 of 188 02/05/2019...

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

    Press the LEFT or RIGHT buttons to adjust the CH Post Pump Time then press the OK button to store the setting. ======================================================================= AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 127 of 188...

  • Page 128: Freeze Protection (Default: Enabled)

    Subjecting the boiler to freezing conditions could lead to freezing of the condensate, and the possibility of causing serious injury or death. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 128 of 188...

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

    CH setpoint will return to the highest CH1 or CH2setpoint. Press the LEFT or RIGHT buttons to adjust the Parallel Shift Value then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 129 of 188...

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

    UP or DOWN buttons to select the desired System Pump operation then press the OK button to store the setting. The System Pump options are: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 130 of 188...
  • Page 131 CH2 – The system pump will only be enabled for a CH2 central heating call. The CH(1) pump will only be enabled for a CH1 central heating call. Figure 18-25 illustrates a system zoned with zone circulators requiring this setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 131 of 188...
  • Page 132 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-23: System Piping with System Pump = CH1/CH2/DHW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 132 of 188 02/05/2019...
  • Page 133 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-24: System Piping with System Pump = CH1/CH2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 133 of 188 02/05/2019...
  • Page 134 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-25: System Piping with System Pump = CH2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 134 of 188 02/05/2019...

  • Page 135: Dhw Settings Menu

    Press the UP or DOWN buttons to scroll through additional CH Settings. See the following for a description of each of these settings. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 135 of 188...

  • Page 136: Dhw Operation (Default: Enabled)

    Disabled: The boiler will not respond to a domestic hot water call. The domestic hot water operation disabled icon is displayed on the home screen when domestic hot water operation has been disabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 136 of 188 02/05/2019...

  • Page 137: Demand Type (Default: Switch)

    Switch option is chosen in DHW Demand. Press the LEFT or RIGHT buttons to adjust the Boiler DHW Setpoint then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

  • Page 138: Dhw Storage Setpoint (Default: 140°F [60°C])

    Failure to comply could result in severe personal injury, death, or substantial property damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 138 of 188...

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

    Press the LEFT or RIGHT buttons to adjust the DHW Post Pump Time then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

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

    DHW priority is set to disabled. The use of a mixing device on the lower temperature zones may be required to protect the lower temperature zones from damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 140 of 188...

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

    Press the LEFT or RIGHT buttons to adjust the DHW To CH Call Blocking time then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 141 of 188...

  • Page 142: Antilegionella Function (Default: Disabled)

    DHW demand. The use of an Indirect Water Heater Sensor ensures that the domestic hot water is heated to 140°f [60°c] at least once per week. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 142 of 188...

  • Page 143: Boiler Settings Menu

    102°F [39°C]: A High Boiler Temperature lockout (E3) will occur when the boiler temperature reaches 102°F [39°C]. • 210°F [99°C]: A High Boiler Temperature lockout (E3) will occur when the boiler temperature reaches 210°F [99°C]. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 143 of 188 02/05/2019...

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

    Reset All Settings allows the installer to reset all CH, DHW, and Cascade settings back to the original factory defaults. Follow the onscreen instructions to reset all settings back to the original factory defaults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 144 of 188...
  • Page 145 CH or DHW Boilers Automatic Rotation Enabled  CH Proportional Gain  CH Integral Gain  DHW Proportional Gain  DHW Integral Gain AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 145 of 188 02/05/2019...

  • Page 146: Cascade Menu And Operating Information

    – Allows the installer to adjust the Cascade System settings for the application. See section 18.8.2. 3. Cascade Autodetection – Automatically finds and configures each boiler of the Cascade System. See section 18.7. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 146 of 188 02/05/2019...
  • Page 147 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-43: Cascade Menu Structure AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 147 of 188 02/05/2019...

  • Page 148: Cascade Installation - System Piping

    Pipe Mounted Installation: A temperature sensor (P/N PTSENS12) can be directly strapped to the outside of a 1” to 3” pipe. Install the PTSENS12 sensor as follows: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B...

  • Page 149: Cascade Installation - Cascade Communication Cable

    Cascade Master. The modulation signal will control the firing rate of the entire Cascade System, not just the Cascade Master. • Modbus Wiring: A building management system (BMS) connection must be wired into the Cascade Master. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 149 of 188 02/05/2019...

  • Page 150: Cascade Installation - Line Voltage Wiring Connections

    Alarm Wiring: The alarm contact closes whenever that particular boiler is in a soft or hard lockout. The alarm contact will also close on the Master boiler when any of the Slave boilers are locked out. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 150 of 188...

  • Page 151: Cascade Autodetection Menu

    Master boiler. The Master boiler Lockout Screen will also indicate which boiler in the Cascade System is locked out. Figure 18-46: Cascade Lockout Displays AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 151 of 188...
  • Page 152 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-47: Standard Primary Secondary Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 152 of 188 02/05/2019...
  • Page 153 Installation, Operation & Maintenance Manual Controller Operation NOTE Reference Figure 18-47 on previous page for cascade piping. Figure 18-48: Standard Primary Secondary Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 153 of 188 02/05/2019...
  • Page 154 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-49: Standard Reverse Return Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 154 of 188 02/05/2019...
  • Page 155 Installation, Operation & Maintenance Manual Controller Operation NOTE Reference Figure 18-49 on previous page for cascade piping. Figure 18-50: Standard Reverse Return Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 155 of 188 02/05/2019...
  • Page 156 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation Figure 18-51: Split Cascade System AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 156 of 188 02/05/2019...
  • Page 157 Installation, Operation & Maintenance Manual Controller Operation NOTE Reference Figure 18- 51 on previous page for cascade piping. Figure 18-52: Split Cascade Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 157 of 188 02/05/2019...

  • Page 158: Cascade Information Menu

    Displays the total number of boilers in the Cascade System. Cascade Firing Rate Displays the current firing rate of the entire Cascade System. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 158 of 188 02/05/2019...

  • Page 159: Menu

    Cascade setting changes must be made on the cascade Master. Cascade auto detection must be performed after making any changes to a cascade Setting before the change will take effect. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 159 of 188...

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

    Figure 18-57: Minimum Firing Rate Menu Press the LEFT or RIGHT buttons to adjust the Minimum Firing Rate then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 160 of 188...

  • Page 161: Boiler Enabling Algorithm

    Figure 18-58: Maximum Firing Rate Menu Press the LEFT or RIGHT buttons to adjust the Maximum Firing Rate then press the OK button to store the setting. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 161 of 188...

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

    All CH or DHW Boilers will respond to a domestic hot water call. It is important that the domestic load is capable of transferring all of the heat generated to prevent excessive boiler cycling. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 162 of 188...

  • Page 163: Automatic Rotation (Default: Enabled)

    Switch option is chosen in CH Demand or every 24 hours when a Constant option is chosen in CH Demand. • Disabled: The lead boiler is always the Master boiler followed by each Slave boiler AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 163 of 188 02/05/2019...

  • Page 164: Proportional Gain (Default: 7)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of CH Proportional Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 164 of 188 02/05/2019...

  • Page 165: Integral Gain (Default: 245)

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of CH Integral Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 165 of 188...

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

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of DHW Proportional Gain could lead to temperature fluctuations and erratic cascade operation. ======================================================================== AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 166 of 188 02/05/2019...

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

    Only make adjustments to this setting after consulting AERCO Technical Support. Improper adjustment of DHW Integral Gain could lead to temperature fluctuations and erratic cascade operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 167 of 188 02/05/2019...

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

    LEFT or RIGHT buttons to change the Modbus Address then press the OK button to store the setting. Figure 18-65: DHW Integral Gain Menu ======================================================================== AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 168 of 188 02/05/2019...

  • Page 169: Modbus Interface

    513 (0x201) 0x06 LB:U8 register becomes active when 255is Firing Rate 0x10 written to register 512 (0x0200) Table 18-10: Holding Registers (Read/Write) - Continued AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 169 of 188 02/05/2019...
  • Page 170 0x04 LB:U8 Value = Firing Rate %. Firing Rate Value = °C. 776 (0x0308) 0x04 Boiler Setpoint LB:U8 Invalid Value = 32768 (0x8000). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 170 of 188 02/05/2019...

  • Page 171: Manual Operation

    DHW circulator. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 171 of 188...

  • Page 172: Ch1 Parameter

    Figure 18-69: Manual Operation Menu with DHW Selected NOTE The auxiliary Boiler circulator is also powered when the DHW circulator is manually enabled. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 172 of 188 02/05/2019...

  • Page 173: Sys Ch2 Parameter

    Press the OK button again while the SYSCH2 icon is highlighted to shut down the System circulator. Figure 18-70: Manual Operation Menu with SYS CH2 Selected AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 173 of 188...
  • Page 174 GF-135 Esteem 399 Low NOx Boiler Chapter 18 Installation, Operation & Maintenance Manual Controller Operation (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 174 of 188 02/05/2019...

  • Page 175: Apenndix A: Part And Dimensional Drawings

    GF-135 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions APENNDIX A: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 175 of 188 02/05/2019...
  • Page 176 Side Jacket Panel (Left or Right) 37124 Top Jacket Panel 37125 Top Jacket Access Panel 33113 Wall Mounting Bracket with Hardware 38038 Combustion Air Deflector AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 176 of 188 02/05/2019...
  • Page 177 60013 LWCO Pressure Device 22123 Condensate Drain Assembly 22124 Boiler Piping - Return Assembly 22125 Boiler Piping - Supply Assembly 41035 Polypropylene Pan AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 177 of 188 02/05/2019...
  • Page 178 92122 Gas Valve 43081 Venturi 58094 Igniter and Cable with Gasket 58028 Sight Glass Assembly (Glass, Gasket and Bracket) 22126 Gas Valve Piping AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 178 of 188 02/05/2019...
  • Page 179 Igniter Cable Grommet 65171 Control Module 5A Fuse (Not Shown) 65172 Circulator 2.5A Fuses (Not Shown) 65173 In-Line Voltage 8A Fuse (Not Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 179 of 188 02/05/2019...
  • Page 180 GF-135 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions Figure A-5: Esteem 399 – Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 180 of 188 02/05/2019...
  • Page 181 GF-135 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions Figure A-6: Esteem 399 – Side View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 181 of 188 02/05/2019...
  • Page 182 GF-135 Esteem 399 Low NOx Boiler Appendix A Installation, Operation & Maintenance Manual Parts & Dimensions (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 182 of 188 02/05/2019...

  • Page 183: Apenndix B: Circulator Pressure Loss Charts

    GF-135 Esteem 399 Low NOx Boiler Appendix B Installation, Operation & Maintenance Manual Pressure Loss Charts APENNDIX B: CIRCULATOR PRESSURE LOSS CHARTS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 183 of 188 02/05/2019...
  • Page 184 Installation, Operation & Maintenance Manual Pressure Loss Charts Figure B-1: Esteem 399 – Grundfos Circulator Pressure Drop Comparison Chart Figure B-2: Esteem 399 – Tacos Circulator Pressure Drop Comparison Chart AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 185 GF-135 Esteem 399 Low NOx Boiler Installation, Operation & Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 185 of 188 02/05/2019...
  • Page 186 06/19/2014 Rev A: Initial released Curtis Harvey Rev B: Removed AHRI certification logo, minor 2/05/2019 Chris Blair reformatting © AERCO International, Inc., 2019 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0B Page 186 of 188 02/05/2019...
  • Page 187 STARTUP RECORD FOR ESTEEM 399 Low NOx BOILER Please complete one (1) form for each unit at the site and return to AERCO for warranty validation within 30 days of start-up. For your convenience, this information can be faxed to (845) 580-8090 or sent via US mail to: AERCO International, Inc., 100 Oritani Drive, Blauvelt, NY 10913.
  • Page 188 Venting How many elbows are in the ducting? ____ Is the vent sealed with RTV? Is the vent pitched back toward the boiler (1/4" per ft. length) per the AERCO Venting Guide? Venting material used is: AL29-4C Other (please specify):...

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