Watts Aerco AM 199RI Installation, Operation & Maintenance Manual
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Watts Aerco AM 199RI Installation, Operation & Maintenance Manual

Gas fired hydronic boilers and water heaters
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Installation, Operation & Maintenance Manual
AMRI Water Heaters
This supplement pertains to the following
AM Series Rapid Recovery – Integrated (AMRI) water
heater models:
• AM 199RI
• AM 250RI
• AM 399RI
• AM 500RI
This document applies only to units with serial number 15270000 and
above.
Supplement to User Manual:
•
OMM-0100 GF-146
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-0106_B
• GF-146-IR • 11/20/2019

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  • Page 1 Installation, Operation & Maintenance Manual AMRI Water Heaters This supplement pertains to the following AM Series Rapid Recovery – Integrated (AMRI) water heater models: • AM 199RI • AM 250RI • AM 399RI • AM 500RI This document applies only to units with serial number 15270000 and above.

  • Page 2: Table Of Contents

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) Supplement to AM Series User Manual GF-146 TABLE OF CONTENTS FOREWORD ........................ 5 CHAPTER 1: GENERA L INFORMATION ............... 6 1.1 WARNINGS & CAUTIONS ........................6 1.2 EMERGENCY SHUTDOWN ........................9 CHAPTER 2: FUNCTIONAL OVERVIEW ..............10 2.1 INTRODUCTION ..........................
  • Page 3 AMRI Water Heaters (Supplement to OMM-0100, GF-146) Supplement to AM Series User Manual GF-146 CHAPTER 6: INSTALLATION – VENTING AND COMBUSTION AIR PIPING ....32 CHAPTER 7: INSTALLATION – NATURAL GAS ............33 CHAPTER 8: UNIT START-UP ..................34 CHAPTER 9: OPERATION ................... 35 CHAPTER 10: MAINTENANCE ..................

  • Page 5: Foreword

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) FOREWORD FOREWORD This supplement provides information regarding the AM Series Rapid Recovery (AMRI) water heaters with integrated buffer tank. For information concerning skid mounted units featuring a selection of exterior mounted buffer tanks and descaling systems, Refer to the main AM Series User Manual, OMM-0100 (GF-146).

  • Page 6: Chapter 1: Genera L Information

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 1: GENERAL INFORMATION CHAPTER 1: GENERA L INFORMATION Warnings & Cautions In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No.
  • Page 7 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 1: GENERAL INFORMATION NOTE: When calling or writing about the water heater, have the unit model and serial number as seen on the unit rating plate. CAUTION! Do not use petroleum-based cleaning or sealing compounds in the water heater system. Gaskets and seals in the system may be damaged.
  • Page 8 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 1: GENERAL INFORMATION OFF. OFF. OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 8 of 54...

  • Page 9: Emergency Shutdown

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 1: GENERAL INFORMATION 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 10: Chapter 2: Functional Overview

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 2: FUNCTIONAL OVERVIEW CHAPTER 2: FUNCTIONAL OVERVIEW INTRODUCTION Figure 2-1 shows the exterior appearance of the AMRI (left), and with covers/panels open showing the interior features (right). The AMRI Series comes in four functionally sized models; the 199RI and 250RI, which feature one burner and an integrated tank, and the 399RI, and 500RI, which feature two burners and an integrated tank.

  • Page 11: Intended Use And Functions

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 2: FUNCTIONAL OVERVIEW Intended Use and Functions The AMRI Integrated water heater is designed to warm domestic water (potable) for civil uses. Any other use is prohibited. The water heater can be installed with a Direct Venting system or with a one pipe vent system and getting combustion air from room.

  • Page 12: Am 399Ri / 500Ri Functional Schematic

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 2: FUNCTIONAL OVERVIEW AM 399RI / 500RI Functional Schematic 2.3.2 Figure 2-3: AM 399RI / 500RI Functional Schematic OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 12 of 54...

  • Page 13: Chapter 3: Installation - Site

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE CHAPTER 3: INSTALLATION – SITE Choosing the Installation Location This section describes the general installation considerations for the AM Series units. WARNING! Provisions for combustion air and ventilation of the water heater 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 14: 3.2 Water Heater Installation Location Factors

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE WARNING! Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: •...

  • Page 15: Safety Concerns

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE Safety Concerns WARNING! Do not store any flammable materials or liquids in the immediate vicinity of the water heater. Closet and Alcove Installation AM water heaters are not approved for installation in a closet or in an alcove site. Clearances for Installation and Servicing Figures 3-1 shows the minimum clearances required for installation and servicing.

  • Page 16: 3.7 Vent And Combustion Air Piping

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE 3.7 Vent and Combustion Air Piping This water heater requires a special vent system, designed for pressurized venting. The water heater is to be configured for either direct vent installation or for installation using room combustion air.
  • Page 17 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE Transport the water heater to its installation location as follows. Transporting the Water Heater 1. Remove the lower and upper covers “A” at front of the AM unit by pulling them off. 2.

  • Page 18: Amri Supply And Return Piping Dimensions

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 3: INSTALLATION - SITE Figure 3-5: Installing the Unit Feet 3.11 AMRI Supply and Return Piping Dimensions Standard connections and dimensions for AMRI Series units are shown in Figure 3-6. ITEM CONNECTION/ITEM SIZE Water Supply Connection 1-1/4”...

  • Page 19: Chapter 4: Installation - Piping

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING CHAPTER 4: INSTALLATION - PIPING 4.1 AMRI Water Connections The AMRI units come with water connections as shown in Figures 3-5 and 4-1. Water heater system piping MUST be sized considering the pressure drops of the water heater (see figure 4-2), piping and storage tank.

  • Page 20: Low Water Cutoff (Lwco)

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING NATURAL GAS INLET TEMPERATURE AND SAFETY RELIEF VALVE 2 PRESSURE GAUGE (FACTORY SUPPLIED) SAFETY RELIEF VALVE 2 DISCHARGE PIPING (FIELD SUPPLIED) TEMPERATURE AND PRESSURE GAUGE SAFETY RELIEF VALVE 1 (FACTORY SUPPLIED) SAFETY RELIEF VALVE 1 DISCHARGE PIPING...

  • Page 21: Recirculator Heating Pump Sizing And Installation

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING CAUTION! Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler failure can result due to this excessive makeup water addition, compromising the functionality of the unit.

  • Page 22: Recirculator Pump Mechanical Installation

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING Recirculator Pump Mechanical Installation 4.5.3 A field supplied pump relay must be installed if the pump current draw is greater than 2.5 amps. This is included with the larger pumps from AERCO. The pump (A, 6-1/2”...

  • Page 23: Domestic Hot Water System Piping With Direct Water Heater

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING with the larger pumps from AERCO. Figure 4-5: AMRI - Single-Unit Installation Piping Example Domestic Hot Water System Piping with Direct Water Heater See Figure 4-5 for recommended piping for AM Series water heater single unit installations, and Figure 4-7 for multiple unit installations.

  • Page 24: Scalding

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING Scalding This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water.
  • Page 25 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING Figure 4-7: AMRI - Multi-Unit Installation Piping Example OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 25 of 54...

  • Page 26: Condensate Disposal

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING Condensate Disposal WARNING! The condensate trap, as shown in Figure 4-8, 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 4-8.
  • Page 27 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 4: INSTALLATION – PIPING Condensate Drain Pipe Floor Drain Drain Pan PROPER DRAIN HOSE ANGLE Figure 4-9: Condensate Tank Drainage A condensate removal pump is required if the water heater is below the drain. When installing a condensate pump, select one approved for use with condensing water heaters and furnaces.

  • Page 28: Chapter 5: Installation - Electrical

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 5: INSTALLATION – ELECTRICAL CHAPTER 5: INSTALLATION – ELECTRICAL Electrical Connections Power Supply Cable Connection 5.1.1 Provide and install a fused disconnect or service switch (15 amp recommended) as required by prevailing codes. To connect the electrical line voltage power supply cable, refer to Figure 5-1. Figure 5-1: Line Voltage Connection Figure 5-2: AMRI Electrical Junction Box Connections OMM-0106_B •...

  • Page 29: Connecting Units In Cascade

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 5: INSTALLATION – ELECTRICAL Connecting Units in Cascade 5.1.2 AM Series water heaters may be combined in a cascading system using the optional Cascade Sequencer. To connect the heater in cascade using the Cascade Sequencer, one must follow the electrical connections as per Figure 5-4.

  • Page 30: Vdc Input Connections - 500Ri Model (Option For 500Ri)

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 5: INSTALLATION – ELECTRICAL 0-10 VDC Input Connections – 500RI Model (Option for 5.1.3 500RI) The AMRI model 500RI is factory supplied with a Communications Module (the 399 model can be equipped with one as an option). This allows driving the appliance via a 0-10 VDC analog input.

  • Page 31: Modbus Interface Connections - 500Ri Model Only

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 5: INSTALLATION – ELECTRICAL MODBUS Interface Connections – 500RI Model Only 5.1.4 The AMRI 500RI model is factory supplied with a Communications Module (the 399 model can be equipped with one as an option). This MODBUS interface can be connected to drive the unit from a building management device.

  • Page 32: Chapter 6: Installation - Venting And Combustion Air Piping

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 6: INSTALLATION – VENTING AND COMBUSTION AIR PIPING CHAPTER 6: INSTALLATION – VENTING AND COMBUSTION AIR PIPING NOTE: Refer to Chapter 6 in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to the installation of the exhaust venting and combustion air piping for the AM series of units.

  • Page 33: Chapter 7: Installation - Natural Gas

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 7: INSTALLATION – NATURAL GAS CHAPTER 7: INSTALLATION – NATURAL GAS NOTE: Refer to Chapter 7 in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to the installation of the natural gas inlet piping for the AM series of units.

  • Page 34: Chapter 8: Unit Start-Up

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 8 – UNIT START-UP CHAPTER 8: UNIT START-UP NOTE: Refer to Chapter 8 in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to unit start up procedures for the AM series of units. WARNING! You MUST refer to, and comply with, all instructions, warnings, cautions, notes, and other information in the main AM Series user manual, OMM-0100 (GF-146), pertaining to Chapter...

  • Page 35: Chapter 9: Operation

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 9 – OPERATION CHAPTER 9: OPERATION NOTE: Refer to Chapter 9 in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to unit operation of the AM series of units. WARNING! You MUST refer to, and comply with, all instructions, warnings, cautions, notes, and other information in the main AM Series user manual, OMM-0100 (GF-146), pertaining to Chapter...

  • Page 36: Chapter 10: Maintenance

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 10 – MAINTENANCE CHAPTER 10: MAINTENANCE NOTE: This chapter contains only maintenance procedures applicable specifically to the AMRI units. Refer to Chapter 10 in the Main AM Series User Manual, OMM-0100 (GF- 146), for the maintenance schedule, as well as all other maintenance procedures applicable to all AM series units.
  • Page 37 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 10 – MAINTENANCE NEW ANODE ROD (3/4” DIAMETER) Anode OLD ANODE ROD NEEDING REPLACEMENT DUE TO EXCESSIVE DIAMETER REDUCTION FRONT VIEW – COVERS OFF Figure 10-14: Buffer Tank Anode Location and Diameter Inspection At the 6 month inspection, unscrew the anode from its port and check the reduction in anode diameter.

  • Page 38: Chapter 11: Technical Data

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 11 – TECHNICAL DATA CHAPTER 11: TECHNICAL DATA AMRI Water Heater Technical Data MODEL DESCRIPTION Category of discharge chimney II and IV II and IV II and IV II and IV Maximum heat input Btu/hr 199,500 250,000...

  • Page 39: Chapter 12: Spare Parts Drawings & Lists

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS CHAPTER 12: SPARE PARTS DRAWINGS & LISTS 12.1 AMRI Spare Parts Drawings Figure 12-1: 199RI-250RI Spare Parts Drawing (1 of 2) OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 39 of 54...
  • Page 40 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS Figure 12-2: AMRI Integrated General Assembly Parts drawing (2 of 2) OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 40 of 54...
  • Page 41 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS Figure 12-3: 199RI/250RI/399RI/500RI Burner/Fan Spare Parts Drawing OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 41 of 54...

  • Page 42: 199Ri/250Ri Spare Parts List

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 12.2 199RI/250RI Spare Parts List 199RI/250RI Spare Parts List Item# Part# Description 60801066 6X12 SCREW WITH WASHER 62617330 3" COMPLETE AIR INLET CONNECTION 62610091 BLACK UPPER COVER 62610098 GREY UPPER COVER 60404391 BENT BOX COVER...
  • Page 43 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 199RI/250RI Spare Parts List Item# Part# Description CONICAL PLUG TAB D.29.2-32,7 61405348 CONDENSATE BLOCKED DRAIN SWITCH 62651066 60801106 SCREW 6X25 GALVANIZED 62111051 MAGNETIC SENSOR D5,8X38 62610093 COMPLETE PLASTIC FRONT COVER BLACK 62610096 COMPLETE PLASTIC FRONT COVER GREY CORRUGATED TUBE DIAM 28 L 1250...
  • Page 44 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 199RI/250RI Spare Parts List Item# Part# Description SCREW SELF-TAPPING 4X10 TC S-TT UNI-8112 60801080 MASTER GAS CABLE UL 885 60504266 60406137 SHAPED BRACKET 67X54X36 60702083 OR RING 3137 EPDM 2,62 X 34,60 61405300 CONDENSATION DISCHARGE PIPE D.46.7 60801138...
  • Page 45 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS Figure 12-4: 399RI-500RI Spare Parts Drawing (1 of 2) OMM-0106_B • GF-146-IR • 11/20/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 45 of 54...
  • Page 46 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS Figure 12-5: 399RI-500RI Spare Parts Drawing (1 of 2) NOTE: See Figure 12-3 for the burner assembly part drawings, as the parts and item numbers are identical for all models of AM series units.
  • Page 47 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 399RI/500RI Spare Parts List Item# Part# Description 60801066 6X12 SCREW WITH WASHER 62617330 3" COMPLETE AIR INLET CONNECTION 62610091 BLACK UPPER COVER 62610098 GREY UPPER COVER 60404391 BENT BOX COVER 60503026 FUSE 3A DELAYED GLASS 62118027...
  • Page 48 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 399RI/500RI Spare Parts List Item# Part# Description 62111051 MAGNETIC SENSOR D5,8X38 62610093 COMPLETE PLASTIC FRONT COVER BLACK 62610096 COMPLETE PLASTIC FRONT COVER GREY 60322021 CORRUGATED TUBE DIAM 28 L 1250 61405320 NO LOGO FRONT COVER 62110088...
  • Page 49 AMRI Water Heaters (Supplement to OMM-0100, GF-146) CHAPTER 12 – SPARE PARTS 399RI/500RI Spare Parts List Item# Part# Description 60702083 OR RING 3137 EPDM 2,62 X 34,60 61405300 CONDENSATION DISCHARGE PIPE D.46.7 60801138 SCREW 4X8 ZINC TC-CR DIN4042 60701022 GASKET KERASIL 325R SQ 56X22X2 62632008 GRP IGNITION PLUG 60702078...

  • Page 50: Appendix A: Control Panel Operation Chart

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) APPENDIX A: CONTROL PANEL OPERATIONAL FLOW CHART APPENDIX A: CONTROL PANEL OPERATION CHART NOTE: Refer to Appendix A in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to unit operation of the AM series of units. WARNING! You MUST refer to, and comply with, all instructions, warnings, cautions, notes, and other information in the main AM Series user manual, OMM-0100 (GF-146), pertaining to Appendix...

  • Page 51: Appendix B: Factory Menu

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) APPENDIX B: FACTORY MENU APPENDIX B: FACTORY MENU NOTE: Refer to Appendix B in the Main AM Series User Manual, OMM-0100 (GF-146), for all information and instructions pertaining to unit operation of the AM series of units. WARNING! You MUST refer to, and comply with, all instructions, warnings, cautions, notes, and other information in the main AM Series user manual, OMM-0100 (GF-146), pertaining to Appendix...

  • Page 52: Standard Warranty

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) INSTALLATION, OPERATION, AND MAINTENANCE MANUAL STANDARD WARRANTY AM Series Gas Fired Hydronic Boilers and Water Heaters BOILER PRESSURE VESSEL/HEAT EXCHANGER: 7 YEARS NON-PRORATED The pressure vessel/heat exchanger shall carry a (7) seven year non-prorated warranty from shipment against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship.

  • Page 53: Standard Warranty

    AMRI Water Heaters (Supplement to OMM-0100, GF-146) INSTALLATION, OPERATION, AND MAINTENANCE MANUAL STANDARD WARRANTY AM Series Gas Fired Hydronic Boilers and Water Heaters (Cont.) CONDITIONS OF WARRANTY Should an AERCO gas-fired Hydronic boiler fail for any of the above reasons within the specified time period from the date of original shipment(s), AERCO shall, at its option, modify, repair or exchange the defective item.
  • Page 54 AMRI Water Heaters (Supplement to OMM-0100, GF-146) INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Change Log: Date Description Changed By 07/22/2015 Rev A: Initial release Curtis Harvey Rev B: 11/30/2016 Update parts list in Chapter 12 (reference DIR 352) Chris Blair Updated kit numbers in section 4.5.1 (DIR 400) Rev B: Linley 11/20/2019...

This manual is also suitable for:

Aerco am seriesAerco am 250riAerco am 399riAerco am 500ri

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