Document Outline

• FOREWORD
• CHAPTER 1: GENERAL INFORMATION
  • 1.1 Warnings & Cautions
  • 1.2 Emergency Shutdown
• CHAPTER 2: FUNCTIONAL OVERVIEW
  • 2.1 Introduction
  • 2.2 Intended Use – Boilers
  • 2.3 Intended Use – Water Heaters
  • 2.4 AM Series Component Diagrams
  • 2.5 AM Series Functional Schematics
    • 2.5.1 AM 399 / 500 Functional Schematic
    • 2.5.2 AM 750 Functional Schematic
    • 2.5.3 AM1000 Functional Schematic
    • 2.5.4 Boiler Efficiency in Outdoor Reset Mode
• CHAPTER 3: Installation
  • 3.1 Choosing the Installation Location
  • 3.2 Boiler and Water Heater Installation Location Factors
  • 3.3 Safety Concerns
  • 3.4 Closet and Alcove Installation
  • 3.5 Clearances for Installation and Servicing
  • 3.6 Clearances to Combustible Material
  • 3.7 Vent and Combustion Air Piping
  • 3.8 Prevention of Combustion Air Contamination
  • 3.9 Transporting the Unit
  • 3.10 Unpacking and Installing the Unit
  • 3.11 Supply and Return Piping - Boilers
    • 3.11.1 Water Quality - Boilers
    • 3.11.2 System Piping Methods - Boilers
    • 3.11.3 Freeze Protection - Boilers
    • 3.11.4 Floor Radiant Heating Systems - Boilers
    • 3.11.5 Near Boiler Heating Piping Components - Boilers
    • 3.11.6 Safety Relief Valve - Boilers
    • 3.11.7 Flow Switch
    • 3.11.8 Low Water Cutoff (LWCO)
    • 3.11.9 Expansion Tank and Makeup Water - Boilers
    • 3.11.10 Circulator Heating Pump - Boilers
    • 3.11.11 Sizing the Heating System - Boilers
    • 3.11.12 Domestic Hot Water System Piping with Indirect Water Heater - Boilers
  • 3.12 Hot and Cold Water Piping – Water Heaters
    • 3.12.1 Near-Boiler Heating Piping Components – Water Heaters
    • 3.12.2 Safety Relief Valve – Water Heaters
    • 3.12.3 Expansion Tank in Closed Water Systems – Water Heaters
    • 3.12.4 Circulator Pump – Water Heaters
    • 3.12.5 Sizing the Water System – Water Heaters
    • 3.12.6 Scalding – Water Heaters
    • 3.12.7 Water Chemistry – Water Heaters
  • 3.13 Condensate Disposal
    • 3.13.1 Commonwealth of Massachusetts Special Requirement
  • 3.14 Electrical Connections
    • 3.14.1 Power Supply Cable Connection – Boilers and Water Heaters
      • 3.14.1.1 Connecting Units in Cascade (Boilers or Water Heaters)
    • 3.14.2 0-10 VDC Input Connections – Boilers & Water Heaters
    • 3.14.3 MODBUS Interface Connections – Boilers and Water Heaters
    • 3.14.4 On/Off Control (Enable/Disable)
    • 3.14.5 Installing the Outdoor Temperature Sensor - Boilers
    • 3.14.6 Indirect Water Heater Connection - Boilers
    • 3.14.7 Indirect Water Heater Priority Selection - Boilers
  • 3.15 Electrical Connections – Water Heaters
    • 3.15.1 Storage Tank Connection - Water Heaters
  • 3.16 Venting and Combustion Air Piping
    • 3.16.1 Combustion Air Contamination Prevention
    • 3.16.2 General Venting and Air Piping Systems
    • 3.16.3 Min/Max Allowable Combustion Air and Vent Piping Lengths
    • 3.16.4 General Venting and Combustion Air Piping Installation
    • 3.16.5 Specific Vent and Combustion Air Installations
      • 3.16.5.1 Sealing of PVC, CPVC or ABS Air Inlet Pipe
      • 3.16.5.2 PVC/CPVC Vent Piping Materials
      • 3.16.5.3 Air Intake and Vent Starter Pieces
      • 3.16.5.4 Single Pipe Venting (Unsealed Combustion)
      • 3.16.5.5 Combustion Air and Ventilation Openings
      • 3.16.5.6 Two Permanent Openings Method
      • 3.16.5.7 One Permanent Opening Method
      • 3.16.5.8 Determining Vent Termination Location
      • 3.16.5.9 Sidewall Termination - Two pipes
      • 3.16.5.10 Determining Location of Sidewall Two-pipe Termination
      • 3.16.5.11 Installing Vent and Air Piping into Sidewall
      • 3.16.5.12 Sidewall Termination and Fittings
      • 3.16.5.13 Multiple Vent and Air Terminations
      • 3.16.5.14 Sidewall Termination – Concentric Vent
      • 3.16.5.15 Sidewall Termination Installation
      • 3.16.5.16 Multi-venting Sidewall Terminations
      • 3.16.5.17 Vertical Termination – Two Pipes
      • 3.16.5.18 Determining Location of Vertical Termination
      • 3.16.5.19 Vertical Vent and Air Roof Termination Preparation
      • 3.16.5.20 Installing Vertical Vent and Air Roof Terminations
      • 3.16.5.21 Installing Multiple Vent and Air Vertical Terminations
      • Installing Vertical Multiple Vent and Air Roof Terminations
      • 3.16.5.22 Vertical Termination – Concentric Vent
      • 3.16.5.23 Determining Location of Vertical Concentric Vent Termination
      • 3.16.5.24 Multi-Venting Vertical Terminations
  • 3.17 Gas Supply Piping
    • 3.17.1 Connection of Gas Supply Piping
    • 3.17.2 Natural Gas Pipe Sizing
      • 3.17.2.1 Natural Gas Supply Pressure Requirements
    • 3.17.3 Propane Gas Pipe Sizing
      • 3.17.3.1 Propane Gas Supply Pressure Requirements
    • 3.17.4 Checking and Adjusting the Unit Inlet Gas Supply Pressure
    • 3.17.5 High Altitude Operation
    • 3.17.6 Conversion from Natural gas to Propane Gas
      • 3.17.6.1 Gas Conversion Kit
      • 3.17.6.2 Gas Conversion Instructions
• CHAPTER 4: UNIT start-up
  • 4.1 INITIAL START-UP REQUIREMENTS
    • 4.1.1 Filling the Condensate Neutralizer
    • 4.1.2 Filling the Heating System
  • 4.2 General Warnings Concerning the Gas Supply
    • 4.2.1 Confirming the Unit’s Gas Type
    • 4.2.2 Gas Type Conversion
  • 4.3 Identification of Controls
  • 4.4 Boiler Startup Procedure
  • 4.5 Water Heater Startup Procedure
  • 4.6 Gas Supply Pressure Test
  • 4.7 Combustion Calibration
  • 4.8 Minimum Water Flow
  • 4.9 Heating System Pressure Test
• CHAPTER 5: OPERATION
  • 5.1 General Operation - Boilers
    • 5.1.1 Control Panel Display - Boilers
    • 5.1.2 Startup Procedure - Boilers
    • 5.1.3 Boiler Summer Mode
    • 5.1.4 Boiler Winter Mode
    • 5.1.5 Adjusting the Domestic Hot Water Temperature - Boilers
    • 5.1.6 Heating System Temperature Adjustment - Boilers
    • 5.1.7 Heating System Type Selection - Boilers
    • 5.1.8 Outdoor Reset Adjustment - Boilers
      • 5.1.8.1 Outdoor Reset: Setting Parameters
      • 5.1.8.2 Outdoor Reset Activation
    • 5.1.9 Boiler Delays, Alarms and Protective Actions
    • 5.1.10 Boiler Circulator Pump Protection
    • 5.1.11 Freeze Protection - Boilers
    • 5.1.12 Display Energy Saving Mode
  • 5.2 General Operation – Water Heaters
    • 5.2.1 Control Panel Display – Water Heaters
    • 5.2.2 Startup Procedure - Water Heaters
    • 5.2.3 Adjusting the Storage Tank Temperature (Water Heaters)
    • 5.2.4 Freeze Protection – Water Heaters
    • 5.2.5 Display Energy Saving Mode
  • 5.3 User Menu – Boilers and Water Heaters
  • 5.4 Installer Menu – Boilers and Water Heaters
  • 5.5 Diagnostics: Status Display
  • 5.6 Diagnostics – Blocking (Loc) Errors
  • 5.7 Diagnostics – Blocking (Err) Errors
  • 5.8 Blocked Flue Pressure Switch
  • 5.9 Unit Shut-Down
• CHAPTER 6: Maintenance
  • 6.1 Care and Maintenance – Boilers and Water Heaters
    • 6.1.1 Checking for Gas Leaks
    • 6.1.2 Flue and Air inlet Piping Inspection
    • 6.1.3 System Piping, Pressure, and Expansion Tank Inspection
    • 6.1.4 Ignition and Flame Sensor Inspection
    • 6.1.5 Wiring and Connections Inspection
    • 6.1.6 Performance Verification Inspection
    • 6.1.7 Flame Inspection
    • 6.1.8 Flame Signal Inspection
    • 6.1.9 Relief Valve Inspection
    • 6.1.10 Unit Vicinity Inspection
    • 6.1.11 Pressure Gauge Inspection
    • 6.1.12 Condensate Drain System Inspection
    • 6.1.13 Low Water Cutoff Test
    • 6.1.14 Flow Switch Test
    • 6.1.15 Removing the Unit Covers
    • 6.1.16 Cleaning the Burner and Primary Heat Exchanger (Flue/Gas Side)
    • 6.1.17 Ignition and Flame Detection Sensor Electrode Positioning
    • 6.1.1 Air Filter Cleaning
    • 6.1.1 Condensate Trap and Neutralizing Reservoir Maintenance
    • 6.1.2 Connection of the Control Panel Display to Each Burner
    • 6.1.3 Control Board Replacement
    • 6.1.4 Draining the Water from the Unit
    • 6.1.5 Water and Flue Temperature Sensor
    • 6.1.6 Outdoor Temperature Sensor (Boilers Only)
  • 6.2 Maintenance Kits Part Lists
    • 6.2.1 Wiring Diagram - Boilers
    • 6.2.2 Wiring Diagram – Water Heaters
• CHAPTER 7: Technical Data
• CHAPTER 8: Spare Parts
  • 8.1 Spare Parts and Maintenance Kits
    • 8.1.1 AM399/500 Spare Parts Drawings
    • 8.1.2 Models AM399/500 Spare Parts List
    • 8.1.3 Models AM 750B / 1000B Spare Parts Drawings
    • 8.1.4 Models AM750/1000 Spare Parts List
• Appendix A: CONTROL PANEL OPERATIONAL FLOW CHART
• Appendix B: Factory Menu
• STANDARD WARRANTY