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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 650
Summarization of Contents
II. Read Before Proceeding
A. Local Codes
Installation must conform to local codes and authorities having jurisdiction.
B. Warranty
Details product warranty, responsibility for controls, and exclusions.
C. Shipment Damage
Inspect unit for shipping damages and verify received parts against packing slip.
D. Connecting Gas Supply Line
Connect gas supply line to appliance gas train at rear; danger of damage if line turns.
E. Gas Leakage (If you detect or smell gas...)
Instructions for handling gas leaks: do not light, do not use phones, call supplier.
F. Maintenance
Safety precautions for maintenance: disconnect power, lockout, allow cooling.
G. Product Identification Label
Locating the nameplate attached to the heat exchanger for identification.
H. Factory Test and Inspections
Details factory tests and inspections performed for safety and performance standards.
I. Disclaimers and Local Codes
Conformance to codes, qualifications for installation/service, manual is integral.
IV. Unpacking The AMP
A. Unpacking and Inspection
Move appliance, remove crate, account for items, check for damage.
B. Check Equipment
Verify model, trim, count pieces, check for shipping damage, identify loose parts.
C. Installation and Operation Manual
Manual is integral, read carefully for safe installation, use, and servicing.
VI. Pre-Installation and Mounting
A. General
Conformance to codes, clearances, protection from water, combustion air.
B. Appliance Mounting
Install on level surface, provide drain, ensure adequate space, secure appliance.
C. Outdoor Installation
For warm climates only, install on level platform, ensure open sides.
VII. Venting
A. General Venting Guidelines
Install per codes, direct vent/room air, material compatibility, condensate prevention.
B. Venting Design Requirements
Engineered or equivalent length methods, flue gas temps, pressures, manifolding.
C. Field Installation
Pipe support, routing, material joining, wall openings, expansion.
VIII. Condensate Disposal
A. Condensate trap
Function of the trap, float switch, disposal notes, pump requirements.
IX. Hydronic Piping
A. General Piping Guidelines
Primary/secondary piping, flow rate, pressure relief, elbow clearance.
B. Factory Supplied Relief Valve Package
Installation of relief valve, T&P gauge, and fittings.
C. Standard Piping Components
Pressure relief valve, drain valves, flow switch, circulator pump, expansion tank.
D. Water Quality
Requirements for water hardness, TDS, chlorine, and pH to prevent corrosion.
E. Oxygen Contamination
Causes and prevention of oxygen contamination in the system.
F. Temperature Rise and Heat Exchanger Head Loss
How head loss affects piping design and pump selection.
XI. Gas Piping
A. Guidelines and Requirements
Conformance to codes, sizing, leak testing, purging.
B. Field Connecting Gas Supply
Installing shut-off valve, sediment trap, pressure tapping.
C. Gas Pressure Switches
Function of high/low gas pressure switches, manual reset requirement.
XII. Electrical
A. General
Install wiring per codes, separate circuit, service switch.
B. Power Requirements
Nominal current draw for planning purposes.
C. Appliance Wiring
Connecting to PCB's, low voltage and line voltage connections.
D. Routing Field Connections
Routing field connections through conduits into the rear control box.
E. System and Circulation Pump Wiring
Wiring system and boiler pumps to the 120 VAC PCB, max current draw.
XIII. System Start-up
A. Check System Setup
Verify venting, piping, electrical, flush system, pressurize fuel line.
B. Start the AMP
Appliance startup sequence, pre-purge, ignition, lockout, manual reset.
C. Combustion Air/Fuel Adjustment
Adjusting O2/CO2 levels for high and low fire using throttle/offset screws.
D. Field Conversion of Gas Type
Steps for converting gas type, ordering kits, adjusting throttle screw.
E. Pump Control
Selecting appropriate pump parameters in the Concert control.
F. Check Thermostat Operation
Verify appliance starts/stops in response to hot water calls.
G. Adjust Supply Water Temperature
Adjusting central heat and DHW setpoint, mixing valve requirement.
H. Testing of Controls and Safety Devices
Performing limit tests on safety devices like pressure switches, LWCO.
XIV. Service and Maintenance
A. General Maintenance
Keep area clear, check components, vacuum dust.
B. Monthly Inspection
Inspect vent, air intake, condensate drain, water/gas lines.
C. Annual Inspections and Service
Annual checks including flow switch test, igniter inspection.
D. Restarting after Prolong Shutdown
Recommended steps after prolonged shutdown.
E. Troubleshooting
Refer to Concert Control manual for limit string status and lockout resolution.
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