Document Outline

• CHAPTER 1: SAFETY PRECAUTIONS
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2: installation
  • 2.1 CODE COMPLIANCE
  • 2.2 DETERMINING PRODUCT LOCATION
  • 2.3 BOILER REPLACEMENT
  • 2.4 RECOMMENDED CLEARANCES
  • 2.5 RESIDENTIAL GARAGE INSTALLATIONS
  • 2.6 BOILER FREEZE PROTECTION FEATURE
• CHAPTER 3: COMBUSTION AIR AND VENTING
  • 3.1 COMBUSTION AIR CONTAMINATION
  • 3.2 POTENTIAL CONTAMINATING PRODUCTS
    • 3.2.1 Areas Likely to Contain Contaminating Products
  • 3.3 VENTILATION AND COMBUSTION AIR REQUIREMENTS - DIRECT VENT
  • 3.4 VENTILATION AND COMBUSTION AIR REQUIREMENTS - CATEGORY IV
  • 3.5 METHODS OF SUPPLYING COMBUSTION AIR TO A CONFINED SPACE - CATEGORY IV
    • 3.5.1 INDOOR COMBUSTION AIR
    • 3.5.2 OUTDOOR COMBUSTION AIR
      • 3.5.2.1 Option 1: One Permanent Opening to Outside
      • 3.5.2.2 Option 2: Two Permanent Openings to Outside
  • 3.6 COMBINATION OF INDOOR AND OUTDOOR COMBUSTION AIR
    • 3.6.1 Outdoor Opening(s) Location
    • 3.6.2 Outdoor Opening(s) Size
  • 3.7 COMBUSTION AIR AND VENT PIPING
  • 3.8 REMOVAL OF AN EXISTING BOILER FROM A COMMON VENT SYSTEM
• CHAPTER 4: UNIT PREPARATION
  • 4.1 HANDLING INSTRUCTIONS
  • 4.2 WALL MOUNTING INSTALLATION
  • 4.3 WALL MOUNTING GUIDELINES
  • 4.4 STUD WALL INSTALLATION
  • 4.5 BOILER MOUNTING
• CHAPTER 5: BOILER PIPING
  • 5.1 GENERAL PIPING REQUIREMENTS
  • 5.2 PRESSURE RELIEF VALVE
  • 5.3 BOILER AIR VENT
  • 5.4 LOW WATER CUTOFF DEVICE
  • 5.5 ADDITIONAL LIMIT CONTROL
  • 5.6 BACKFLOW PREVENTER
  • 5.7 BOILER SYSTEM PIPING APPLICATIONS
  • 5.8 EXPANSION TANK AND MAKEUP WATER
    • 5.8.1 Diaphragm Expansion Tank
    • 5.8.2 Closed-Type Expansion Tank
  • 5.9 CIRCULATOR
  • 5.10 SIZING PRIMARY PIPING
  • 5.11 DOMESTIC HOT WATER SYSTEM PIPING
  • 5.12 SYSTEM PIPING - ZONE CIRCULATORS
  • 5.13 SYSTEM PIPING - ZONE VALVES
  • 5.14 SYSTEM PIPING - THROUGH BOILER
  • 5.15 SYSTEM PIPING - RADIANT HEATING
  • 5.16 SYSTEM PIPING—SPECIAL APPLICATIONS
  • 5.17 SYSTEM PIPING—MULTIPLE UNITS INSTALLATION
• CHAPTER 6: Installing Vent, Air Intakes, AND Drain
  • 6.1 INSTALLING VENT AND COMBUSTION AIR INTAKE
  • 6.2 INSTALLING CONDENSATE DRAIN ASSEMBLY
• CHAPTER 7: GAS PIPING
  • 7.1 GAS SUPPLY PIPING CONNECTION
  • 7.2 NATURAL GAS
    • 7.2.1 Pipe Sizing - Natural Gas
    • 7.2.2 Natural Gas Supply Pressure Requirements
  • 7.3 PROPANE GAS
    • 7.3.1 Pipe Sizing – Propane Gas
    • 7.3.2 Propane Gas Supply Pressure Requirements
• CHAPTER 8: INTERNAL WIRING
  • 8.1 GENERAL REQUIREMENTS
  • 8.2 FUSE LOCATIONS
    • 8.2.1 EZ-SETUP Controller Module Fuses Location
    • 8.2.2 Line Voltage Fuses Location
• CHAPTER 9: EXTERNAL WIRING
  • 9.1 INSTALLATION COMPLIANCE
  • 9.2 LINE VOLTAGE CONNECTIONS
  • 9.3 CIRCULATOR WIRING
  • 9.4 ALARM WIRING
  • 9.5 LOW VOLTAGE CONNECTIONS
  • 9.6 THERMOSTAT WIRING
  • 9.7 OUTDOOR SENSOR WIRING
  • 9.8 DOMESTIC HOT WATER WIRING
  • 9.9 ADDITIONAL BOILER LIMITS
  • 9.10 EXTERNAL MODULATION CONTROL
  • 9.11 SYSTEM SENSOR WIRING
  • 9.12 CASCADE WIRING
  • 9.13 MODBUS WIRING
• CHAPTER 10: Basic EZ-SET Controller Operation
  • 10.1 EZ-SET CONTROLLER INTRODUCTION
  • 10.2 EZ-SET CONTROLLER FEATURES AND FUNCTIONS
  • 10.3 CONTROLLER NAVIGATION
  • 10.4 HOME SCREEN
  • 10.5 MAIN MENU
  • 10.6 EZ SETUP
  • 10.7 HEATING EZ SETUP
    • 10.7.1 Select CH Demand (Default: Switch & Outdoor Reset)
    • 10.7.2 CH1 Setpoint (Default: 180 F [82 C])
    • 10.7.3 CH2 Setpoint (Default: 140 F [60 C])
    • 10.7.4 Select CH1 Reset Curve (Default: Finned Tube Baseboard)
    • 10.7.5 Select CH2 Reset Curve (Default: Low Mass Radiant)
    • 10.7.6 Set Warm Weather Shutdown Temperature (Default: OFF)
  • 10.8 DOMESTIC HOT WATER EZ SETUP
    • 10.8.1 Select DHW Demand (Default: Switch)
    • 10.8.2 Boiler DHW Setpoint (Default: 186 F [86 C])
    • 10.8.3 DHW Storage Setpoint (Default: 140 F [60 C])
    • 10.8.4 DHW Priority Timeout (Default: Off)
  • 10.9 EZ SETUP RESET
  • 10.10 DISPLAY EZ SETUP
  • 10.11 CH/DHW OPERATION
  • 10.12 BOILER INFORMATION
    • 10.12.1 Boiler Information Logging
  • 10.13 LOCKOUT HISTORY
    • 10.13.1 Lockout Details
• CHAPTER 11: START-UP PREPARATION
  • 11.1 CHECK BOILER SYSTEM WATER CHEMISTRY
    • 11.1.1 Water pH Level 6.0 to 8.0
    • 11.1.2 Water Hardness Less Than 7 Grains
    • 11.1.3 Chlorinated Water
    • 11.1.4 Flush Boiler to Remove Sediment
    • 11.1.5 Check and Test Antifreeze
    • 11.1.6 Use of Antifreeze in the Boiler System
  • 11.2 BOILER CLEANING
    • 11.2.1 Cleaning an Old Boiler and System
    • 11.2.2 Cleaning of New Boiler/System:
    • 11.2.3 Filling the Boiler System
  • 11.3 CHECK LOW WATER CUT-OFF DEVICE
  • 11.4 CHECK FOR GAS LEAKS
  • 11.5 CHECK THERMOSTAT CIRCUIT
  • 11.6 INSPECTION OF CONDENSATE DRAIN ASSEMBLY
• CHAPTER 12: Start-Up Procedures
  • 12.1 FINAL CHECKS BEFORE START-UP
  • 12.2 ESTEEM START-UP
  • 12.3 OPERATING INSTRUCTIONS (READ BEFORE OPERATING BOILER)
    • 12.3.1 Troubleshooting Start-Up Problems
  • 12.4 INSPECTION OF THE ESTEEM BOILER AND SYSTEM
    • 12.4.1 Boiler Piping inspection
    • 12.4.2 Vent Piping and Combustion Air Piping inspection
    • 12.4.3 Gas Piping Inspection
    • 12.4.4 Flame Pattern and Combustion Verification
    • 12.4.5 Measure and Verify Input Rating - Natural Gas Only
    • 12.4.6 High Temperature Limit Testing
• CHAPTER 13: Outdoor Reset Control
  • 13.1 OUTDOOR TEMPERATURE SENSOR INSTALLATION
  • 13.2 OUTDOOR TEMPERATURE SENSOR WIRING
• CHAPTER 14: External Modulating Control
  • 14.1 WIRING THE EXTERNAL MODULATING CONTROLLER
  • 14.2 EZ-SETUP CONTROLLER PROGRAMMING FOR EXTERNAL 0-10V SIGNAL
  • 14.3 EXTERNAL PROGRAMMING OF 0-10V MODULATING CONTROL
• CHAPTER 15: Check-Out Procedures
• CHAPTER 16: Maintenance Schedule
  • 16.1 SERVICE TECHNICIAN MAINTENANCE
    • 16.1.1 General Maintenance
    • 16.1.2 Poor Performance Maintenance
    • 16.1.3 Owner Maintenance
• CHAPTER 17: Maintenance Procedures
  • 17.1 REPORTED PROBLEMS
  • 17.2 SURROUNDING AREA INSPECTION
  • 17.3 BURNER AREA INSPECTION
  • 17.4 SYSTEM PIPING INSPECTION
  • 17.5 CLEAN CONDENSATE DRAIN ASSEMBLY
  • 17.6 VENTILATION AIR OPENINGS INSPECTION
  • 17.7 VENT AND COMBUSTION AIR PIPING INSPECTION
  • 17.8 BOILER SYSTEM INSPECTION
  • 17.9 EXPANSION TANK INSPECTION
  • 17.10 BOILER RELIEF VALVE INSPECTION
  • 17.11 IGNITION ELECTRODE INSPECTION
  • 17.12 IGNITION WIRING AND GROUND WIRING INSPECTION
  • 17.13 CONTROL WIRING INSPECTION
  • 17.14 CONTROL SETTINGS INSPECTION
  • 17.15 PERFORM START-UP AND CHECKOUT PROCEDURES
  • 17.16 BURNER FLAME INSPECTION AND TROUBLESHOOTING
  • 17.17 FLAME SIGNAL INSPECTION
  • 17.18 COMBUSTION LEVELS INSPECTION
  • 17.19 FLUE GAS TEMPERATURE CHECK
  • 17.20 HEAT EXCHANGER CLEANING
  • 17.21 REVIEWING MAINTENANCE REQUIREMENTS WITH OWNER
  • 17.22 Handling Previously Fired Combustion Chamber Insulation
• CHAPTER 18: EZ-SETUP CONTROLLER OPERATION AND SETTINGS
  • 18.1 ENTERING THE INSTALLER ACCESS CODE
  • 18.2 USING THE INSTALLER MENU
  • 18.3 CH and DHW SETTINGS MENU
    • 18.3.1 Heating Operation (Default: Enabled)
    • 18.3.2 Demand Type (Default: Switch & Outdoor Reset)
    • 18.3.3 Absolute Max CH Setpoint (Default: 188 F [87 C])
    • 18.3.4 CH1 Maximum Setpoint (Default: 180 F [82 C])
    • 18.3.5 CH1 Minimum Setpoint (Default: 120 F [49 C])
    • 18.3.6 Reset Curve Coldest Day (Default: 0 F [-18 C])
    • 18.3.7 Reset Curve Warmest Day (Default: 64 F [18 C])
    • 18.3.8 CH2 Circuit (Default: Enabled)
    • 18.3.9 CH2 Maximum Setpoint (Default: 140 F [60 C])
    • 18.3.10 CH2 Minimum Setpoint (Default: 80 F [27 C])
    • 18.3.11 Warm Weather Shutdown (Default: Off)
    • 18.3.12 Pump Constant Circulation (Default: Disabled)
    • 18.3.13 CH Post Pump Time (Default: 1 Minute)
    • 18.3.14 Freeze Protection (Default: Enabled)
    • 18.3.15 Frost Protection Setpoint (Default: -22 F [-30 C])
    • 18.3.16 Parallel Shift Value (Default: 0 F [0 C])
    • 18.3.17 CH Call Blocking (Default: 1 Minute)
    • 18.3.18 System Pump (Default: CH1/CH2)
  • 18.4 DHW SETTINGS MENU
    • 18.4.1 DHW Operation (Default: Enabled)
    • 18.4.2 Demand Type (Default: Switch)
    • 18.4.3 Boiler DHW Setpoint (Default: 186 F [86 C])
    • 18.4.4 DHW Storage Setpoint (Default: 140 F [60 C])
    • 18.4.5 DHW on Differential (Default: 6 F [3 C])
    • 18.4.6 DHW Storage Adder (Default: 46 F [25 C])
    • 18.4.7 DHW Post Pump Time (Default: 1 Minute)
    • 18.4.8 DHW Priority Timeout (Default: OFF)
    • 18.4.9 DHW Priority (Default: ENABLED)
    • 18.4.10 DHW Call Blocking (Default: 0 Minutes)
    • 18.4.11 DHW to CH Call Blocking (Default: 1 Minute)
    • 18.4.12 Antilegionella Function (Default: DISABLED)
  • 18.5 BOILER SETTINGS MENU
    • 18.5.1 Lockout Temp (Default: 210 F [99 C])
    • 18.5.2 Modbus Address (Default: 0=BCST)
  • 18.6 RESET ALL SETTINGS MENU
  • 18.7 CASCADE MENU AND OPERATING INFORMATION
    • 18.7.1 Cascade Installation – System Piping
    • 18.7.2 Cascade Installation – System Sensor Installation
    • 18.7.3 Cascade Installation – Cascade Communication Cable
    • 18.7.4 Cascade Installation – Low Voltage Wiring Connections
    • 18.7.5 Cascade Installation – Line Voltage Wiring Connections
  • 18.8 CASCADE AUTODETECTION MENU
    • 18.8.1 Cascade Operation – Lockouts
  • 18.9 CASCADE INFORMATION MENU
    • 18.9.1 System Temperature Logging
    • 18.9.2 Cascade Settings Menu
    • 18.9.3 Stage Delay (Default: 60 Seconds)
    • 18.9.4 Minimum firing Rate (Default: 30%)
    • 18.9.5 Boiler Enabling Algorithm
    • 18.9.6 Boiler Disabling Algorithm
    • 18.9.7 Maximum Firing Rate (Default: 398 MBH)
    • 18.9.8 CH or DHW Boilers (Default: 0)
    • 18.9.9 Automatic Rotation (Default: Enabled)
    • 18.9.10 CH Proportional Gain (Default: 7)
    • 18.9.11 CH Integral Gain (Default: 245)
    • 18.9.12 DHW Proportional Gain (Default: 7)
    • 18.9.13 DHW Integral Gain (Default: 245)
    • 18.9.14 Modbus Address (Default: 0 = BcST)
    • 18.9.15 Modbus Interface
  • 18.10 MANUAL OPERATION
    • 18.10.1 Fan Parameter
    • 18.10.2 CH CH1 Parameter
    • 18.10.3 DHW Parameter
    • 18.10.4 SYS CH2 Parameter
• Apenndix A: Part AND DIMENSIONAL Drawings
• Apenndix B: CIRCULATOR PRESSURE LOSS CHARTS
• 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., 1...
• Completed By:______________________________________________ Date:___________
• LOCATION
• Installation Name: __________________________________ SST Technician:_____________________
• Street Address: ___________________________________ Company:__________________________
• City, State, Zip: ___________________________________ Phone#:___________________________
• AERCO Sales Rep.: _________________________________ Unit Serial#: _______________________
• GENERAL INSTALLATION
• Number of units at site: ______ ______ ______ _______ _______ _______
• GAS SUPPLY
• Type of Gas Supply: Natural Gas Propane Gas
• Is an external gas supply regulator installed within two to six feet of the unit? …….......... Yes No
• What are the make and model number of the external gas supply regulator? Make: _____________
• Model: _____________
• What is the static gas supply pressure to the external supply regulator? …….___________________
• If this is a lock-up style external regulator, what is the size of the orifice? ……___________________
• What is the supply regulator’s outlet spring range? …………………………….. ___________________
• The external gas supply vent regulator lines are: Individually Run Manifolded together with other regulator vent lines.
• What is the BTU content of the gas? ___________________________________________________
• What is the size of the gas supply header _______________________________________________
• What is the length of gas pipe from the main meter? _______________________________________
• STARTUP RECORD FOR ESTEEM 399 BOILER - (Continued)
• Venting
• Combustion Air
• Boiler Installation
• Combustion Settings
• CO2: _______________% Measured Rate of Input: _________________ Btu/hr
• O2: _______________%
• CO: _______________ppm