AERCO Esteem 399 Installation and Maintenance Manual

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Page 1

Instruction

No.

AERCO INTERNATIONAL, Inc. Northvale, New Jersey, 07647 USA

Installation and Maintenance

Manual

Esteem 399

GF-125

Low NOx Gas Fired Boiler

Visit www.aerco.com to View the Latest

Product Manuals and Information.

Printed in U.S.A. REVISED MAY 2010

Page 2

Telephone Support

(800) 526-0288

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through Friday)

Please have the unit’s model number and the serial number from the rating label on the backside of the control panel when calling about service or troubleshooting.

Model #_________________________

Serial #__________________________

AERCO International, Inc. 159 Paris Avenue Northvale, NJ 07647-0128

www.aerco.com

The information contained in this document 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. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

Page 3

Esteem 399 Low NOx Installation and Maintenance Manual GF-125

Contents

Chapter 1 Warnings and Cautions 1

Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Prolonged Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IF YOU SMELL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 2 Pre-Installation Items 4

Code Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Boiler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 3 Combustion Air and Venting 7

Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Potential contaminating products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Areas likely to have contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Ventilation and Combustion Air Requirements - Direct Vent. . . . . . . . . . . . . . . . . . . . . . . . 8

Ventilation and Combustion Air Requirements - Category IV . . . . . . . . . . . . . . . . . . . . . . . 8

Indoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Outdoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Combination of Indoor and Outdoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . . . . . . . . . . . . . 11

Commonwealth of Massachusetts Installations Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 4 Unit Preparations 14

Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Stud Wall Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Boiler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Chapter 5 Boiler Piping 16

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Low Water Cutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Backflow Preventer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Boiler System Piping Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Page 4

Domestic Hot Water System Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Zone Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

System Piping - Zone Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Through Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Special Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

System Piping - Multiple Units Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 6 Installing Vent, Air Intake & Drain 27

Installing Vent and Combustion Air Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installing Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Chapter 7 Gas Piping 29

Gas Supply Piping Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pipe Sizing - Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Natural Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chapter 8 Internal Wiring 33

General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Control Module Circulator AMP Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Wiring Tool Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 9 External Wiring 35

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Domestic Hot Water Aquastat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

CH and DHW Circulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

External Modulating Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Additional 24V Limit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

External Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chapter 10 Start-Up Preparation 39

Check Boiler System Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Water pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Water Hardness Less Than 7 Grains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . . . . . . . . . . . . 39

Check and Test Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Page 5

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Check For Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Check Thermostat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Inspect the Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chapter 11 Start-Up Procedures 42

Final Checks Before Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Esteem 399 Low NOx Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

If Esteem 399 Low NOx Does Not Start Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

First Run Check of the Unit and System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Set Boiler CH Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Operation Verification - Domestic Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 12 Operating Instructions 47

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

TO TURN OFF GAS TO APPLIANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Boiler Control Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

To temporarily place the burner into high fire test mode: . . . . . . . . . . . . . . . . . . . . . . 49

Parameter mode—Setting The Boiler Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Information Mode—Accessing Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 13 Outdoor Reset Control 54

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Summer / Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Adjusting Outdoor Reset Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CH Maximum Boiler Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CH Minimum Boiler Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CH Reset Curve Coldest Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Entering MCBA Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 14 External Modulating Control 58

Wiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Parameter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Factory Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Chapter 15 Check-Out Procedures 60

Check-Out Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Chapter 16 Installation Record 61

iii

Page 6

Chapter 17 Maintenance Schedule 62

Professional Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 18 Maintenance Procedures 63

Attend to Reported Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Check Surrounding Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Check System Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Inspect Ignition Electrode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Check Flame Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Check Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Clean Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Start-up and Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Review With Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Chapter 19 Troubleshooting 69

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Control Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Soft Lockout Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Hard Lockout Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Insulation Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Appendices 87

Appendix A: Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Appendix B: Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Appendix C: Pressure Drop Comparison Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Page 7

Chapter 1 Warnings and Cautions

Installers and operating personnel MUST, at all times, observe all safety

regulations.

The following general warnings and cautions must be given the same attention as specific precautions included in these instructions. In addition to the requirements included in this Manual, the installation MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54). Where ASME CSD-1 is required by local jurisdiction, the installation must conform to CSD-1.

Where applicable, the equipment must be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CGA B149, and applicable Provincial regulations for the class. Authorities having jurisdiction should be consulted before installations are made.

CAUTIONS!

Must be observed to prevent damage or loss of operating effectiveness.

NOTICE

Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.

WARNING!

BEFORE ATTEMPTING TO PERFORM ANY MAIN-

TENANCE ON THE UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.

WARNING!

THE EXHAUST VENT PIPE OF THE UNIT OPER-

ATES UNDER A POSITIVE PRESSURE AND THERE- FORE MUST BE COMPLETELY SEALED TO PRE- VENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES.

IMPORTANT

This Instruction Manual is an integral

part of the product and must be main-

tained in legible condition. It must be giv-

en to the user by the installer and kept in

a safe place for future reference.

DANGER!

INDICATES THE PRESENCE OF A HAZARDOUS

SITUATION WHICH, IF IGNORED, WILL RESULT IN DEATH, SERIOUS INJURY OR SUBSTANTIAL PROP- ERTY DAMAGE.

WARNINGS!

MUST BE OBSERVED TO PREVENT SERIOUS IN-

JURY OR SUBSTANTIAL PROPERTY DAMAGE.

WARNING!

FLUIDS UNDER PRESSURE MAY CAUSE INJURY

OR DAMAGE TO EQUIPMENT WHEN RELEASED.

E SURE TO SHUT OFF ALL INCOMING AND OUT-

GOING WATER SHUT OFF VALVES. CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING ANY BOILER MAINTE- NANCE.

WARNING!

DO NOT USE MATCHES, CANDLES, FLAMES, OR

OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

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Page 8

Emergency Shutdown

CAUTION!

Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean water after leak checks have been completed.

CAUTION!

DO NOT use this boiler if any part has been under water. Call a qualiﬁ ed serv- ice technician to inspect and replace

any part that has been underwater.

IMPORTANT

The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

Emergency Shutdown

To shut Down the Unit

Turn the service switch on the Esteem 399 Low NOx control panel to “OFF”

Turn the external manual gas valve handle clockwise

to “CLOSE”.

If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1) located external to the unit.

Prolonged Shutdown

After prolonged shutdown, it is recommended that the startup procedures in Chapter 10 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 the unit. The installer must identify the emergency shut-off device.

Figure 1: Typical Manual Gas Shutoff Valve

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Page 9

IF YOU SMELL GAS

DANGER!

IF YOU SMELL GAS

• Do Not try to light any appliance

• Do Not touch any electrical switch

• Do Not use any phone or cell phone in your building.

• Immediately call your gas supplier from a different location.

• Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

IMPORTANT

Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

DANGER!

DO NOT USE THIS APPLIANCE IF ANY PART

HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM WHICH HAS BEEN UNDER WATER.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS

SUPPLY FAILS TO SHUT OFF, TURN OFF THE MANUAL GAS CONTROL VALVE EXTERNAL TO THE APPLIANCE.

WARNING

DO NOT ADD COLD MAKE UP WATER WHEN THE

BOILER IS HOT. THERMAL SHOCK CAN CAUSE POTENTIAL CRACKS IN THE HEAT EXCHANGER.

CAUTION

Avoid electrical shock by disconnecting the electrical supply prior to performing maintenance when servicing the boiler:

WARNING

PRIOR TO INSTALLING THIS PRODUCT READ ALL

INSTRUCTIONS INCLUDED IN THIS MANUAL AND ALL ACCOMPANYING MANUALS/DOCUMENTS.

ERFORM ALL INSTALLATION STEPS REQUIRED

IN THESE MANUALS IN THE PROPER ORDER GIV- EN. FAILURE TO ADHERE TO THE GUIDELINES WITHIN THESE MANUALS CAN RESULT IN SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

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 ﬁ ttings not speciﬁ ed by AERCO International.

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Page 10

Chapter 2 Pre-Installation Items

Code Compliance

This product must be installed in accordance to the following:

• All applicable local, state, national and provincial codes, ordinances, regulations and laws.

• For installations in Massachusetts, code requires the boiler to be installed by a licensed plumber or gas ﬁ tter, and if anti- freeze is utilized, the installation of a reduced pressure backﬂ ow preventer device is required in the boiler’s cold water ﬁ ll or make up water supply line.

• For installation in Massachusetts all direct vented appliances must comply with the guidelines as outlined on page 13.

• The National Fuel Gas Code NFPA54/ ANSI Z 223.1 - Latest edition.

• National Electric Code ANSI/NFPA 70.

• For installations in Canada -“Installation Code for Gas Burning Equipment” CGA/ B149.1 or B149.2 Canadian Electrical Code Part 1 CSA C22.1.

Standards for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD1, when required.

Determining Product Location

Before locating the Esteem 399 Low NOx check for convenient locations to:

• Heating system piping

• Venting

• Gas supply piping

• Electrical service

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 Low NOx is free of any combustible materials, gasoline and other flammable liquids.

WARNING

FAILURE TO REMOVE OR MAINTAIN THE AREA

FREE OF COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE LIQUIDS OR VAPORS CAN RESULT IN SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

NOTICE

The Esteem 399 Low NOx boiler gas manifold and gas controls meet the safe lighting and other performance requirements as speciﬁ ed in ANSI Z21.13 latest edition.

Ensure the Esteem 399 Low NOx and its controls are protected from dripping or spraying water during normal operation or service.

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.

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Page 11

Boiler Replacement

If the Esteem 399 Low NOx is replacing an existing boiler, the following items should be checked and corrected prior to installation:

• Boiler piping leaks and corrosion.

• Improper location and sizing of the expansion tank on the boiler heating loop.

• If applicable, level and quality of freeze protection within the boiler system.

See Warning on ”Handling Previously Fired Combustion Chamber Insulation” on page 67

Recommended Clearances

Boiler Replacement

The Esteem 399 Low NOx is approved for zero clearance to combustibles, excluding vent and boiler piping.

• Boiler Piping - 1/4 inch from combustible materials.

• See Concentric Vent System Installation Supplement GF-125V for vent clearance requirements.

To provide service access to the unit it is recommended that the following clearances be maintained:

Top jacket 24 inches [610 mm]. Front 24 inches [610 mm]. Rear 0 inches Sides 6 inches [153 mm] Bottom piping 24 inches [610 mm].

WARNING

IF THE CLEARANCES LISTED ABOVE CANNOT BE

MAINTAINED OR THE ENCLOSURE IN WHICH THE BOILER IS INSTALLED IS LESS THAN 85 CUBIC FEET, THE SPACE MUST BE VENTILATED. SEEP- AGE 8 FOR REQUIREMENTS.

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Page 12

NOTICE

CAUTION

When maintaining zero clearance or less than recommended clearances, some product labeling may become hidden and unreadable.

WARNING

WHEN INSTALLING THE ESTEEM 399 LOW NOX

IN A CONFINED SPACE, SUFFICIENT AIR MUST BE PROVIDED FOR PROPER COMBUSTION AND VENTING AND TO ALLOW, UNDER NORMAL OPER- ATING CONDITIONS, PROPER AIR FLOW AROUND THE PRODUCT TO MAINTAIN AMBIENT TEMPERA- TURES WITHIN SAFE LIMITS TO COMPLY WITH THE NATIONAL FUEL GAS CODE NFPA 54 - LATEST EDITION.

Residential Garage Installations

When installing the Esteem 399 Low NOx in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken:

The boiler freeze protection feature is disabled during a hard lockout, however the space heating circulator will operate.

CAUTION

The boiler freeze protection feature is designed to protect the boiler. The boiler should be installed in a primary/ secondary piping arrangement if it is installed in an unheated space or exposed to water temperatures of 46ºF or less. See “Chapter 5 Boiler Piping” on page 16 for primary/secondary piping examples. See Chapter 10 for antifreeze guides.

• Mount the unit a minimum 18 inches [458 mm] above the floor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches [458 mm] above the floor level.

• Locate or protect the unit in a manner so it cannot be damaged by a moving vehicle.

Boiler Freeze Protection Feature

The boiler control has a freeze protection feature built in. This feature monitors the boiler temperature and responds as follows when no call for heat is present:

• 46ºF Boiler circulator is ON

• 38ºF Boiler circulator is ON and burner operates at low fire

• 50ºF Burner OFF and boiler circulator operates for approximately 10 minutes

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Page 13

Chapter 3 Combustion Air and Venting

Combustion Air Contamination

WARNING

IF THE ESTEEM 399 LOW NOX COMBUSTION

AIR INLET IS LOCATED IN ANY AREA LIKELY TO CAUSE OR CONTAIN CONTAMINATION, OR IF PRODUCTS, WHICH WOULD CONTAMINATE THE AIR CANNOT BE REMOVED, THE COMBUSTION AIR MUST BE RE-PIPED AND TERMINATED TO ANOTHER LOCATION. CONTAMINATED COMBUS- TION AIR WILL DAMAGE THE UNIT AND ITS BURN- ER SYSTEM, RESULTING IN POSSIBLE SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

WARNING

DO NOT OPERATE AN ESTEEM 399 LOW NOX

IF ITS COMBUSTION AIR INLET IS LOCATED NEAR A LAUNDRY ROOM OR POOL FACILITY. THESE AREAS WILL ALWAYS CONTAIN HAZARDOUS CONTAMINANTS.

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the burner and vent system, they can form strong acids. These acids can create corrosion of the heat exchanger, burner components and vent system, causing serious damage and presenting a possible threat of flue gas spillage or water leakage into the surrounding area.

Please read the information listed below. If contaminating chemicals are located near the area of the combustion air inlet, the installer should pipe the combustion air inlet to an outside area free of these chemicals per Chapter 5 of this installation manual.

Potential contaminating products

• Spray cans containing chloro/ﬂ uorocar- bons

• Permanent Wave Solutions

• Chlorinated wax

• Chlorine - based swimming pool chemicals / cleaners

• Calcium Chloride for melting ice

• Sodium Chloride for water softening

• Refrigerant leaks

• Paint or varnish removers

• Hydrochloric acid / muriatic acid

• Cements and glues

• Antistatic fabric softeners used in clothes dryers

• Chlorine-type bleaches, detergents, and cleaning solvents

• Adhesives and other similar products

Areas likely to have contaminants

• Dry cleaning / laundry areas and establishments

• Beauty salons

• Metal fabrication shops

• Swimming pools and health spas

• Refrigeration Repair shops

• Photo processing plants

• Auto body shops

• Plastic manufacturing plants

• Furniture reﬁ nishing areas and establish- ments

• New building construction

• Remodeling areas

• Garages with workshops

The above lists are NOT comprehensive. Installer, The end user and service personnel are responsible for certifying the safety of any and all materials that may affect the quality of

the combustion air.

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Page 14

Ventilation and Combustion Air Requirements - Direct Vent

A Direct Vent appliance uses uncontaminated outdoor air (piped directly to the appliance) for combustion.

For Direct Vent installations, involving only the Esteem 399 Low NOx , in which the minimum service clearances are maintained as listed on page 5, no ventilation openings are required.

For Direct Vent, zero clearance installations involving only the Esteem 399 Low NOx , the space / enclosure must have two openings for ventilation. The openings must be sized to

provide 1 square inch of free area per 1,000 BTUH of boiler input. The openings must be

placed 12 inches from the top of the space and 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. Sizing of the ventilation / combustion air openings must comply with the National Fuel Gas Code NFPA 54, ANSI Z223.1 for installations in the U.S. or CSA B149.1 and B149.2 for installations in Canada.

INGS IS NOT REQUIRED. FAILURE TO PROVIDE PROPERLY SIZED OPENINGS COULD RESULT IN SEVERE PERSONAL INJURY, DEATH OR PROP- ERTY DAMAGE.

Ventilation and Combustion Air Requirements - Category IV

A Category IV appliance uses uncontaminated indoor or outdoor air (surrounding the appliance) for combustion.

Piping uncontaminated combustion air directly from the outdoors to the appliance is recommended. This reduces the risks associated with indoor contaminates, flammable vapors and tight housing construction. This practice also promotes higher system efficiency.

For installations in which 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. Sizing of the ventilation / combustion air openings must comply with the National Fuel Gas Code NFPA 54, ANSI Z223.1 for installations in the U.S. or CSA B149.1 and B149.2 for installations in Canada, as referenced in this chapter of the manual and titled Methods of Supplying Combustion Air to a Space.

WARNING

THE SPACE MUST BE PROVIDED WITH VENTILA-

TION / COMBUSTION AIR OPENINGS PROPERLY SIZED FOR ALL MAKE-UP AIR REQUIREMENTS

EXHAUST FANS, CLOTHES DRYERS, ETC.) AND

(

THE TOTAL INPUT OF ALL APPLIANCES LOCATED IN THE SAME SPACE AS THE ESTEEM 399 LOW

X , EXCLUDING THE INPUT OF A DIRECT

ENT ESTEEM 399 LOW NOX WHICH USES

COMBUSTION AIR DIRECTLY FROM THE OUTSIDE, THUS ADDITIONAL FREE AREA FOR THE OPEN-

WARNING

THE SPACE MUST BE PROVIDED WITH VENTILA-

TION / COMBUSTION AIR OPENINGS PROPERLY SIZED FOR ALL MAKE-UP AIR REQUIREMENTS

EXHAUST FANS, CLOTHES DRYERS, ETC.) AND

(

THE TOTAL INPUT OF ALL APPLIANCES, INCLUD- ING THE ESTEEM 399 LOW NOX WHEN LOCAT- ED IN THE SAME SPACE. FAILURE TO PROVIDE PROPERLY SIZED OPENINGS COULD RESULT IN SEVERE PERSONAL INJURY, DEATH OR PROP- ERTY DAMAGE.

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Page 15

Ventilation and Combustion Air Requirements - Category IV

Methods of Supplying Combustion Air to a Confined Space - Category IV

INDOOR COMBUSTION AIR

NOTICE

The methods listed in this section for accessing Indoor Combustion Air assume that the inﬁ ltration rate is adequate and not less than .40 ACH. For inﬁ ltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas Code for additional guidance.

Opening Size and Location

Openings used to connect indoor spaces shall be sized and located in accordance with the following see Figure 2

• Combining spaces on the same story.

one opening shall commence within 12 inches of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 inches.

• Combining spaces in different stories. The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 sq. in./1000 Btu/hr of total input rating of all gas utilization equipment.

OUTDOOR COMBUSTION AIR

Isolating the combustion appliance room from the rest of the building and bringing in uncontaminated outside air for combustion and ventilation is always preferred.

Opening Size and Location

Figure 2: : All Combustion Air from Adjacent Indoor Spaces Through Indoor Combustion Openings

Each opening shall have a minimum free area of 1 sq. in./1000 Btu/hr of the total input rating of all gas utilization equipment in the space, but not less than 100 sq. inches. One opening shall commence within 12 inches of the top, and

The minimum dimension of air openings shall be not less than 3 inches

Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:

One Permanent Opening Method. See Figure 3

One permanent opening, commencing within 12 inches of the top of the enclosure, shall be provided. The equipment shall have clearances of at least 1 inch from the sides and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:

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Page 16

Ventilation and Combustion Air Requirements - Category IV

Figure 3: : All Combustion Air from Outdoors Through One Permanent Air Opening

• 1 sq. in./3000 Btu/hr of the total input rating of all equipment located in the enclosures, and

• Not less than the sum of the areas of all vent connectors in the space.

Two Permanent Openings Method.

Two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

• Where directly communicating with the outdoors or where communication to the outdoors is through vertical ducts, each opening shall have a minimum free area of 1 sq. in./4000 Btu/hr of total input rating for all equipment in the enclosure. See Figure 4.

Figure 4: : All Combustion Air from Outdoors Through Ventilated Attic

• Where communicating with the outdoors is through horizontal ducts, each opening shall have a minimum free area of not less than 1 sq. in./2000 Btu/hr of total input rating of all equipment in the enclosure. See

Figure 5.

Figure 5: : All Combustion Air from Outdoors through Horizontal Ducts

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Page 17

Combustion Air and Vent Piping

COMBINATION OF INDOOR AND OUTDOOR

OMBUSTION AIR

Indoor Openings: Where used, openings connecting the interior spaces shall comply with the Indoor Combustion Air section on page 9.

Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with the Outdoor Combustion Air section.

Outdoor Opening(s) Size. Outdoor opening(s) shall be calculated in accordance with the following:

• The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume.

• The outdoor size reduction factor shall be 1 minus the ratio of interior spaces.

• The minimum size of outdoor opening(s) calculated in accordance with the above outdoor air section multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in.

The Esteem 399 Low NOx is certified per ANSI Z21.13 as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the appliance) for combustion. A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion.

NOTICE

Install combustion air and vent pipe as detailed in the Esteem 399 Low NOx Vent Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for addition vent installation instructions.

DANGER!

DO NOT INSTALL THE ESTEEM 399 LOW NOX

INTO A COMMON VENT WITH OTHER GAS OR OIL APPLIANCES. THIS MAY CAUSE FLUE GAS SPILL- AGE OR APPLIANCE MALFUNCTION, RESULTING IN POSSIBLE SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

Combustion Air and Vent Piping

DANGER!

COMBUSTION AIR AND VENT PIPING MUST BE

SEALED GAS TIGHT AND MEET ALL PROVIDED IN- STRUCTIONS AND APPLICABLE CODES, FAILURE TO COMPLY WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.

The Esteem 399 Low NOx requires a Category IV venting system, which is designed for pressurized venting and condensate.

Removal of an Existing Boiler from a Common Vent System

DANGER!

DO NOT INSTALL THE ESTEEM 399 LOW NOX

INTO A COMMON VENT WITH OTHER GAS OR OIL APPLIANCES. THIS MAY CAUSE FLUE GAS SPILL- AGE OR APPLIANCE MALFUNCTION, RESULTING IN POSSIBLE SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

NOTICE

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the com-

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Page 18

Removal of an Existing Boiler from a Common Vent System

mon venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

• Seal any unused openings in the common venting system.

• Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

• Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close ﬁ replace dampers.

• Operate the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

• Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ﬂ ame of a match or candle, or smoke from a cigarette, cigar or pipe.

• After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers, and any other gas-burning appliance to their previous condition of use.

• Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation codes. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the appropriate tables in Part II of the National Fuel Gas Code ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation codes.

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Page 19

Commonwealth of Massachusetts Installations Only

For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

• 1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

• 2. A carbon monoxide detector shall also be located in the room that houses the appliance or equipment and shall:

• a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector;

• b. Have battery back-up power;

• c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and

• d. Have been approved and listed by the Nationally Recognized Testing Laboratory as recognized under 527 CMR.

• 3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used. 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.

location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

NOTICE

Installer must provide tag identiﬁ cation plate and ensure the lettering meets code requirements.

For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake are installed above four feet above grade the following requirements must be satisfied:

• 2. A carbon monoxide detector shall:

• a. Be located in the room that houses the appliances or equipment;

• b. Be either hard wired or battery powered or both; and

• c. Shall comply with NFPA 720 (2005 Edition)

• 4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the

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Page 20

Chapter 4 Unit Preparations

Handling Instructions

The Esteem 399 Low NOx is generally easier to handle and maneuver once removed from the shipping carton.

To remove the shipping carton:

CAUTION

Use care not to lift the unit from, or place the unit on the front plastic control panel, damage can occur. Use care not to drop, bump or rotate the boiler upside down, as damage to the boiler will result.

1. Remove any shipping straps and open the side of the shipping carton.

2. Slide the unit with the foam inserts out of the carton.

3. Discard all packing materials.

Wall Mounting Installation

The Esteem 399 Low NOx should be wall mounted using the bracket provided with the boiler. The Esteem 399 Low NOx is not designed for floor installation. If floor installation is required an optional floor stand is available through AERCO International.

WARNING

THE WALL USED FOR MOUNTING THE ESTEEM 399 L

AND CAPABLE OF SUPPORTING A MINIMUM 250 POUNDS [115 KG] FOR ESTEEM 399 LOW NOX

. F

MENTS COULD RESULT IN PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

Wall Mounting Guidelines

• The boiler is heavy and bulky. A minimum

• DO NOT mount or attempt to mount the

OW NOX MUST BE VERTICALLY PLUMBED

AILURE TO COMPLY WITH THESE REQUIRE-

of 2 people is required for mounting the boiler.

wall bracket to hollow sheet rock or lath

walls using anchors. Only install boiler to studs or equivalent wood structure.

• The wall-mounting bracket is designed for stud spacing of 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.

• For mounting on wood studs, install the bracket using the lag screws provided with the boiler. Ensure both lag screws are installed securely in the studs.

• For mounting on metal studs, install the bracket to the studs using 3/16” toggle bolts and washers.

• For mounting on solid walls (rock, concrete, brick, cinder block, etc.), install the wall bracket using anchors (double expansion shields) and bolts with washers provided with the boiler.

WARNING

USE EXTREME CARE NOT TO DROP THE BOILER

OR CAUSE BODILY INJURY WHILE LIFTING OR MOUNTING THE BOILER ONTO THE BRACKET.

NCE MOUNTED VERIFY THAT THE BOILER IS

SECURELY ATTACHED TO THE BRACKET AND WALL. FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN PROPERTY DAM- AGE, PERSONAL INJURY OR DEATH.

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 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.

• If the structure of wall is questionable, in supporting a minimum weight of 250 pounds [115 kg.], it is recommended to use the optional ﬂ oor stand.

Wall Bracket Installation - Solid Walls

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Page 21

Boiler Mounting

• Locate the general area of the boiler placement.

• Place the wall-mounting bracket on the wall ensuring the upper edge of the bracket is away from the wall.

• Level the bracket and use a pencil to mark the location of the mounting slots on the wall.

• Remove the bracket from the wall and drill a 5/8” diameter hole by 1-3/8” deep positioned in the center of each mark.

• Install the anchors (provided) ﬂ ush or slightly recessed in the drilled holes with threaded side facing down.

• Reposition the bracket on the wall and align mounting slots/holes. Insert the two bolts (provided) through the mounting slots/holes and loosely tighten.

• Level bracket and tighten bolts securely.

Boiler Mounting

• Obtain assistance in lifting the boiler onto the wall bracket.

• Install the boiler making sure the boiler mounting lip located along the upper edge of the rear jacket panel engages the wallmounting bracket. Ensure the boiler is

seated properly and is secure.

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Page 22

Chapter 5 Boiler Piping

General Piping Requirements

• All plumbing must meet or exceed all local, state and national plumbing codes.

• Support all piping using hangers. DO NOT support piping by the unit or its components.

• Use isolation valves to isolate system components.

• Install unions for easy removal of the Esteem 399 Low NOx from the system piping.

WARNING!

USE A TWO WRENCH METHOD WHEN TIGHTEN-

ING PIPING ONTO THE BOILER CONNECTIONS.

SE ONE WRENCH TO PREVENT THE BOILER

PIPING FROM TURNING / TWISTING. FAILURE TO SUPPORT THE BOILER PIPING AND CONNEC- TIONS IN THIS MANNER COULD CAUSE DAMAGE TO THE BOILER AND ITS COMPONENTS.

Pressure Relief Valve

• Length should be as short and direct as possible. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.

• Should be directed downward towards the floor at all times. The piping should terminate at least 6 inches [153 mm] above any drain connection to allow clear visibility of the discharge.

• Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating of 250ºF or greater.

• Should not be subject to conditions where freezing could occur.

• Should not contain any shut-off valves or obstructions. No shut-off valve should be piped between the boiler and relief valve.

WARNING!

FAILURE TO COMPLY WITH THE GUIDELINES ON

INSTALLING THE PRESSURE RELIEF VALVE AND DISCHARGE PIPING CAN RESULT IN PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

The Esteem 399 Low NOx is supplied with a 30 psi pressure relief valve and must be piped using the PRV connection as shown in Figure 6, page 17.

To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping:

• Must be connected to the discharge outlet of the relief valve and directed to a safe place of disposal.

Low Water Cutoff Device

• The Esteem 399 Low NOx is equipped with a factory installed pressure switch type Low Water Cut Off device.

• The minimum operating system pressure allowable with this device is 10 psig.

• Check local codes if a Low Water Cutoff Device is required. If so, determine if this device meets the requirements of the local codes.

WARNING!

THE ESTEEM 399 LOW NOX CONTROL SYSTEM

SENSES THE SYSTEM WATER TEMPERATURES ENTERING AND EXITING THE HEAT EXCHANGER TO PROVIDE PROTECTION AGAINST LOW WATER CONDITIONS WHERE LOCAL CODES AND JURIS- DICTION DO NOT ACCEPT A PRESSURE DEVICE FOR LOW WATER PROTECTION, THEY MAY AC- CEPT THESE INTEGRAL CONTROL FUNCTIONS AS A MEANS OF PROVIDING LOW WATER PROTEC- TION.

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Additional Limit Control

If a separate LWCO device is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed:

• The LWCO device must be designed for water installations, electrode probe-type is recommended.

• The LWCO device must be installed in a tee connection on the boiler supply piping above the boiler.

• Wiring of the LWCO device to the Esteem 399 Low NOx is done directly onto the 24V terminal strip, see Figure 20, page 34 for available terminals for an external limit (manual or auto reset).

If the installation is to comply with ASME or Canadian requirements, an additional high temperature limit may be needed. Consult local code requirements to determine compli-

ance. The limit should be installed as follows:

• Install the limit in the boiler supply piping between the boiler and any isolation valve.

• Maximum set point for the limit is 194ºF.

• For wiring of the limit, see Figure 20, page 34, using the external limit/manual reset terminals on the 24V terminal strip. This will provide a “hard” lockout requiring a manual reset of the control.

Backﬂ ow Preventer

• Use a backflow preventer valve in the make-up water supply to the unit as required by local codes.

Boiler System Piping Applications

All piping applications should use a primary/ secondary piping arrangement as a means to provide freeze protection of the boiler, which is an integral function of the boiler control. Maintain the minimum boiler flow rate, see

Figure 6: Pressure Relief Valve and Boiler Drain Installation

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Page 24

Expansion Tank and Makeup Water

Graph 2 and Graph 3 on page 91 For other piping arrangements, consult the Engineering Department at AERCO International.

On piping applications using a single zone or other recognized piping design arrangements, it is recommended that the installer uses flow/ check valves with weighted seats at or near the appliance to prevent gravity circulation.

Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized for the boiler volume 7 gallons [26 L] for Esteem 399 Low NOx and the system volume and temperature.

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 heat exchanger failure can result due to this excessive makeup water addition.

The expansion tank must be located as shown in Figure 7 and Figure 8 on page 21 when using a primary/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details.

Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system fill connection at the same location as the expansion tank connection to the system.

DIAPHRAGM EXPANSION TANK

Always install an automatic air vent on the top of the air separator to remove residual air from the system.

CLOSED-TYPE EXPANSION TANK

It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet of piping. Use 3/4” piping for the expansion tank to allow air within the system to rise.

CAUTION

DO NOT install automatic air vents on a closed-type expansion tank system. Air must remain in the system and be returned to the expansion tank to provide an air cushion. An automatic air vent would cause air to be vented from the system resulting in a water-logged expansion tank.

Circulator

The Esteem 399 Low NOx must be supplied with a Central Heating (CH) circulator. The circulator when wired directly to the Esteem 399 Low NOx will allow for domestic hot water priority and to provide circulation for the freeze protection feature of the boiler control. See Graph 2 and Graph 3 on page 91 for pressure drop and minimum flow rate through the boiler.

Sizing Primary Piping

See Figure 9 through Figure 15, page 22 and following, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system, using recognized design methods.

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Page 25

Domestic Hot Water System Piping

See Figure 9, page 22 for recommended piping to a DHW system. This recommended piping configuration ensures priority is given to the production and recovery of the DHW.

The piping for the DHW is separate from the boiler system piping and does not require a primary / secondary piping configuration.

To wire the DHW circulator to the boiler control module, see Chapter 9 External Wiring.

System Piping - Zone Circulators

Connect the Esteem 399 Low NOx to the system piping as shown in Figure 10 page 23 when zoning with zone circulators.

The installer must provide a separate circulator for each zone of space heating as well as the boiler circulator.

System Piping - Through Boiler

In new or retrofit applications in which primary/ secondary arrangement is not used, the Esteem 399 Low NOx allows this flexibility due to a lower boiler pressure drop, see Graph 2 and Graph 3 on page 91.

Figure 12, page 24 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure differential valve must be installed on the system piping.

Figure 13, page 24 illustrates a single zone utilizing the boiler circulator as the system circulator.

System Piping - Radiant Heating

The heat exchanger design of the Esteem 399 Low NOx allows operation in a condensing mode. This feature requires no return water temperature regulation in radiant heating applications.

NOTICE

To ensure an adequate ﬂ ow rate through the Esteem 399 Low NOx , the boiler supply and return piping size must be a minimum 1-1/2 inch for the Esteem 399 Low NOx .

System Piping - Zone Valves

Connect the Esteem 399 Low NOx to the system piping as shown in Figure 11, page 23 when zoning with zone valves. The primary / secondary piping ensures that the boiler loop has sufficient flow.

NOTICE

To ensure an adequate ﬂ ow rate through the Esteem 399 Low NOx , the boiler supply and return piping size must be a minimum of 1-1/2 inch for the Esteem 399 Low NOx .

Esteem 399 Low NOx can maintained the boiler water supply temperature, eliminating the need for a mix system to achieve the desired temperature.

A high temperature limit as shown in Figure 14, page 25 should be installed to ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.

The addition of the high temperature limit is important if the Esteem 399 Low NOx is connected to a domestic hot water system, which requires a high primary supply water temperature.

Size the system piping and circulator to provide the flow needed for the radiant system.

NOTICE

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The Esteem 399 Low NOx supply and return piping must be a minimum of 1-1/2 inch .

Page 26

System Piping - Special Application

If the boiler is used in conjunction with a chilled water/medium system, the boiler and chiller must be piped in parallel. Install flow/ check valves to prevent the chilled medium from entering into the boiler.

If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install flow/check valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles.

System Piping - Multiple Units Installation

Use a balanced manifold system as the primary / secondary connection to the space heating piping as shown in Figure 15 page 26.

Maintain a minimum of 6 inches [153 mm] of clearance between units to allow for servicing.

Refer to Figure 7 and Figure 8, page 21 to install air separator and expansion tank.

For the space heating piping refer to the applications mentioned in this manual or use recognized design methods..

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Page 27

Figure 7: Near Boiler Piping - Diaphragm Expansion Tank

System Piping - Special Application

Figure 8: Near Boiler Piping - Closed Type Expansion Tank

1. System circulator

2. Automatic air vent

3. Air separator

4. Automatic fill valve

5. Diaphragm expansion tank

6. Isolation valve

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Note: Pitch horizontal piping upwards (1” of pitch per 5 ft of piping) towards expansion tank.

7. Drain/purge valve

8. Tank fitting

9. Closed type expansion tank

10. Primary/secondary connection

11. Boiler circulator

12. Flow/check valve

Page 28

System Piping - Special Application

Figure 9: DHW Boiler Piping with an Esteem 399 Low NOx

1. Esteem 399 Low NOx boiler

2. water heater

3. Isolation valve

4. DHW circulator

5. CH circulator

NOTICE

The boiler system piping shown in Figure 8 must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the water heater.

6. Flow/check valve

7. Pressure relief valve

8. Drain/purge valve

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Page 29

Figure 10: CH System Piping - Zoning with

Zone Circulators

System Piping - Special Application

1. Esteem 399 Low NOx boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone circulator

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

Figure 11: CH System Piping - Zoning with Zone

Valves

1. Esteem 399 Low NOx boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

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7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. System circulator

Page 30

System Piping - Special Application

Figure 12: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator

Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.

1. Esteem 399 Low NOx boiler

2. CH circulator

4. Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. Pressure Differential Valve

Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.

Figure 13: CH System Piping - Single Zone System with Single System/Boiler Circulator

1. Esteem 399 Low NOx boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

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Page 31

System Piping - Special Application

• Note: Manifold mounted valve actuators may be used in lieu of zone valves.

Figure 14: CH System Piping - Radiant/Low Temp. Heating

1. Esteem 399 Low NOx boiler

2. CH circulator

3. Flow check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. System circulator

13. High temperature limit control

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Page 32

1. Boiler circulator

2. Isolation valve

3. Flow/check valve

4. System circulator

5. Drain/purge valve

6. Automatic air vent

7. Air separator

8. Diaphragm expansion

tank

9. Automatic fill valve

Figure 15: Multiple Esteem 399 Low NOx Boiler Piping - Primary / Secondary / Piping using Balanced Manifold System

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Page 33

Chapter 6 Installing Vent, Air Intake & Drain

Installing Vent and Combustion Air Intake

DANGER!

THE ESTEEM 399 LOW NOX MUST BE VENTED

AND SUPPLIED WITH COMBUSTION AIR AS SHOWN IN THE ESTEEM 399 LOW NOX VENT SUPPLE- MENT, INCLUDED IN THE BOILER INSTALLATION

ENVELOPE. REFER TO VENT KIT INSTRUCTIONS

(GF-125V)

TION INSTRUCTIONS. ONCE INSTALLATION IS

COMPLETE, INSPECT THE VENT AND COMBUS- TION AIR SYSTEM THOROUGHLY TO ENSURE SYSTEMS ARE AIRTIGHT AND COMPLY WITH THE INSTRUCTIONS GIVEN IN THE VENTING SUPPLE- MENT AND ARE WITHIN ALL REQUIREMENTS OF APPLICABLE CODES. FAILURE TO COMPLY WITH ALL INSTALLATION REQUIREMENTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

FOR ADDITIONAL VENT INSTALLA-

Installing Condensate Drain Assembly

1. Locate the condensate drain assembly and install as shown in Figure 16, page 28.

NOTICE

The installer may want to ﬁ ll the con- densate trap with water prior to assembling on the unit.

2. Remove the retaining nut and rubber seal from the condensate drain assembly and slide over the heat exchanger condensate drain nipple. Connect the condensate drain assembly to the retaining nut and tighten. Hand tight only!

WARNING!

ENSURE THE CONDENSATE DRAIN ASSEMBLY

CONTAINS THE PLASTIC SEATED BALL. DO NOT INSTALL THE CONDENSATE DRAIN ASSEMBLY IF THE BALL IS LOST OR MISSING, REPLACE THE ENTIRE ASSEMBLY.

4. Using 3/4” x 2’ flexible PVC tube provided, slide the compression nut and rubber seal over the pipe

NOTICE

The use of 3/4” PVC or CPVC pipe is also acceptable. If 3/4” pipe is used deburr and chamfer pipe to allow mating onto the drain assembly.

5. Thread the rubber seal into the compression nut to ease installation of the pipe to the drain assembly.

6. Seat the pipe onto the drain assembly and tighten the compression nut. Hand tight only!

NOTICE

The installer may opt to using 13/16” ID tubing in lieu of rigid piping.

NOTICE

The drain line materials must be materials approved by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845. The cement and primer used on the piping must comply with ASME D2564 or F493. For installations in Canada, use CSA or ULC certiﬁ ed PVC or CPVC pipe, ﬁ ttings and cement/primer.

7. Continue the pipe from the drain assembly to a floor drain or condensate pump.

NOTICE

When selecting and installing a condensate pump, ensure the pump is approved for use with condensing boilers and furnaces. The pump should be equipped with an overﬂ ow switch to prevent property damage from potential condensate spillage.

3. Remove the compression nut and rubber seal from the drain outlet.

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8. The Esteem 399 Low NOx will typically produce a condensate that is considered

Page 34

slightly acidic with a pH content below

3.0. Install a neutralizing filter if required by authority having jurisdiction.

CAUTION

The condensate drain must remain ﬁ lled and unobstructed and allow unrestricted ﬂ ow of condensate. The con- densate should not be subject to conditions where freezing could occur. If the condensate is subjected to freezing or becomes obstructed , it can leak, resulting in potential water damage to the boiler and surrounding area.

Figure 16: Condensate Drain Assembly

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Chapter 7 Gas Piping

Gas Supply Piping Connection

NOTICE

The gas supply piping must be installed in accordance to all local, state and national codes and utility requirements.

1. Install a 1” NPT for the pipe union at the factory supplied gas nipple, for ease of service.

2. Install a manual shutoff valve in the gas supply piping as shown in Figure 17. For Canadian installations the main shutoff valve must be tagged and identified by the installer

3. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the Esteem 399 Low NOx gas train as shown in Figure 17.

4. Support the gas piping using hangers. Do not support the piping by the unit or its components.

WARNING

FAILURE TO APPLY PIPE DOPE AS DETAILED

ABOVE CAN RESULT IN SEVERE PERSONAL IN- JURY, DEATH OR SUBSTANTIAL PROPERTY DAM- AGE.

WARNING!

USE A TWO-WRENCH METHOD OF TIGHTENING

GAS PIPING NEAR THE UNIT AND ITS GAS PIPING CONNECTION. USE ONE WRENCH TO PREVENT THE BOILER GAS LINE CONNECTION FROM TURN- ING AND THE SECOND TO TIGHTEN ADJACENT PIPING. FAILURE TO SUPPORT THE BOILER GAS PIPING CONNECTION COULD DAMAGE THE GAS LINE COMPONENTS.

5. Purge all air from the gas supply piping.

6. Before placing the boiler into operation, test all connections for leaks.

• Close the manual shutoff valve during any pressure test with less than 13”w.c..

• Disconnect the Esteem 399 Low NOx and its gas valve from the gas supply piping during any pressure test greater than 13”w.c..

WARNING!

DO NOT CHECK FOR GAS LEAKS WITH AN OPEN

FLAME. USE A GAS DETECTION DEVICE OR BUB- BLE TEST. FAILURE TO CHECK FOR GAS LEAKS CAN CAUSE SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow.

Figure 17: Recommended Gas Supply Piping

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Page 36

Natural Gas

PIPE SIZING - NATURAL GAS

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

• Table 1 is based on Natural Gas with a speciﬁ c gravity of 0.60 and a pressure drop through the gas piping of 0.30”w.c..

• - For additional gas piping sizing information, refer to ANSI Z223.1. For Canadian installations refer to B149.1 or B149.2.

NATURAL GAS SUPPLY PRESSURE REQUIREMENTS

1. Pressure required at the gas valve inlet

supply pressure port:

• Maximum 13”w.c. at flow or no flow conditions to the burner.

2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum.

WARNING!

DO NOT ADJUST OR ATTEMPT TO MEASURE

GAS VALVE OUTLET PRESSURE. THE GAS VALVE IS FACTORY-SET FOR THE CORRECT OUTLET PRESSURE. THIS SETTING IS SUITABLE FOR NATURAL GAS AND PROPANE AND REQUIRES NO FIELD ADJUSTMENT. ATTEMPTS BY THE INSTALL- ER TO ADJUST OR MEASURE THE GAS VALVE OUTLET PRESSURE COULD RESULT IN DAMAGE TO THE VALVE, CAUSING POTENTIAL SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

NOTICE

The natural gas oriﬁ ce for the Esteem 399 Low NOx is 0.339” (8.6 mm)

• Minimum 5”w.c. during flow conditions to the burner. Must be verified during start up and with all other gas appliances operating within the building.

Table 1: Gas Piping Sizing - Natural Gas

Length of Pipe in

Feet

SCH 40 1/2” 3/4” 1” 1-1/4” 1-1/2”

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 890

40 63 130 245 500 760

50 56 115 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per

Hour (based on 0.60 specific gravity, 0.30” w.c. pressure drop)

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Page 37

Propane Gas

NOTICE

The propane oriﬁ ce required for the Es- teem 399 Low NOx is 0.264” (6.7 mm)

WARNING!

DO NOT ADJUST OR ATTEMPT TO MEASURE

GAS VALVE OUTLET PRESSURE. THE GAS VALVE IS FACTORY-SET. THIS SETTING IS SUITABLE FOR NATURAL GAS AND PROPANE AND RE- QUIRES NO FIELD ADJUSTMENT. ATTEMPTS TO ADJUST OR MEASURE THE GAS VALVE OUTLET PRESSURE COULD RESULT IN DAMAGE TO THE VALVE, CAUSING POTENTIAL PROPERTY DAMAGE PERSONAL INJURY, OR DEATH.

On propane gas applications the incoming gas regulator should be installed as follows:

• Size the regulator for the appropriate ﬂ ow.

• The regulator diaphragm should be installed horizontally

• Piping before and after the regulator should be straight rigid pipe for a minimum of 10 pipe diameters.

• Avoid ﬂ exible pipe between boiler and the outlet of the regulator.

• If regulator is installed and vented inside, a vent limiter should be used.

• If regulator is installed or vented outside, an inverted trap piping arrangement should be used.

WARNING

PRIOR TO START UP, ENSURE THE UNIT IS SET

TO FIRE PROPANE. CHECK THE RATING LABEL FOR THE TYPE OF FUEL. CHECK THE GAS VALVE FOR PROPANE CONVERSION LABEL. IF THERE IS A CONFLICT OR DOUBT ON THE BURNER SET UP, REMOVE THE GAS VALVE AND CHECK FOR THE PROPANE ORIFICE, SEE FIGURE 18, PAGE

AILURE TO ENSURE PROPER BURNER SETUP

31. F

COULD RESULT IN PROPERTY DAMAGE PERSON- AL INJURY, OR DEATH.

Figure 18: Gas Valve / Venturi Assembly

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Page 38

PIPE SIZING - PROPANE GAS

Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator.

PROPANE GAS SUPPLY PRESSURE REQUIREMENTS

• Adjust the propane supply regulator provided by the gas supplier for 13”w.c. maximum pressure

• Pressure required at the gas valve inlet supply pressure port:

• Maximum 13”w.c. at ﬂ ow or no ﬂ ow condi- tions to the burner

• Minimum 5”w.c. during ﬂ ow conditions to the burner. Must be veriﬁ ed during start up and with all other gas appliances operating within the building.

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Page 39

Chapter 8 Internal Wiring

WARNING

ELECTRICAL SHOCK HAZARD. FOR

YOUR SAFETY, DISCONNECT ELECTRICAL POW- ER SUPPLY TO THE UNIT BEFORE SERVICING OR MAKING ANY ELECTRICAL CONNECTIONS TO AVOID POSSIBLE ELECTRIC SHOCK HAZARD.

AILURE TO DO SO CAN CAUSE SEVERE PER-

SONAL INJURY OR DEATH.

CAUTION

Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and operation after servicing.

General Requirements

• Wiring must be NEC Class 1.

• If original wiring as supplied with the unit must be replaced, use only Type T 90ºC wire or equivalent as a minimum.

• The Esteem 399 Low NOx must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 - latest edition and / or the Canadian Electrical Code Part 1, CSA C22.1, Electrical Code.

Control Module Circulator AMP Ratings

- AMP draw of the CH circulator not

to exceed 2 amps.

AMP draw of the DHW circulator not to exceed 2 amps.

Wiring Tool Instructions

1. Locate the wiring tools on the Esteem 399 Low NOx just below the MCBA control in a plastic bag and below the extra fuses.

2. Locate the terminal blocks on the Esteem 399 Low NOx below the MCBA control.

NOTICE

The 120V Terminals are located on the left set of Terminal Blocks. The 24V Terminals are located on the right set of terminal blocks.

3. Carefully pull down on the lower half of the terminal block to remove.

4. Hook the wiring tool into the desired slot of the terminal block as shown in Figure

19.

5. Push wiring tool in towards the terminal block and insert wire in slot at bottom of terminal block.

6. Repeat steps 4 & 5 until all wiring is complete.

7. Re-connect the lower half of the terminal block to the upper half.

Figure 19: Using the Wiring Tool on the Terminal Blocks

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8. Place the wiring tool back into the plastic bag or leave tool hooked to a slot on the 24V terminal block.

When wiring the Esteem 399 Low NOx allow additional length of wire for the access panel to swing open during servicing.

Page 40

Internal Wiring Diagram

Figure 20: Esteem 399 Low NOx Boiler Factory Wiring

See wiring tool instructions, page 33.

To properly connect wires to terminal block, use wiring tool included with Esteem 399 Low NOx .

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Page 41

Chapter 9 External Wiring

Installation Compliance

All field wiring made during installation must comply with:

• National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements.

• In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any other local codes.

WARNING!

ELECTRICAL SHOCK HAZARD. BEFORE

MAKING ANY ELECTRICAL CONNECTIONS TO THE

STEEM 399 LOW NOX , DISCONNECT ELEC-

TRICAL POWER SUPPLY AT THE SERVICE PANEL.

AILURE TO COMPLY CAN CAUSE SEVERE PER-

SONAL INJURY OR DEATH.

Line Voltage Connections

1. Use shielded cable.

2. Connect a 120 VAC/15A service to the

120V terminal strip on the wiring panel below the Esteem 399 Low NOx control module, as shown in Figure 20, page 34.

3. Route the incoming 120 VAC power wire

through the provided openings in the bottom jacket panel.

4. The unit is provided with a service switch

located on the front panel, check local code requirements for compliance.

NOTICE

If local codes or conditions require an additional service switch, the installer must install a fused disconnect for 15 amp (minimum) service switch.

Domestic Hot Water Aquastat Wiring

NOTICE

Use only AERCO International supplied aquastat (P/N 69107). Other models can be incompatible with the Esteem Controller

1. Connect the DHW thermostat (aquastat) to the 24V terminal strip on the wiring panel located below the Esteem 399 Low NOx control module as shown in Figure 20, page 34.

2. Route all wiring through the provided openings, in the bottom jacket panel. Allow enough wire for access panel to swing open during servicing.

Thermostat Wiring

1. Connect room thermostat or the end switch (isolated contact only) of a relay control panel to the 24V terminal strip on the wiring panel below the Esteem 399 Low NOx control module, as shown in Figure 20, page 34.

2. For proper operation install the room thermostat on an inside wall away from influences of heat and cold, i.e. water pipes, areas of draft, lighting fixtures and fireplaces.

3. Set the thermostat anticipator (if applicable) as follows:

• Set for 0.2 amps when wired directly to the Esteem 399 Low NOx .

• Set to match the total electrical power requirements of the connected devices when wired to zone relays or other devices. Refer to the relay manufacturers’ specifications and the thermostat instructions for additional information on the anticipator setting.

NOTICE

When making low voltage connections to the Esteem 399 Low NOx, ensure no external voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to

prevent damage to the control.

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Page 42

CH and DHW Circulator

1. Connect the space heating primary circulator to the Esteem 399 Low NOx 120 V terminals 1,2 and 3 as shown in Figure 20, page 34.

2. Connect the DHW circulator to the Esteem 399 Low NOx 120 V terminals 4, 5 and 6 as shown in Figure 20, page 34.

Maximum circulator continuous current draw is 2A for each circulator.

System Circulator - Zone Valve Application

To energize the system circulator shown as item 12 in Figure 11 page 23 see Figure 21. Installer to provide a Transformer / Relay such as Honeywell R8285 or equivalent and zone valves with isolated end switch such as Honeywell V8043 or equivalent.

External Modulating Control

The Esteem 399 Low NOx firing rate can be controlled by an external modulating boiler controller. See page 34 for wiring and page 58 for

control module setup.

Outdoor Reset Control

The Esteem 399 Low NOx may operate with a variable boiler operating temperature using the AERCO International outdoor sensor, see page 54 for information.

NOTICE

If a ﬁ xed operating temperature is cho- sen for the boiler system, the outdoor sensor is not required and should not be installed.

Additional 24V Limit Wiring

The Esteem 399 Low NOx provides 24V terminal connections for additional limit controls as shown in Figure 20 page 34. These limit terminal connections will provide a “hard” lockout requiring a manual reset of the boiler control, or a “soft” lockout in which the Esteem 399 Low NOx will automatically reset.

Figure 21: Secondary System Circulator Wiring

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Page 43

External Wiring Diagram

4 Wire Zone Valve

External Wiring Diagram

Figure 22: Field Wiring with Zone Circulators

3 Wire Zone Valve

Figure 23: Multiple Zone Field Wiring Using Zone Valves

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Page 44

Figure 24: Field Wiring with Zone Circulators

Figure 25: Typical Zone Relay Panel Wiring

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Page 45

Chapter 10 Start-Up Preparation

Check Boiler System Water Chemistry

WARNING!

DO NOT USE PETROLEUM-BASE CLEANING OR

SEALING COMPOUNDS IN THE BOILER SYSTEM.

AMAGE TO SEALS AND GASKETS IN THE SYS-

TEM COMPONENTS COULD OCCUR, RESULTING IN SUBSTANTIAL PROPERTY DAMAGE.

NOTICE

System water including additives must be practically nontoxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

WATER PH LEVEL 6.0 TO 8.0

Maintain the boiler water pH between 6.0 and

8.0. Check using litmus paper or contact a water treatment company for a chemical analysis.

Flush the systems until the water runs clean and is free of sediment.

For zoned systems, each zone should be flushed through a purge valve. Purge valves and isolation valves should be installed on each zone to allow proper flushing of the system.

Check and Test Antifreeze

For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specifications.

Due to the degradation of inhibitors over time, antifreeze fluids must be periodically replaced. Refer to the manufacturer of the antifreeze for additional instructions.

If the pH does not meet this requirement, do not operate the Esteem 399 Low NOx or leave the unit filled until the condition is corrected.

WATER HARDNESS LESS THAN 7 GRAINS

For areas with unusually hard water (hardness above 7 grains) consult a water treatment company.

CHLORINATED WATER

Do not use the Esteem 399 Low NOx to heat a swimming pool or spa directly.

Maintain the chlorine level of the water at levels considered safe for drinking.

Flush Boiler and Domestic System to Remove Sediment

The installer must flush the boiler system to remove any sediment to allow proper operation of the Esteem 399 Low NOx .

NOTICE

System water including additives must be practically nontoxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

Use of Antifreeze in the Boiler System

WARNING!

NEVER USE AUTOMOTIVE OR ETHYLENE GLY-

COL ANTIFREEZE OR UNDILUTED ANTIFREEZE IN THE PRIMARY SYSTEM AS FREEZE PROTECTION.

HIS CAN CAUSE SEVERE PERSONAL INJURY,

DEATH OR PROPERTY DAMAGE.

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 is approximately 7 gallons [26 L] for Esteem 399 Low NOx . Remember to include the volume of the expansion tank.

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Page 46

Filling the Boiler System

Check with local codes requirements for the installation of backflow preventers or actual disconnection from the boiler’s cold water fill or make up water supply line.

NOTICE

Massachusetts Code requires the installation of a backﬂ ow preventer if anti- freeze is used.

Ensure the concentration of antifreeze to water does not exceed a 50/50 ratio.

NOTICE

System water, including additives, must be practically nontoxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products.

Filling the Boiler System

1. Close the boiler drain valve located on the bottom of the unit and any manual or automatic air vent in the system.

2. Open all system isolation valves.

3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application.

NOTICE

Typical residential system ﬁ ll pressure is 12 psi. System pressure will increase when system temperature increases. Operating pressure of the system should never exceed 25 psi.

4. Purge air and sediment in each zone of the boiler system through the purge valve. Open air vents to allow air to be purged in the zones.

5. Once the system is completely filled and purged of all air and sediment, check the system pressure and check/repair any leaks.

WARNING!

UNREPAIRED SYSTEM LEAKS WILL CAUSE CON-

TINUAL MAKEUP WATER TO BE ADDED TO THE BOILER. CONTINUAL MAKEUP WATER COULD CAUSE MINERAL BUILDUP WITHIN THE HEAT EXCHANGER, REDUCING THE HEAT TRANSFER, CAUSING POSSIBLE HEAT BUILDUP AND EVEN- TUAL HEAT EXCHANGER FAILURE.

Check Low Water Cut-Off Device

• The Esteem 399 Low NOx is provided with a factory installed LWCO device that measures system pressure of more than 10 psi.

• Remove the front jacket panel and check for continuity across the low water cut-off device wire terminals. The contacts should be closed when system pressure is greater than 10 psi. See Figure 29 page 86 for location of the LWCO.

Check For Gas Leaks

WARNING!

PRIOR TO START-UP AND DURING INITIAL OP-

ERATION, SMELL CLOSE TO THE FLOOR AND AROUND THE UNIT FOR GAS ODORANT OR ANY UNUSUAL ODOR. DO NOT PROCEED WITH THE START-UP IF THERE IS ANY INDICATION OF A GAS LEAK. ANY LEAKS FOUND MUST BE REPAIRED IMMEDIATELY.

WARNING!

PROPANE INSTALLATIONS ONLY - THE PROPANE

SUPPLIER MIXES AN ODORANT WITH THE PRO- PANE TO MAKE ITS PRESENCE DETECTABLE. IN SOME CASES THE ODORANT CAN FADE AND THE GAS MAY NO LONGER HAVE AN ODOR.

RIOR TO START-UP OF THE UNIT AND PERI-

ODICALLY AFTER START-UP HAVE THE PROPANE SUPPLIER CHECK AND VERIFY THE ODORANT LEVEL.

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Page 47

Check Thermostat Circuit

1. Disconnect the external thermostat wires from the 24V terminal strip on the wiring panel.

2. Connect a voltmeter across the wire ends of the external thermostat wiring.

3. Close each thermostat, zone valve and relay in the external circuit one zone at a time and check the voltage reading across the wire ends.

There should NEVER be voltage measured at the wire ends.

1. If voltage is measured at the panel under any condition, check and correct the external wiring.

NOTICE

In systems using 3-wire zone valves, feedback of voltage to the unit is a common problem. Use an isolation relay to prevent voltage from the external circuit entering the Esteem 399 Low NOx control panel.

NOTICE

The condensate drain assembly must be ﬁ lled with water when the Esteem 399 Low NOx is in operation. The condensate drain assembly prevents ﬂ ue gas emissions from entering the condensate line. Failure to ensure trap is ﬁ lled with water could result in severe personal injury or death.

3. Re-Install plug in condensate drain assembly.

2. Reconnect the external thermostat wires to the 24V terminal strip on the wiring panel.

Inspect the Condensate Drain Assembly

1. Inspect and ensure the Condensate

Drain Assembly is properly installed as described on page 27 and shown in Figure 16 on page 28.

2. Remove the plug from the Condensate

Drain Assembly and fill with fresh water.

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Page 48

Chapter 11 Start-Up Procedures

Final Checks Before Start-Up

 Read Operating Instructions beginning

on page 47 regarding the operation of the Esteem 399 Low NOx controls.

 Verify the Esteem 399 Low NOx and the

boiler system are full of water and all system components are correctly set for operation, including the minimum ﬂ ow rate through the boiler, see page 91.

 Verify Start-up Preparation items outlined on

page 39 through page 41 have been completed.

 Verify all electrical connections are cor-

rect and securely fastened.

 Inspect vent and combustion air piping for

signs of deterioration from corrosion, physical damage or sagging. Verify combustion air and vent piping are intact and correctly installed and supported. See the Esteem 399 Low NOx vent supplement GF-125V.

 Verify burner conﬁ guration - Propane

only.

• Check for proper labeling on the gas valve and the rating label for propane configuration.

• If there is doubt on the burner configuration, remove the gas valve and check for proper propane gas orifice size: 6.7 mm for Esteem 399 Low NOx . Refer to Figure 18, page 31 for location of the propane gas orifice.

NOTICE

For natural gas applications the Esteem 399 Low NOx requires an oriﬁ ce: 0.330” (8.6 mm)

 Ensure the vent Condensate Drain As-

sembly is ﬁ lled with water.

Esteem 399 Low NOx Start-Up

4. Turn the ON-OFF switch located on the front control panel to the OFF position. Turn ON the electrical supply/service to the unit.

5. Read and follow the Operating Instructions outlined on page 47.

If Esteem 399 Low NOx Does Not Start Correctly

• Make sure the heating thermostats are set

above room temperature,

• Check that gas supply valve(s) are open at

the unit and meter.

• Verify DHW (parameter 2) and space

heating (parameter 3) systems are turned ON or set to “01”. Read the Boiler Display Standby and Parameter Section of the manual starting on page 49 for more information.

• Check for loose electrical connections,

blown fuse (external or internal to the MCBA Control) or open service switch.

• Check continuity across the LWCO device

for a closed circuit. See item 6 Figure 29, page 86.

• if applicable, ensure the external limit is

reset to the closed position.

• Ensure incoming gas supply pressure at

the unit is more than 5”w.c. and less than 13” w.c. for natural or propane with all gas appliances ON or OFF.

If none of these conditions correct the problem, refer to the Esteem 399 Low NOx Trouble-Shooting Guide or contact AERCO International Tech Service. (800) 526-0288 Please have unit model and serial numbers when you call.

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Page 49

First Run Check of the Unit and System

 Check Boiler Piping.  Check Boiler system piping and compo-

nents for leaks. If found, shut down the unit and repair immediately.

 Purge remaining air from the system

piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise. Check Vent Piping and Combustion Air Piping.

 Check for gas-tight seal at every connec-

tion and seam of the venting and combustion air piping.

WARNING!

VENTING SYSTEM MUST BE SEALED GAS-TIGHT

TO PREVENT FLUE GAS SPILLAGE AND POTEN- TIAL CARBON MONOXIDE EMISSIONS, WHICH WILL RESULT IN PERSONAL INJURY OR DEATH.

 Check Gas Piping  Check around the unit for gas odor fol-

lowing the procedure on page 40 of this manual.

WARNING!

IF ANY GAS LEAKS ARE FOUND OR SUSPECTED,

SHUT THE UNIT DOWN IMMEDIATELY. LOCATE AND REPAIR ALL LEAKS. DO NOT OPERATE THE UNIT UNTIL THE LEAK IS CORRECTED. FAILURE TO COMPLY WITH THIS PROCEDURE COULD RE- SULT IN PERSONAL INJURY, DEATH OR PROPER- TY DAMAGE.

 Verify Flame Pattern and Combustion  Check the ﬂ ame pattern through the

inspection port of the heat exchanger. The ﬂ ame should be blue and stable. The ﬂ ame should be the length of the burner head openings.

WARNING!

THE COMBUSTION TESTING AND ADJUSTMENTS

MUST BE PERFORMED BY A QUALIFIED INSTALL- ER, SERVICE AGENCY OR THE GAS SUPPLIER.

LL COMBUSTION MEASUREMENTS MUST BE

PERFORMED WITH CALIBRATED EQUIPMENT TO ENSURE PROPER READING AND ACCURACY.

 Test for CO2 or O2 and for CO during

high ﬁ ring rate. To manually place the boiler into high ﬁ re mode, refer to page 49. The combustion reading should be within the range listed in Table 2. The CO level should not exceed 100 ppm when combustion is correct.

WARNING!

THE COMBUSTION LEVELS SHOULD BE MEAS-

URED AT HIGH FIRING RATE, REFER TO PAGE

OF THE ESTEEM 399 LOW NOX CONTROL

SECTION ON HOW TO SET THE FIRING RATE. IF THE COMBUSTION LEVELS ARE NOT WITHIN THE RANGE GIVEN IN TABLE 2 FOR THE FIRING RATE, SHUT THE BOILER DOWN AND CONTACT AERCO

NTERNATIONAL ENGINEERING DEPARTMENT.

AILURE TO COMPLY WITH THIS REQUIREMENT

COULD RESULT IN SEVERE PERSONAL INJURY, DEATH OR PROPERTY DAMAGE.

Table 2: Recommended Combustion Levels

Natural Gas Propane

O2 Min. 2.30% 3.70%

O2 Max. 5.30% 5.20% CO2 Min. 8.80% 10.00% CO2 Min. 10.50% 11.00%

CO Max. 100 ppm 100 ppm

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Page 50

Set Boiler CH Set Point

 Measure Input - Natural Gas Only

1. Ensure the boiler is firing at maximum firing rate. To manually place the boiler into high fire mode, see page 49.

2. Operate the unit for approximately 10 minutes.

3. Turn off all gas appliances within the building, except the Esteem 399 Low NOx .

4. At the gas meter, record the time required to use one cubic foot of gas.

5. Calculate Natural gas input using the following equation:

• 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.

Set Boiler CH Set Point

1. Press the MODE button until the display shows PARA. This is the parameter mode of the control.

Operation Veriﬁ cation - Space Heating

NOTICE

Digits and characters shown as [0000], in the following outline, represent the control panel display. The last three digits on the display represent the measured boiler water temperature and may differ from what is shown in the manual.

1. Disconnect the DHW (Domestic Hot Water) thermostat wiring from the Esteem 399 Low NOx or turn down DHW tank aquastat (if used) to ensure the boiler does not receive a DHW call for heat.

2. Set the room thermostat to the lowest setting.

3. Turn off power to the boiler, wait a few seconds and turn on power to the boiler.

4. The following displays should occur:

• [

U1.22] Software version

2. Press the STEP button until the first digit on the display shows “4”. The last three digits on the display shows the space heating Maximum Boiler Operating Setpoint.

3. Press the “+” or “-” button to change the setting.

NOTICE

When an outdoor sensor is used, the setting of Parameter 4 is the space heating setpoint when the outdoor temperature is at or below 0ºF. When the outdoor temperature is above 0ºF, the Esteem 399 Low NOx control will calculate the boiler setpoint between the minimum and maximum temperature settings.

4. Press the “STORE” button to save the setting.

A140] Self check on power up

• [

• [0140] No call for heat

5. Initiate a call for heat by raising the set point of the room thermostat to the highest setting. The following display sequence should occur.

• [

5140] This is a fan / air flow check. The

burner blower will be energized momentarily prior to the prepurge cycle.

• [1140] This is the prepurge cycle. The

burner blower and the space heating circulator become energized. The blower has a 10 second prepurge cycle.

2140] This is the ignition cycle. The

• [ control module will energize and open the gas valve and begin the spark for ignition.

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Page 51

Operation Veriﬁ cation - Domestic Hot Water

• If the burner flame proves, the burner will continue to fire at the ignition fan speed for approximately 10 seconds to stabilize the flame.

• If the burner flame is not proven the control module will repeat the ignition sequence. If the flame is not proven after five attempts the control will lock-

out and the display will show [

• To verify flame failure lockout, close the manual shut off valve on the gas supply piping to the boiler and repeat ignition sequence. When verification is completed, ensure the manual shut off valve is returned to the open position.

3140] This is the normal space heat-

• [ ing operation cycle. After the flame is proven and stabilized the burner will fire at low input for approximately 1 minute. After this time period, the control module will begin to modulate the burner firing rate based on actual boiler outlet temperature and the set point temperature.

E-02]

additional 30 seconds before starting a new ignition sequence.

• [

7180] The space heating circulator

will continue to run for a 1 minute post pump cycle.

• [0180]The boiler is in standby MODE

waiting for a call for heat.

8. Verify the operation of the boiler by repeating the operational sequence several times.

9. Return the room thermostat to a desired setting. Reconnect the DHW wiring or return the DHW aquastat to desired setting, placing the DHW system into operation.

6. Allow the boiler to operate and allow the boiler outlet temperature to reach the set point temperature.

• [

6180] This begins the burner shut-

down and post purge cycle. The space heating circulator will continue to run until the room thermostat is satisfied.

7. Lower the room thermostat set point below the room temperature to end the call for heat.

1180] This begins a post purge cycle.

• [ When the room thermostat is satisfied, the boiler will shutdown. The control module will close the gas valve and the blower will continue for 30 seconds for a post purge cycle before shutting down. If another call for heat is initiated, the boiler will remain off for an

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Page 52

Operation Veriﬁ cation - Domestic Hot Water

1. As outlined in the verification for space heating, repeat STEPS 2 through 4.

2. Raise the DHW aquastat setting to initiate a call for heat. As in the space heating operation the display should show:

• [5140] This is a fan / air flow check. The

burner blower will be energized momentary prior to the prepurge cycle.

1180] This is prepurge cycle. The burn-

• [ er blower and DHW circulator become energized and the 10 second prepurge cycle begins.

• [2180] The boiler will begin the ignition sequence. The same sequence of establishing flame, trail for ignition and attempts for ignition as described in the space heating applies for domestic water heater.

4. Verify the DHW operation of the boiler by repeating the outlined operation sequence several times.

5. Return the DHW aquastat and room thermostat to the desired setting.

4180] This indicates normal operation

• [ for DHW. The burner will begin modulating its input to maintain the DHW set point. The burner will not go into the low input rate for the 1 minute flame stabilization period that occurs in CH mode.

3. Lower the DHW aquastat to satisfy the call for heat.

• [

1180] The post purge cycle begins.

The control module closes the gas valve and the blower continues for a 30 second post purge.

8180] The DHW circulator will continue

• [ for a 30 second post pump cycle. If another DHW call for heat is initiated the boiler ignition sequence will begin immediately.

• [0180] Boiler is in standby MODE waiting for a space heating or DHW call for heat.

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Page 53

Chapter 12 Operating Instructions

Safety

FOR YOUR SAFETY READ COMPLETE

INSTRUCTIONS BEFORE PROCEEDING

WARNING

IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RE-

SULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

IF YOU SMELL GAS

• DO NOT try to light any appliance.

• DO NOT touch any electric switch; do not use any phone in your building

• DO NOT use a cell phone in your building

• Immediately call your gas supplier from a different location. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department.

NOTICE

This appliance does not have a pilot.

It is equipped with an ignition device which automatically lights the burner.

DO NOT try to light the burner by hand.

CAUTION

BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell close to the ﬂ oor because some gas is heavier than air and will settle on the ﬂ oor.

WARNING

USE ONLY YOUR HAND TO TURN THE EXTERNAL MANUAL GAS VALVE. NEVER USE TOOLS. IF

THE VALVE WILL NOT TURN BY HAND, DON’T TRY TO REPAIR IT; CALL A QUALIFIED SERVICE TECHNICIAN. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

WARNING

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL

A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER. OP-

ERATING INSTRUCTIONS

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Page 54

Operation

STOP!

• Read all the safety information on the preceding page. This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand.

1. Set room thermostat(s) to lowest setting.

2. Turn the external manual gas valve handle clockwise “CLOSE” (valve handle shall be per-

pendicular to gas piping).

3. Turn the service switch on the Esteem 399 Low NOx control panel OFF.

4. Remove the front jacket panel on the unit.

5. Turn the external manual gas valve handle counter-clockwise to “OPEN” gas supply

(valve handle shall be parallel to gas piping).

6. Wait five (5) minutes to clear out any gas.

• If after 5 minutes, you smell gas in the jacket enclosure or around the unit, STOP! Do not touch any electrical equipment. Leave the building and call your gas supplier.

• If you don’t smell gas, go to the next step.

7. Turn the service switch on the Esteem 399 Low NOx control panel “ON”.

8. Set room thermostat(s) to desired setting(s).

9. Replace the front jacket panel.

10. Make sure the panel is seated firmly in place and all mounting screws are tightened.

WARNING

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 SERV- ICE TECHNICIAN OR GAS SUPPLIER.

NOTICE

The Esteem 399 Low NOx control panel display will show a sequence of numbers (0,1,2,3,4,etc.) as the left digit. Sequence digit 3 or 4 indicates the boiler is ﬁ ring. Sequence digit 0 means there is no call for heat (all external thermostats are satisﬁ ed).

TO TURN OFF GAS TO APPLIANCE

1. Set the room thermostat to lowest setting.

2. Turn the service switch on the Esteem 399 Low NOx control panel to “OFF”

3. Turn the external manual gas valve handle clockwise

to “CLOSE”

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Page 55

Boiler Control Display

STANDBY MODE

This is the standard mode for the Esteem 399 Low NOx. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display. Any parameters that were modified are then stored.

The first character on left side of display shows the current status of the boiler depending on the condition of both the boiler and the burner. The last 3 characters show the boiler supply temperature.

If the burner is blocked due to a soft lockout, the display alternates between a by the boiler supply temperature and a b

with a two digit error code. See “Chapter 19 Troubleshooting” on page 69 for more on error codes

TO TEMPORARILY PLACE THE BURNER INTO

HIGH FIRE TEST MODE:

Press the MODE button until “StbY” is displayed. Then press and hold both the MODE and “+” buttons simultaneously until the first

digit flashes

While in the test mode:

9 followed

TO TEMPORARILY PLACE THE BURNER INTO

LOW FIRE TEST MODE:

Press the MODE button until StbY is displayed. Then press and hold both MODE and

“-” buttons simultaneously until the first digit flashes L.

TO DEACTIVATE THE HIGH OR LOW FIRE TEST

MODE:

Press the MODE button until StbY is displayed. Then press and hold both the “+” and “-” buttons simultaneously to deactivate the high or low fire test mode.

NOTICE

If the “+” button is held in, the space heating system (parameter 3) will be turned OFF and the display will show

“cOFF”. Press and hold the “+” button to turn the space heating system back ON, the display will show “c” followed by space heating set point. If the “-” button

is held in while in the “StbY” mode, domestic system (parameter 2) will be turned OFF and the display will show

• high limit will function

• boiler space heating circulator will function

• domestic circulator will not function

• the test mode will time out in approximately 10 minutes

GF-125

“dOFF”. Press and hold “-” button to turn the domestic system back ON, the

display will show d followed by domestic set point temperature.

Page 56

Operation

Standby Mode Display

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Page 57

Boiler Control Display

PARAMETER MODE—SETTING THE BOILER P

ARAMETERS

To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once.

To scroll through the list of parameters, simply press the “STEP” button. The first digit is the parameter number followed by the parameter value. To modify a parameter value, use the + or - keys. Then press “STORE” to save the value you just changed. The display flashes once to confirm the data has been stored.

Note 1: This parameter is factory set to 140ºF. It is important to note the control adds 46ºF to this setting, therefore the actual domestic hot water boiler setpoint is 140ºF + 46ºF = 186ºF.

Note 2: This parameter should not be changed from the factory setting of 01. The performance of the DHW will be affected and can become unreliable.

Note 3: This parameter should not be changed from the factory setting of 01. The performance of the space heating will be affected and can become unreliable.

To activate the parameters you changed, press “RESET”. However, if you do not press a key, the system returns to STANDBY mode after 20 minutes and automatically stores the changes.

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Page 58

Boiler Control Display

INFORMATION MODE—ACCESSING BOILER

NFORMATION

To switch from STANDBY mode to INFORMATION mode, press MODE twice.

Press STEP until the system displays the information you need. The first digit is the information item number followed by the items value. The decimal point located behind the first position flashes to indicate that the boiler is in INFO mode.

NOTICE

The ignition counters and burner hours are split into three two digit numbers. For example:

Write the numbers down from left to right to arrive at 123,456 space heating ignitions.

NOTICE

In the INFO Mode a temperature reading of -22 typically indicates an “open” circuit. A temperature reading of 240

typically indicates a short-circuit.

DISPLAY DIGIT

SEGMENTS

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Page 59

ERROR (HARD LOCKOUT) MODE

If a serious fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button. A hard lock is indicated by displaying an E for the first digit, followed by the error code.

For a detailed description of the error codes, see Chapter 19 Troubleshooting

CAUTION

The boiler freeze protection feature is disabled during a Hard Lockout, however the space heating circulator will operate.

CAUTION

Boiler Control Display

During a hard lockout or low water condition the boiler will not re-start without service. If the heating system is left unattended in cold weather appropriate safeguards or alarms should be installed to prevent property damage.

The boiler setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the boiler. If an outdoor temperature sensor is connected to the boiler, the outdoor reset function is automatically enabled and will vary the space heating setpoint with the change in outdoor temperature. The outdoor reset function has no affect on the DHW setpoint during a domestic call.

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Page 60

Chapter 13 Outdoor Reset Control

Mounting the Outdoor Sensor

1. Remove the front cover, mounting screws & anchors from the sensor enclosure.

2. When mounting the enclosure the exterior wall selected should represent the heat load of the building. Typically a northern or northeastern wall will suit most buildings. A southern facing wall may suit buildings that have large glass walls or windows on the southern face.

3. Ensure the sensor enclosure is shielded

Figure 26: Sensor Enclosure and Components

from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature sensing.

4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering.

5. Avoid mounting the enclosure in areas subjected to excessive moisture.

6. Once an area on the exterior wall has been determined, to affix the enclosure use the enclosure as a template to mark the location of the mounting screws.

7. Using a 3/16” drill bit, drill 2 pilot holes on the marked locations.

8. Tap the enclosed plastic anchors into the pilot holes. Use care not to damage the anchors.

9. Mount the sensor enclosure using the screws provided.

Wiring the Sensor

1. Remove the sealing nut and sealing gasket from the sensor enclosure.

2. Route two 18 gauge wires through the sealing nut and gasket. Connect the wires to the sensor terminals 1 and 2.

3. Re-insert the sealing gasket and tighten the sealing nut to the sensor enclosure.

4. Route the sensor wire back to the Esteem 399 Low NOx boiler, ensuring the wires are not run parallel to telephone or power cables.

NOTICE

If the sensor wires are located in an area with sources of potential electromagnetic interference (EMI) the sensor wires should be shielded or the wires should be routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the unit.

5. Connect the sensor wires to the outdoor sensor terminals on the 24V terminal strip located inside the boiler enclosure (see boiler wiring diagram, Figure 20 page 34).

Summer / Winter Switch at Boiler

If required the space heating system can be turned off at the boiler, similar to a manual summer / winter switch by pressing and holding

the “+” button while in the “StbY” mode. The display will show “cOFF”. Pressing and holding

the “+” button turns the space heating system back on. The display will show “c” followed by the space heating set point temperature.

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Page 61

Adjusting Outdoor Reset Curve

CAUTION!

If a parameter setting is changed but the STORE button is not pressed to save the setting, the MCBA will automatically store the setting after 20 minutes. Ensure all parameters are at their factory settings or appropriately revised for the application prior to commissioning the boiler. Failure to comply could result in erratic or unreliable operation of the Esteem 399 Low NOx boiler.

NOTICE

Once a parameter setting has been revised and stored pressing the STEP button will display the setting of the next parameter without showing P_XX. To avoid confusion, continue pressing the STEP button until Parameter 46 is reached. The next press of the STEP button will cause the display to roll over to Parameter 1. Continue pressing the STEP button until the next parameter to be adjusted is reached and revise the setting.

Adjusting Outdoor Reset Curve

setpoint on the CH Reset Curve Coldest Day. The outdoor temperature can be monitored on the boiler display via item 4 of the INFO menu.

CH MINIMUM BOILER OPERATING SETPOINT

(Parameter 10)

Factory Setting Minimum Setting Maximum Setting

86ºF 60ºF 140ºF

When an outdoor temperature sensor is connected, the CH Minimum Boiler Operating Setpoint becomes the boiler setpoint on the CH Reset Curve Warmest Day.

CH RESET CURVE COLDEST DAY

(Parameter 11)

Factory Setting Minimum Setting Maximum Setting

00ºF (-)22ºF 50ºF

This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the CH Reset Curve Coldest Day is the coldest

design temperature of the heating system.

Parameters 4, 10, 11, & 12 define the settings of the outdoor reset curve. See Graph 1 and Table 3, page 57 for an example of modifying the outdoor reset curve.

CH MAXIMUM BOILER OPERATING SETPOINT

(Parameter 4)

Factory Setting Minimum Setting Maximum Setting

186ºF 86ºF 194ºF

If an outdoor temperature sensor is not connected to the boiler, the setpoint for a heating call will be the space heating Maximum Boiler Operating Setpoint. If an outdoor temperature sensor is connected, the CH Maximum Boiler Operating Setpoint becomes the boiler

GF-125

CH RESET CURVE WARMEST DAY

(Parameter 12)

This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the

Factory Setting Minimum Setting Maximum Setting

64ºF 60ºF 78ºF

CH Reset Curve Warmest Day is the warmest design temperature of the heating system.

Page 62

Entering MCBA Access Code

The installer must enter the MCBA Access Code to adjust the advanced parameter settings of the MCBA. The Access Code can be entered as follows:

1. Press the MODE button until the display shows

2. Press and hold the MODE and STEP buttons together for 2 to 3 seconds until the display shows

3. Press the STEP button once and the display will show sents a random number.

4. Press the “+” or “–“ buttons to change the number displayed to read and hold the “+” or “–“ button to rapidly change the number.

5. When the display reads STORE button to save the Access Code. The display should flash to indicate that the Access Code was saved.

StbY.

CODE.

C_XX where XX repre-

C_54.. Press

C_54, press the

After the Access Code has been entered, the advanced parameters can be accessed by pressing the MODE button until the display shows press the STEP button to reach the appropriate parameter. The display should follow the following sequence:

Press STEP once-

Press STEP x2 - 2_01

Press STEP x3 - 3_01

Press STEP x4 - 4186

Press STEP x5 - P_10

Press STEP x6 - P_11 Etc......

After Parameter 4, the display will show P followed by the parameter number. Once a particular parameter is reached, the display will change to show the current setting of that parameter.

PARA. Once the display shows PARA,

1140

NOTICE

The actual parameter values displayed on the display may vary depending on the application, but the sequence will always occur in the order shown.

Changing a Parameter Setting

1. Use the “+” or “–“ button to change the parameter setting.

2. Press the STORE button to save the change. The display should flash to indicate that the change was saved.

3. Press the RESET button to leave the Access Code mode.

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Entering MCBA Access Code

Graph 1: Outdoor Air Temperature Reset Curve (Example)

Table 3: Outdoor Air Temperature Reset (Example)

Outdoor Temperature

0ºF or Lower 140ºF

23ºF 122ºF

40ºF 108ºF

64ºF or Higher 86ºF

Boiler target Temp. Based on

Outdoor Temp.

Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoor air temperature

Note: Factory setting of Parameter 4 is 186ºF.

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Chapter 14 External Modulating Control

The boiler can directly accept an analog 0-10 VDC signal to control the firing rate from an external modulating boiler controller.

Wiring the Modulating Controller

Run two 18 gauge wires from the external modulating boiler controllers 0-10 VDC boiler output to the external input terminals on the low voltage terminal strip inside the boiler. (see boiler wiring diagram, Figure 20 page

34). This signal will both enable and modulate the boiler. No wiring is required at the thermostat (T-T) terminals 7 and 8 of the boiler.

NOTICE

Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct. Reversed polarity could lead to erratic and/or no response from the boiler controller.

NOTICE

Ensure that Parameter 4 is set above the highest setpoint of the external modulating control. Parameter 4 is a boiler high temperature limit when using an external modulating controller.

Programming of External Modulating Control

The external modulating control must be programmed to send 1.8 VDC to enable the boiler and run it at low fire, and 10 VDC to run the boiler at high fire. Once the control enables the boiler, it must wait 2 minutes to allow the burner to stabilize before modulating the boiler.

Parameter Adjustment

The Esteem 399 Low NOx MCBA control module must be programmed to accept the 0-10 VDC signal from the external modulating boiler control.

CH Operating Signal Section

(Parameter 45)

Factory Setting Revised Setting

00 02

Follow the procedure for entering the MCBA Access Code on page 56, and then change the setting of Parameter 45 from the factory setting of 00 to 02.

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Factory Parameter Settings

1 140ºF DHW Setting

2 01 DHW Application Selection

3 01 CH Application Selection

4 186ºF CH Maximum Boiler Operating Setpoint

10 86ºF CH Minimum Boiler Operating Setpoint

11 00ºF CH Reset Curve Coldest Day

12 64ºF CH Reset Curve Warmest Day

13 -22ºF Frost Protection Setpoint

Factory Parameter Settings

18 32ºF CH Block Temperature Setting

19 00 Minutes Boost Feature Setting

20 00ºF Parallel Shift Value

21 46ºF Setpoint Value Addition for DHW

32 01 Minutes CH Circulator Post Pump Time Period

33 03 x 10.2 Sec. DHW Circulator Post Pump Time Period

38 02ºF DHW On Differential

39 06ºF DHW Off Differential

40 03 x 10.2 Sec. CH Call Blocking Time

41 00 x 10.2 Sec. DHW Call Blocking Time

42 00 x 10.2 Sec. DHW to CH Call Blocking Time

43 00 Minutes DHW Priority Timeout

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45 00 CH Operating Signal Selection

46 02 DHW Operating Signal Selection

Page 66

Chapter 15 Check-Out Procedures

NOTICE

Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 61.

Check-Out Procedures

 Boiler system water chemistry checked

and veriﬁ ed as outlined on page 39.

 The boiler air vent and any automatic air

vents placed within the system are open one full turn.

 Air is purged from the heating zones and

boiler system piping.

 Conﬁ rm that the burner is properly conﬁ g-

ured for the fuel supply.

• Natural Gas—page 30

• Propane—page 31.

 Thermostat circuit wiring checked and

veriﬁ ed that no voltage is present to the low voltage terminals as outlined on page

41.

 Operating Instructions on page 47 were fol-

lowed during start-up.

 Combustion levels and ﬂ ame pattern veri-

ﬁ ed as outlined on page 43.

 Measured the rate of input on Natural

Gas as outlined on page 44.

 Checked the incoming gas pressure to

the Esteem 399 Low NOx to ensure a minimum pressure of 5”w.c during ﬂ ow conditions to all gas appliances and a maximum pressure of 13”w.c during nonﬂ ow conditions for Natural and Propane.

 Adjusted balancing valves and system

limit controls to provide design temperatures to the primary space heating system.

 In multiple zone applications, adjusted for

correct ﬂ ow of boiler water to each zone.

 Checked and veriﬁ ed room thermostat(s)

function properly and the thermostat(s)

heat anticipator (if used) was properly set.

 Observed several operating cycles for

proper operation of the Esteem 399 Low NOx and the system.

 Set the room thermostat(s) to the desired

room temperature.

 Reviewed all instructions shipped with the

Esteem 399 Low NOx with the homeowner or maintenance personnel.

 Completed the Installation Record on

page 61.

 Ensure all manuals and other documents

are returned to the Installation envelope and given to the owner for safekeeping.

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Chapter 16 Installation Record

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Chapter 17 Maintenance Schedule

Professional Maintenance

At least on an annual basis the following maintenance should be performed by a qualified service technician:

General

• Attend to any reported problems.

• Inspect the interior of the boiler jacket area; clean and vacuum if necessary.

• Clean the condensate drain assembly and ﬁ ll with fresh water.

• Check for leaks: water, gas, ﬂ ue and con- densate.

• Verify ﬂ ue vent piping and air inlet piping are in good condition, sealed tight and properly supported.

• Check boiler water pressure, piping and expansion tank.

• Check control settings.

• Check ignition electrode (sand off any white oxide; clean and reposition).

• Check ignition wiring and ground wiring.

• Check all control wiring and connections.

• Check burner ﬂ ame pattern (stable and uniform).

Additional items if combustion or performance is poor:

• Clean heat exchanger and ﬂ ue ways.

• Remove burner assembly and clean burner head using compressed air only.

Owner Maintenance

• On going as conditions warrant:

• Check the area around the unit.

• Check and remove any blockage from the combustion air inlet and ventilation openings.

• Check the temperature and pressure gauges.

• Monthly:

• Check vent piping.

• Check combustion air inlet piping.

• Check the pressure relief valve.

• Check the condensate drain system.

• Every 6 months:

• Check boiler piping and gas supply piping for corrosion or potential signs of leakage.

• Operate the pressure relief valve.

WARNING!

FAILURE TO PERFORM THE SERVICE AND MAIN-

TENANCE OR FOLLOW THE DIRECTIONS IN THIS MANUAL COULD RESULT IN DAMAGE TO THE

STEEM 399 LOW NOX OR SYSTEM COMPO-

NENTS, RESULTING IN SEVERE PERSONAL IN- JURY, DEATH OR SUBSTANTIAL PROPERTY DAM- AGE.

Once the maintenance items are completed, review the service with the owner.

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Chapter 18 Maintenance Procedures

WARNING!

THE ESTEEM 399 LOW NOX SHOULD BE IN-

SPECTED AND SERVICED ANNUALLY, PREFER- ABLY AT THE START OF THE HEATING SEASON, BY A QUALIFIED SERVICE TECHNICIAN. IN AD- DITION, THE MAINTENANCE AND CARE OF THE UNIT AS OUTLINED ON PAGE 62 AND FURTHER EXPLAINED IN THIS CHAPTER SHOULD BE PER- FORMED TO ASSURE MAXIMUM EFFICIENCY AND RELIABILITY OF THE UNIT. FAILURE TO SERVICE AND MAINTAIN THE ESTEEM 399 LOW NOX AND THE SYSTEM COMPONENTS COULD RESULT IN EQUIPMENT FAILURE, CAUSING POSSIBLE SE- VERE PERSONAL INJURY, DEATH OR SUBSTAN- TIAL PROPERTY DAMAGE.

NOTICE

The following information provides detailed instruction for completing the maintenance items outline in the maintenance schedule on page 62. In addition to this maintenance, the Esteem 399 Low NOx should be serviced at the beginning of the heating season by a qualiﬁ ed service technician.

Inspect Burner Area

Remove the boiler front jacket panel and venturi inlet elbow.

Vacuum any dirt or debris from the burner/ blower components.

Re-install venturi inlet elbow and front jacket panel when completed.

WARNING!

DO NOT USE SOLVENTS TO CLEAN ANY OF THE

BURNER COMPONENTS. THE COMPONENTS COULD BE DAMAGED, RESULTING IN UNRELIABLE OR UNSAFE OPERATION.

Check System Piping

Inspect all piping (water and gas) on the boiler system for leaks and verify that the piping is leak free and properly supported.

Inspect the fittings and components on the unit and verify they are leak free.

WARNING!

Attend to Reported Problems

Any problems reported by the owner should be checked, verified and corrected before proceeding with any maintenance procedures.

Check Surrounding Area

Verify that the area surrounding the Esteem 399 Low NOx is free of combustible / flammable materials or flammable vapors or liquids. Remove immediately if found.

Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed on page 7 of this manual. If any of these products are in the area from which the unit takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.

ELIMINATE ALL BOILER WATER SYSTEM LEAKS.

ONTINUAL FRESH MAKE-UP WATER WILL RE-

DUCE THE HEAT EXCHANGER LIFE CAUSING BOIL- ER FAILURE. LEAKING WATER MAY ALSO CAUSE SEVERE PROPERTY DAMAGE TO THE SURROUND- ING AREA. INSPECT THE GAS SUPPLY PIPING US- ING THE PROCEDURE OUTLINED ON PAGE 40.

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Clean Condensate Drain Assembly

1. Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler.

2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean.

3. Check the drain piping from the condensate drain assembly to the drain. Flush to clean as necessary.

4. Reassemble the condensate drain assembly onto the boiler by tightening the retaining nut with rubber seal onto the boiler. Hand tight only.

5. Remove the fill plug on the condensate drain assembly and fill with water. See Figure 16 on page 28.

6. Replace the fill plug on drain assembly.

Check Ventilation Air Openings

Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers.

Check and verify the vent discharge and the combustion air intake are free of debris and obstructions.

Inspect Vent and Combustion Air Piping

Visually inspect the venting system and combustion air piping for blockage, deterioration or leakage. Repair any deficiencies.

Verify that the combustion air inlet piping is connected, sealed and properly supported.

WARNING!

FAILURE TO INSPECT THE VENT SYSTEM AND

COMBUSTION AIR INLET PIPING AND TO HAVE ANY CONDITIONS REPAIRED, CAN RESULT IN SE- VERE PERSONAL INJURY OR DEATH.

Check Boiler System

Verify all system components are correctly installed and operating properly.

Check the cold fill pressure for the system, typical cold water fill pressure is 12 psig.

Verify the system pressure, as the unit operates at high temperature, to ensure the pressure does not exceed 25 psig. Excessive pressure reading indicates expansion tank sizing is incorrect or system performance problems.

Inspect air vent and air separators in the system. Remove the caps on automatic air vents and briefly depress the valve stem to flush vent. Replace the cap when completed. Ensure vents do not leak, replace any leaking vents.

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Check Expansion Tank

Refer to Section IV - Boiler Piping for recommended location of the expansion tank and air eliminators.

Closed -Type Tank:

• Ensure tank is partially filled with water leaving an air gap as a cushion. Refer to the manufacturer’s instruction for proper fill level.

• Ensure the tank is fitted with a device that reduces gravity circulation of airsaturated tank water back into the system. This device prevents air from bubbling up through the water as it returns from the system.

• Ensure no automatic air vents are used in the system. This will allow air to escape from the system instead of returning to the tank.

Diaphragm Tank:

• Ensure the system contains a minimum of one automatic air vent. Recommended location of the air vent should be atop an air eliminator.

• Remove the tank from the system and check the charge pressure. For residential applications the charge pressure is typically 12 psig. If tank does not hold a charge pressure, then the membrane is damaged and the tank should be replaced.

Check Boiler Relief Valve

Inspect the relief valve and lift the lever to verify flow at least annually or as recommended on the warning tag of the valve.

WARNING!

BEFORE MANUALLY OPERATING THE PRESSURE

RELIEF VALVE, ENSURE THE DISCHARGE PIPING IS DIRECTED TO A SUITABLE PLACE OF DISPOS- AL TO AVOID A POTENTIAL SCALD HAZARD. THE DISCHARGE PIPING MUST BE FULL SIZE WITHOUT RESTRICTION AND INSTALLED TO PERMIT COM- PLETE DRAINAGE OF BOTH THE VALVE AND LINE.

If when closed, the valve fails to seat properly or continually weeps and it has been determined that the cause is not system over-pressurization due to an undersized or waterlogged expansion tank, replace the relief valve.

Inspect Ignition Electrode

1. Remove the ignition electrode from the burner mounting plate.

2. Remove any white oxides on the electrode using fine grit sandpaper or steel wool. If the electrode does not clean to a satisfactory condition, replace the ignitor .

3. Ensure the gasket is in good condition and correctly positioned, replace gasket if necessary.

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Check Ignition Wiring and Ground Wiring

• Inspect the burner wiring from the burner control module to the ground terminal behind the control panel.

• Ensure wiring is in good condition and securely connected.

• Check ground continuity of the wiring to the boiler jacket or piping using a continuity meter.

• Replace and correct ground wire if ground continuity is not satisfactory.

Check Control Wiring

Inspect all control wiring. Ensure wiring is in good condition and properly connected.

Check Control Settings

1. Set the control display to PARAMETER

mode and check all boiler settings. Adjust setting as necessary. See page 51.

2. Check any external limit control settings

(if used). Adjust settings as necessary.

Check Burner Flame

Inspect the burner flame through the observation port on the heat exchanger.

Not damage combustion chamber insulation during removal of burner mounting plate assembly. See WARNING page 67.

8. Remove the burner head mounting screws and remove the burner head.

9. Inspect the burner head for deterioration. Use compressed air or a vacuum to clean the burner head.

10. Remove the venturi and gas valve assembly from the blower.

11. Use a vacuum cleaner or compressed air to clean the interior of the blower assembly.

12. Inspect the blower blades to ensure they are clean and not damaged.

13. Re-assemble the venturi and gas valve onto the blower.

14. Ensure the venturi gasket is in good condition, positioned correctly and replace gasket if necessary.

15. Re-assemble the burner head onto the burner mounting plate.

16. Ensure the burner head gasket is in good condition, positioned correctly and replace gasket if necessary.

If flame pattern is not fully blue and covers the entire burner surface during high fire, shut the unit down and allow it to cool thoroughly.

3. Close the external manual gas valve on the gas supply line and disconnect the gas piping and rectifier plug.

4. Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts.

5. Remove the blower from the unit.

6. Remove the mounting nuts securing the burner mounting plate to the heat exchanger and set aside.

7. Remove the burner mounting plate assembly from the heat exchanger. Do

17. Re-assemble the burner mounting plate assembly onto the heat exchanger.

18. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page

67.

19. Re-assemble the blower onto the burner mounting plate and reconnect the wiring harness connectors.

20. Re-assemble the gas supply connection and rectifier to gas valve. Open the external manual gas valve. Check for any gas leaks as outlined on page 40 and repair if necessary. Place the unit back into service.

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Check Flame Signal

The flame signal can be read from item E of the information mode. It should be a min. 3μ Α −DC.

Check the ignitor for fouling or damaged insulation if a low flame signal is read.

Check ground wiring and continuity as a cause for low flame signal. Replace ignitor if conditions are satisfactory.

Check Combustion Levels

Refer to page 43 of this manual for measuring combustion levels and burner adjustments.

Check Flue Gas Temperature

1. Adjust the boiler to fire at HIGH fire, see page 49. Place the control display to INFO mode, see page 52 for procedures.

2. The flue gas temperature is indicated on the display when the first digit is 5. The measured temperature (shown as the last 3 digits) should not be more than 54ºF higher than the measured supply water temperature.

3. The measured supply water temperature is indicated on the information display when the first digit is 1 and the temperature shown as the last 3 digits.

4. If the measured flue gas temperature is higher than 54ºF over the supply water temperature, shut the boiler down and follow the procedures listed below to clean the heat exchanger.

Insulation Handling

Handling Previously Fired Combustion Chamber Insulation

WARNING

WHEN REMOVING OR REPAIRING THE COMBUSTION CHAMBER INSULATION FOLLOW

PRECAUTIONARY MEASURES:

THESE

• Use a NIOSH approved respirator which meets OSHA requirements for cristobalite dust, similar to N95. Contact NIOSH at 1-800-356-4676 or on the web at www.cdc.gov/niosh for latest recommendations.

• Wear long sleeved, loose ﬁ tting clothing, gloves and eyes protection.

• Assure adequate ventilation.

• Wash with soap and water after contact.

• Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly.

• Discard used insulation in an air tight plastic bag.

NIOSH Stated First Aid:

Eye/Skin: Immediately irrigate

Breathing: Clean fresh air

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Clean Heat Exchanger

1. Shut down the boiler:

• Turn Off Gas to Appliance. See instructions on page 48

• Do not drain the boiler unless the boiler will be subject to freezing conditions.

• Do not drain the boiler if freeze protection fluid is used in the system.

2. Allow the boiler to cool down to room temperature before servicing.

3. Disconnect the gas piping and rectifier plug to the gas valve.

4. Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts.

5. Remove the blower from the unit.

6. Remove the mounting nuts securing the burner mounting plate to the heat exchanger and set aside.

7. Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 67.

8. Carefully remove the combustion chamber insulation from the heat exchanger and set aside. See WARNING on page 67.

9. Use a vacuum cleaner, compressed air or water to remove any accumulation from the heat exchanger flue ways. Do not use any solvent.

10. Re-install the combustion chamber insulation onto the heat exchanger.

11. Re-assemble the burner mounting plate assembly onto the heat exchanger. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insula-

tion if necessary. See WARNING on page

67.

12. Re-assemble the blower onto the burner mounting plate and reconnect the wiring harness connectors.

13. Reconnect the gas piping and rectifier to gas valve. Check for leaks, repair if necessary.

14. Close isolation valves on the boiler water piping to isolate the boiler from the heating system.

15. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.

16. Once the boiler has been completely flushed, return the boiler and system piping back to operation.

17. Perform the required startup and checkout procedures See page 42 and following.

Start-up and Checkout Procedures

Start the unit and perform the start-up procedure as listed in this manual.

Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range.

Complete the “Check-Out Procedures” on page 60

Review With Owner

• Ensure the owner understands the impor-

tance to perform the maintenance schedule speciﬁ ed in this manual.

• Remind the owner of the importance to

call a licensed contractor should the unit or system exhibit any unusual behavior.

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Introduction

Chapter 19 Troubleshooting

Introduction

This guide is to be used in conjunction with the AERCO International Esteem 399 Low NOx Boiler Installation and Maintenance Manual.

Good Troubleshooting Practices

Before leaving for the job site:

• Check your parts and tools

• Test equipment and tools you will need:

• Electrical meter that tests both voltage (AC/DC), continuity (ØΩ), resistance ( Ω,ohms), and frequency (Hz)

• Temperature gauge or metering device

• Manometer

• Calibrated Combustion Analyzer

• Standard tools of the trade (wrenches, screwdrivers...)

• Parts to solve most problems

• Control module

• Transformer with surge protection

• Blower with gasket

• Esteem 399 Parts Case - P/N 58029

• Review all appropriate manuals before leaving for the job site

At the job site:

• Clarify problem

• Have the Esteem 399 Low NOx manual and any other wiring, zone control or piping diagrams, or installation guides readily available.

IMPORTANT

Follow the Troubleshooting Guide step by step, always double checking your results. Skipping steps or not completing steps can lead to wrong conclusions, repeated visits to the job site, unhappy customers and unnecessary warranty claims.

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Control Module Fuses

Initial Troubleshooting Checks

WARNING

LABEL ALL WIRES AND WIRE CONNECTIONS PRIOR TO DISCONNECTING WHEN SERVICING ANY BOILER CON-

TROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. ALWAYS DISCONNECT THE POWER SUPPLY TO THE BOILER BEFORE SERVICING. FAILURE TO COMPLY COULD RESULT IN SEVERE PER- SONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

WARNING

NEVER BYPASS (JUMPER) ANY BOILER, CONTROL OR DEVICE EXCEPT FOR MOMENTARY TESTING WHEN

TROUBLESHOOTING THE BOILER AS OUTLINED IN THIS GUIDE, SEVERE PERSONAL INJURY, DEATH OR SUB- STANTIAL PROPERTY DAMAGE CAN RESULT.

• Ensure all wire connectors to the control module and sensors are securely connected.

• Ensure the maximum gas supply pressure does not exceed 13”w.c. during ﬂ ow or no ﬂ ow con- ditions.

• Ensure the gas supply pressure is a minimum 5” w.c. during ﬂ ow conditions (burner ﬁ ring on all gas appliances).

Control Module Fuses

NOTICE

The control module contains 2 internal replaceable fuses. Ensure the fuses are in working condition prior to replacing the control module or any boiler component. If one of the fuses has blown, it will prevent the control module and/or boiler components from operating properly.

To check or replace the control module fuses:

1. Disconnect the external power supply to the boiler.

2. Remove the front jacket panel of the boiler by removing the thumb screw along the top edge.

3. Remove the electrical connectors at the MCBA control module for the igniter, transformer and

display (ribbon cable) and the black plastic housing cover off the control module. Use care not to damage the cover when removing it.

4. Remove both fuses and check for continuity to determine if fuse is blown, replace if neces-

sary.

5. The control module is supplied from the factory with 2 spare fuses, a 5 amp fast acting fuse

and a 4 amp slow acting fuse, attached to the control module cover.

6. When replacing the fuses ensure the amp rating and type of the fuse matches the replace-

ment fuse. See Figure 27 on page 71, page 4 for amperage and location of the fuses.

WARNING

DO NOT BYPASS ANY FUSE WITH A JUMPER. DO NOT REPLACE ANY FUSE WITH A FUSE THAT IS NOT

SPECIFIED. FAILURE TO COMPLY COULD RESULT IN SEVERE PERSONAL INJURY, DEATH OR SUBSTAN- TIAL PROPERTY DAMAGE.

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Control Module Fuses

7. Re-install the control module cover, electrical connectors and the front jacket panel when completed.

8. Reconnect the external power supply to the boiler and perform the verification of operation steps as outline in the Esteem 399 Low NOx Installation Manual.

WARNING

AFTER COMPLETING ANY SERVICING OF THE BOILER VERIFY PROPER OPERATION OF THE BOILER.

TEPS TO VERIFY PROPER OPERATION ARE OUTLINED IN THE START-UP PROCEDURES IN THE ES-

TEEM 399 LOW NOX BOILER INSTALLATION AND MAINTENANCE MANUAL. FAILURE TO COMPLY COULD RESULT IN SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

Control Module

120V-High Voltage

Electrical Quick

Connect

F1 Fuse Rating

5 - AMP/250V

Fast Acting

for 120V-High Voltage

F3 Fuse Rating

4 - AMP/250V

Slow Acting

for 24V-Low Voltage

Figure 27: Fig. 1 Control Module Fuse Locations (Housing Cover Removed)

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Boiler Control Module Display Messages

Display shows a number of 1 to 8 for the first digit on the left followed by 2 or 3 digits (boiler temperature)

The boiler is in normal operating mode.

Display is blank

• Check for 120 volts at terminals L and N of the 120V terminal strip

• If no power is measured check the external power supply, external fuse or breaker.

• Check the internal fuse F1 by locating the control module and removing the black housing. The internal fuse F1 is located in the right corner of the control module near the 120V high voltage electrical connector on the control as shown in Figure 27 on page 71. See “Control Module Fuses” on page 70, for accessing the internal fuses of the control module.

• Disconnect electrical supply power to the boiler and remove the F1 fuse from the MCBA. Check continuity across the fuse. If continuity is not present, the fuse has blown, replace the fuse with a 5 amp/250V fast acting fuse. Check the wiring for possible causes for the fuse to blow.(shorted wiring to circulator)

• Check external wiring at 120V terminal strip and boiler internal wiring, ensure all wiring is properly connected, in good condition and all control module and boiler connections are secure.

• Correct/replace any mis-wiring or wiring components if needed. If problem continues replace the control module.

Display shows UI.25 or UI.22

• Check transformer connections

• Check the internal fuse F3 by locating the control module and removing the black housing. The internal fuse F3 is located in the center of the control module as shown in Figure 27 on page 71. See “Control Module Fuses” on page 70, for accessing the internal fuses of the control module.

• Disconnect electrical supply power to the boiler and remove the F3 fuse from the MCBA.

• Check continuity across the fuse. If continuity is not present, the fuse has blown.

• • If fuse F3 has blown, replace the fuse with a 4-amp/250V slow acting fuse. Check external boiler wiring for external source of 24V feedback.

Display shows a 0 for the first digit on the left followed by 2 or 3 digits (boiler temperature)

• Check to see if room and DHW thermostats are satisﬁ ed.

• If the thermostats are satisﬁ ed the boiler is off due to no call for heat. Turn up a thermostat and the boiler should begin ignition sequence.

• If the room thermostat or DHW thermostat is calling for heat and the boiler is not ﬁ ring and the boiler is below the maximum operating temperature.

• Check and verify Parameters 2 and 3 are correct as outlined on page 6. Both parameters should be set as “01”, which turns DHW and CH modes ON.

Temporarily jump low voltage terminals 7 and 8 on the 24V terminal strip. If boiler operates check the room thermostat wiring and thermostat control. Replace as needed. Remove jumper when completed.

• Temporarily jump low voltage terminals 11 and 12 on the 24V terminal strip. If boiler operates

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Boiler Control Module Display Messages

check the DHW thermostat wiring and thermostat control. Replace as needed. Remove jumper when completed.

• Disconnect power to the boiler. Check all wiring and wiring connections and compare to the wiring diagram. Ensure all wiring and wiring connection are in good condition and secure. If necessary, replace complete wiring harness.

• Check for 24 volts across the control module internal fuse F3, which is located toward the middle of the control see Figure 27 on page 71.. If necessary replace the fuse. See “Control Module Fuses” on page 70, for accessing the internal fuses of the control module.

• Check Item 6 in the INFO mode. If Item 6 shows a reading of 32, remove the air inlet tube from venturi on the Blower/Burner Assembly. Looking into the inlet of the venturi, check for any rotation of the blower impeller. If the blower impeller is rotating, replace the blower.

• If all the above steps fail to resolve the problem, replace the control module.

Boiler Display shows FUSE

• Check and ensure the transformer is properly connected to the MCBA module.

• Check and ensure 24V are measured at the transformer when properly connected to the MCBA module. If necessary, replace the transformer.

• Check the internal fuse F3 by locating the control module and removing the black housing. The internal fuse F3 is located in the center of the control module as shown in Fig. 1 page 4.

• See “Control Module Fuses” on page 70, for accessing the internal fuses of the control module.

• If fuse F3 has blown, replace the fuse with a 4-amp/250V slow acting fuse. Check external boiler wiring for external source of 24V feedback.

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Page 80

tions given in the installation instructions or other approved design configuration.

• Verify the boiler and heating system are filled with water and LWCO is operating properly.

• Ensure the boiler and system have been properly purged & there is no trapped air.

• Inspect heating system piping and components. Ensure piping is per the recommenda-

Occurs if heat load demand is less than the low input-firing rate.

High Temperature Limit,

Boiler Supply,

If the primary boiler sup-

ply water temperature

• Ensure system and/or zone circulators are operating properly

exceeds 200ºF, the burn-

er shuts down until the

measured temperature with the display temperature (See page 52.)

• Replace supply temperature sensor if temperature comparison is off by more than 10ºF.

• Use a device to measure the supply water temperature leaving the boiler. Compare the

supply temperature drops

below 200ºF. Circulator

• Verify the boiler and heating system are filled with water and LWCO is operating properly.

• Ensure boiler and heating system have been properly purged and there is no trapped air.

continues operating.

High Temperature Limit,

Boiler Return

the installation instructions or other approved design configuration

• Inspect heating system piping and its components. Ensure piping is per recommendations in

If primary boiler return

• Ensure the boiler piping is correct and water flow is not reversed nor pipes cross connected.

water temperature

exceeds 200ºF, the burn-

measured temperature with the display temperature (See page 52.)

• Replace return temperature sensor if temperature comparison is off by more than 10ºF.

• Use a device to measure the return water temperature entering the boiler. Compare this

er shuts down until the

return temperature drops

below 200ºF. Circulator

continues operating.

• Boiler and heating system are filled with water and the LWCO is operating properly.

• Boiler and heating system have been properly purged and there is no trapped air.

• Check the following:

High Temperature Limit,

Boiler Supply and Return

If the primary boiler

tions given in the installation instructions or other approved design configuration

measured temperature with the temperature displayed at controller (See page 52.)

• Inspect heating system piping and its components. Ensure piping is per the recommenda-

return water temperature

• Boiler piping is correct and the water flow is not reversed nor pipes cross connected.

exceeds the boiler supply

temperature, the burner

sured temperature with the temperature

• Replace supply temperature sensor if temperature comparison is off by more than 10ºF.

• Use a device to measure the supply water temperature leaving the boiler. Compare mea-

will shut down until the

boiler return temperature

drops below the boiler

supply temperature. The

• Replace return temperature sensor if the temperatures are off by more than 10ºF.

• Use a device to measure the return water temperature entering the boiler. Compare this

boiler circulator will con-

tinue operating.

b 18

The boiler will display Soft Lockouts with a flashing “9”, then “b” as the first digit on the left of the display followed by a steady two digit

code. Boiler will automatically reset a Soft Lockout once the condition has been corrected and unit has been returned to standard oper-

Soft Lockout Error Codes

74 GF-125

ating condition.

b 19

b 24

Page 81

sured, check circulator wiring and connections.

• Boiler and heating system are filled with water and the LWCO is operating properly.

• Boiler and heating system have been properly purged and there is no trapped air.

• Occurs if the flow rate on the boiler is too low. Check the following:

High Temperature Limit,

Boiler Supply

If the primary boiler

tions given in the installation instructions or other approved design configuration

for pump curves and boiler pressure drop. Consult the circulator manufacturer for additional pump

curve data or for assistance in sizing a circulator properly.

• Inspect heating system piping and its components. Ensure piping is per the recommenda-

supply water tempera-

• Pump is properly sized for flow rate required based on the head loss of the system. See page 91

ture rate of increase is

deemed too quick, the

burner will shut down for

a 3 minutes If the condi-

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Boiler space heating circulator is operating properly.

tion is not corrected dur-

ing the next cycle, the

burner shut down period

b 25

Check circulator wire harness from the boiler to the circulator if necessary.

• Verify 120V at the 120V terminal strip along terminals 1 and 2 inside the boiler enclosure.

will increase an additional

minute. The boiler will

continue for 5 cycles until

sured, check circulator wiring and connections.

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Verify the external DHW circulator is operating properly.

a “hard” lockout occurs.

Check circulator wire harness from the boiler to the circulator. Replace if necessary.

• Verify 120V at the 120V terminal strip, terminals 4 and 5 inside the boiler enclosure.

• Ensure proper operation of the boiler make up system and fill valve.

• Check the pressure gauge on the boiler and ensure the system is at minimum 10 psig.

LWCO Device

• Check continuity across the LWCO terminals for closed contacts if the boiler system pres-

If Control module deter-

mines LWCO device is

b 26

sure is 10 psig or greater.

ity check shows a close circuit.

sure gauge reads 10 psig or greater.

• Replace the LWCO device if the continuity shows an open circuit and the system pres-

open boiler will shut

down until the condition

• Check the wiring and contacts from the LWCO to Control module terminals if the continu-

is corrected. Once cor-

rected the boiler will re-

start after 150 seconds.

the connector between the black and white wires (pin 1 & 5).

• Disconnect the connector at the blower. Restart the boiler sequence and check for 35Vdc at

Blower Assembly

Occurs if the blower

b 28

a secure connection. Replace the blower assembly if problem is not resolved.

• If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure

ness, if there is any damage visible

• If 35Vdc is not present at the connector, inspect the wiring harness. Replace the wire har-

• Contact AERCO International Technical Support if problem is not resolved.

5 during the ignition

does not start. during

the ignition sequence.

Boiler display will show

code

sequence.

GF-125

Page 82

erly.

ing schematic, page 27 and 28.

• Verify the wiring from the blower to Control module is correct as shown in the appliance wir-

Blower Assembly

• Contact AERCO International Technical Support if problem is not resolved.

Control module detects

unwarranted blower oper-

ation.

• Verify the boiler and heating system are filled with water and the LWCO is operating prop-

• Occurs if the flow rate and demand on the boiler is too low. Check the following:

High Temperature Limit,

Boiler Supply and Return

Temperature Differential

entrapped air.

ommendations given in this Installation Manual or per other approved/recognized designed

configurations.

• Ensure the boiler and heating system have been properly purged and there is no

is greater than 72ºF

• Inspect and verify heating system piping and its components. Ensure piping is per the rec-

Temperature difference

between the supply and

the return sides of the

primary boiler water is

tor.

• Ensure the piping system pressure drop is within the flow rate parameters of the circula-

greater than 72ºF, the

burner shuts down for

180 seconds. The circula-

sured, check circulator wiring and connections.

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Verify the boiler space heating circulator is operating properly.

tor continues running until

the start of the next cycle.

Check circulator wire harness if voltage is measured at Control module.

• Verify 120V at the 120V Terminal strip terminals 1 and 2 inside the boiler enclosure.

If the condition is not cor-

rected during the next

cycle, the burner shut

sured, check circulator wiring and connections.

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Verify the external DHW circulator is operating properly.

down period will increase

by an additional minute.

sure. Check circulator wire harness and replace if needed if voltage is measured at

Control module.

• Verify 120V at the 120V terminal strip between terminals 4 and 5 inside the boiler enclo Burner will remain off until the condition is corrected.

The boiler will continue

for 15 cycles until a “hard

“ lockout will occur.

Indirect Water Heater

Application Supplement GF-125C for proper selection.

• Review parameter setting for DHW operating signal selection. See the Esteem Control

Temperature Sensor

Control module detects a

• Replace the sensor if problem persists.

• Inspect the DHW temperature sensor and wiring, ensure it is secure and in good condition.

short of the indirect water

heater temperature sen-

Will also appear briefly prior to a hard lockout if the flue gas temperature exceeds 250ºF. The

sor.

Flue Temperature Sensor

burner will remain off until the condition is corrected.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

Control module detects a

short of the flue tempera-

ture sensor.

b 29

76 GF-125

b 30

b 33

b 35

Page 83

Supplement GF-125C for proper selection.

• Review parameter setting for DHW operating signal selection. See Esteem Control

Typically an improper or missing connection of the sensor.

Indirect Water Heater

Temperature Sensor

b 38

• Replace the sensor if problem persists.

• Inspect the DHW temperature sensor and wiring, ensure it is secure and in good condition.

Control module detects

“open” indirect water

heater temperature sen-

Typically an improper or missing connection at the sensor.

sor.

Flue Temperature Sensor

• Replace the sensor if problem persists.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

Control module detects

“open” flue temperature

sensor.

b 40

on cleaning.

• An indication the heat exchanger flue ways may need cleaning. See page 68 for procedures

Flue Temperature Sensor

b 52

the boiler heat exchanger several times, checking the discharge water for signs of scale or

sediment.

• Isolate the boiler from the boiler system piping and drain the boiler heat exchanger. Flush

Control module detects

flue temperature greater

than 241ºF, less than

250ºF. Burner off for 150

replace as needed.

• Replace the sensor if problem persists.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition,

seconds

• Disconnect the 35Vdc connector at the blower. Restart the boiler sequence and check for

Blower Assembly

b 65

a secure connection. Replace the blower assembly if problem is not resolved.

harness if the inspection reveals any signs of damage.

35Vdc at the connector between the black and white wires (pin 1 & 5).

• If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure

• If 135Vdc is not present at the connector, inspect the wiring harness. Replace the wire

Control module does

not detect proper blower

operation during a call for

heat.

• Contact AERCO International Technical Support if problem is not resolved

frequency supplied and adjust accordingly.

• If the incoming voltage is being supplied by a generator or alternative source, check the

Control module requires an incoming voltage of 120V and a frequency of 60 Hz.

Incoming Voltage

Frequency

Inadequate power to con-

b 116

- Contact AERCO International Technical Support for further assistance.

trol module

Flame Current Signal

Lost

b 118

GF-125

Page 84

propane orifice is properly seated in the gas valve gasket.

pattern and combustion should be tested at both high fire and low fire inputs. See page 49

regarding high and low fire input procedures. See Table 2 on page 43 for combustion require-

ments.

• If the application is propane, verify the propane orifice size is 0.264” (6.7mm). Ensure the

• This problem maybe related to the burner operating too hot due to poor combustion. Flame

Flame Detection

Error

Control module

detects a burner

• Inspect the burner head through the burner sight port during shut down sequence of the

flame prior to the igni-

tion sequence.

gas pressure is less than 13 inches w.c. If the gas pressure is less than 13 inches w.c.,

replace the gas valve.

boiler.

• If the flame remains after shut down sequence, the gas valve maybe leaking. Verify the The lockout will occur after 5 tries.

Failed Ignition Error

cable if damaged.

• Check ignition electrode cable, electrode boot connector and all connections. Replace

• No ignition spark during the ignition sequence:

Boiler has failed to

establish flame detec-

tion during the igni-

burner mounting plate.

• Inspect insulation of electrode cable and electrode igniter. Replace as needed.

• Use a ground continuity check to verify a good ground between Control module ground &

tion sequence.

• Verify the manual shutoff valve on the gas supply piping is in the OPEN position.

• Spark present during the ignition sequence, but no flame:

pressure maintains a minimum 5 inches w.c during ignition sequence. Note: All gas appli-

ances within the building should be operating during this measurement.

• Verify the gas pressure at the inlet of the valve during ignition sequence. Ensure the gas

• Verify all gas piping is free of obstructions and has been purged of all air.

• Check the gas meter for indications of gas flow during the ignition sequence.

• Remove the ignition electrode to inspect. Replace the electrode if fouled or damaged.

• Replace the gas valve rectifier cable.

• Remove and inspect gas valve and venturi gas ports. Ensure ports are obstruction free.

• Contact AERCO International Technical Support for additional assistance.

E-00

Hard Lockout Codes

The boiler will display a Hard Lockout with an E as the first digit on the left of display followed by a two-digit code. The boiler must be

manually reset by pressing the RESET button on the display once the condition has been corrected. A Hard Lockout will occur when

78 GF-125

boiler conditions, that are considered critical in terms of safety, are not met or exceeded.

E 02

Page 85

er mounting plate. Use a ground continuity check to verify a good ground.

Inspect and clean the burner head. Replace the burner head if damaged.

flame signal detection by Control module.

• Inspect flame pattern on the burner head during high and low fire inputs (See page 49).

• Flame is established during the ignition sequence, but not maintained. May be due to low

Failed Ignition Error

Boiler has failed to

establish flame detec-

measured rate is not at or below 15% of the boiler rating, replace the gas valve.

• Note: Length of venting and combustion air piping will affect the measure boiler rating.

• Check the ground lead for a secure connection from Control module ground to the burn-

• Check the input rate of the boiler at the gas meter during high fire input. If the gas meter

tion during the igni-

tion sequence.

E 02

Continued

Replace the electrode if damaged or will not clean.

• Remove the ignition electrode. Inspect for damage. Clean white oxides off the electrode. continues, replace the rectifier cable.

• Reset the boiler control module and retry ignition sequence and boiler operation. If problem

Gas Valve Harness • Ensure gas valve rectifier cable is properly connected to the gas valve and secured.

E 03

OFF and then ON as an attempt to reset the boiler.

The boiler must be manually reset and the original lockout code will be lost.

• Will also occur if the service technician tries to reset a hard lockout by turning the boiler

• Verify polarity and proper ground on incoming 120V power connections

Loss of Power

Power to the boiler

is lost after a lockout

E 04

available and may be installed on the incoming voltage to the boiler.

• May occur in rare cases if there is power interruption, surge or “Dirty” voltage. A relay kit is

has occurred.

• Check flat ribbon cable to display for short.

• Check for moisture at display and repair cause of moisture, dry and/or replace display.

• Inspect ignition cable replace if necessary.

• Reset the boiler control module and retry ignition sequence and boiler operation.

Internal Failure

Short in either the

ignition cable or dis-

E 05

tance.

• If problem continues, contact AERCO International Technical Support for additional assis-

play panel.

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If problem

E 06

E 07

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If problem

E 08

GF-125

Page 86

minals 13 and 14.

continues, contact AERCO International Technical Support for additional assistance.

• If no external limit is used, then Verify connection of the factory applied jumper across ter-

Determine reason for the limit to be open and correct condition.

replace if necessary.

• If the external limit is closed, check the boiler internal wiring connections and repair or

verify operation.

• Remove the external limit and apply a temporary jumper across terminals 13 and 14 and

lem continues, contact AERCO International Technical Support for additional assistance.

• Isolate the IDWH aquastat from the boiler terminals 11 and 12 using an isolation relay.

• Replace the aquastat using AERCO International’s PSRKIT22, IDWH Sensor Kit.

Most applications experiencing E-14 have a Honeywell L4000 series aquastat in an Indirect

Domestic Water Heater system. If an L4000 aquastat is present, it must be replaced.

• Ensure the wiring is shielded cable.

• Check the wiring of the outdoor sensor

and 18 in the boiler enclosure.

• Check for feedback of voltage to terminals 7 and 8, terminals 11 and 12 and terminals 17

• Remove all field wiring from the boiler’s and reset the boiler control module.

nals 7 and 8 (space heating) and terminals 11 and 12 (DHW heating).

• Initiate a call for heat external to the boiler and check for voltage on field wiring to termi-

the voltage to the boiler is a dedicated line and there is no drop in voltage at any time.

• Check for the line voltage being supplied to the boiler for polarity and for 120 VAC. Ensure

present use a hair dryer or some other means to dry the terminals trip.

• Check moisture on and around the low voltage terminal strip of the boiler. If moisture is

• If moisture is present in the boiler, check for possible moisture on the display. If there are

signs of moisture or corrosion, resolve the moisture issue and replace the display panel.

Reset the boiler control module and retry ignition sequence and boiler operation. If problem

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If problem

E.09

External Limit

Lockout

E 11

E 12

An external limit con-

trol at the 24V ter-

minal strip, between

terminals 13 and 14

is open, breaking the

circuit.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If prob-

E 13

Low Voltage Internal

Short or Voltage

Feedback

Short or voltage

feedback in the 24V

circuit.

E 14

80 GF-125

Page 87

tions given in this Installation Manual or other approved design configurations.

• The boiler and heating system are filled with water and the LWCO is operating properly.

• The boiler and heating system have been properly purged and there is no trapped air.

• Inspect heating system piping and its components. Ensure piping is per the recommenda-

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure Reset the boiler control module and retry ignition sequence and boiler operation. If problem

E 15

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure Reset the boiler control module and retry ignition sequence and boiler operation. If problem

E 16

continues, contact AERCO International Technical Support for additional assistance.

• Check the following.

Internal Failure Reset the boiler control module and retry ignition sequence and boiler operation. If problem

High Temperature

Limit, Supply

Temperature

E 17

E 18

Boiler supply water

measured temperature with the display temperature (See page 52.)

• Replace supply temperature sensor if temperature comparison is off by more than 10ºF.

• Use a device to measure the supply water temperature leaving the boiler. Compare this

temperature exceeds

212ºF.

• The boiler and heating system are filled with water and the LWCO is operating properly.

• The boiler and heating system have been properly purged and there is no trapped air.

Check the following:

High Temperature

Limit, Return

Temperature

E 19

tions given in this manual or other approved design configurations.

• Inspect heating system piping and its components. Ensure piping is per the recommenda-

• Ensure boiler piping is correct and water flow is not reversed nor pipes cross-connected.

Boiler return water

temperature exceeds

212ºF.

measured temperature with the display temperature (See page 52.)

• Replace return temperature sensor if temperature comparison is off by more than 10ºF.

• Use a device to measure the return water temperature leaving the boiler. Compare this

voltage is supplied from “OFF-GRID” source, check conditions.

Check the following:

• Line voltage to the boiler for polarity and 120VAC. Ensure the boiler is on a dedicated line. If

• Moisture on and around the low voltage terminal strip on the boiler. Resolve moisture issue.

• Moisture on the display. Resolve moisture issue and replace the display panel.

Low Voltage Internal

Short or Voltage

Feedback

Short or voltage

• Remove all field wiring from the boiler and reset the boiler control module.

• Voltage feedback to Terminals 7 and 8, Terminals 11 and 12, and Terminals 17 and 18.

feedback in the 24V

circuit.

nals 7 and 8 (space heating) and terminals 11 and 12 (DHW heating).

• Initiate a call for heat external to the boiler and check for voltage on field wiring to termi-

E 24

continues, contact AERCO International Technical Support for additional assistance.

• Reset the boiler control module and retry ignition sequence and boiler operation. If problem

GF-125

Page 88

tions given in this manual or other approved design configuration.

• Boiler and heating system are filled with water and the LWCO is operating properly.

• Boiler and heating system have been properly purged and there is no trapped air.

• Inspect heating system piping and components. Ensure piping is per the recommenda-

Flow rate and demand load on the boiler are too low. Check for the following:

boiler pressure drops. Consult the circulator manufacturer for additional pump curve data or

assistance in sizing a circulator.

• Verify pump is properly sized for the flow rate required. See page 91 for pump curves and

• Verify the boiler space heating circulator operation.

sured, check wiring and connections.

Check circulator wire harness. Replace if needed, if voltage is measured at Control mod-

ule.

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Verify 120V between terminals 1 and 2 at the terminal strip inside the boiler enclosure.

sured, check circulator wiring and connections.

• Verify 120V at the circulator wiring in the circulator junction box. If no voltage is mea-

• Verify the external DHW circulator operation.

Check circulator wire harness. Replace if needed, if voltage is measured at Control mod-

ule.

• Verify 120V between terminals 4 and 5 at the terminal strip inside the boiler enclosure. Display indicates status code 5 during ignition sequence for 4 minutes before lock out.

• Disconnect the connector at the blower. Restart the boiler sequence and check for 35Vdc at

sary. Replace Control module if wire harness replacement does not resolve the problem.

the connector between the black and white wires (pin 1& 5).

• If 35Vdc is not present at the connector, inspect the wiring harness and replace if neces-

a secure connection. If problem is not resolved, contact AERCO International Technical

Support for additional assistance.

• If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure

b 25

and start a recycle

sequence. After 5

High Temperature

Limit, Supply

Temperature Rate of

Increase

Supply water temper-

ature rate of increase

is too rapid

Control module

will display

cycles a hard lockout.

Blower Assembly

Occurs if blower does

not start during igni-

tion sequence.

the replacement of the wiring harness does not resolve the problem. If problem is not

resolved, contact AERCO International Technical Support for additional assistance.

ing schematic, pages 27-28.

• Replace the wiring harness from Control module to the blower. Replace the blower if

• Verify the wiring from the blower to Control module is correct as shown in the appliance wir-

Blower Assembly Control module is detecting the blower in operation when it should not be.

E 25

82 GF-125

E 28

E 29

Page 89

the boiler heat exchanger several times, checking the discharge water for signs of scale

or sediment.

cleaning the flue side of the heat exchanger.

condition, replace as needed.

• Replace the sensor and wiring if problem persists.

Control module detects a short or jumped out condition of the boiler supply (outlet) temperature

sensor.

• Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good

Boiler Supply

Temperature Sensor

E 31

Control module detects a short or jumped out condition of the boiler return (inlet) temperature

sensor.

Boiler Return

Temperature Sensor

E 32

dition, replace as needed.

• Replace the sensor and wiring if problem persists.

• Inspect the boiler return temperature sensor and wiring, ensure it is secure and in good con-

Control module detects a short or jumped out condition of flue temperature sensor.

• Replace the sensor and wiring if problem persists.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

Control module detects the boiler supply (outlet) temperature sensor as an open circuit.

Flue Temperature

condition, replace as needed.

• Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good

Sensor

Control module detects the boiler return (inlet) temperature sensor as an open circuit.

Boiler Supply

E 35

dition, replace as needed.

• Inspect the boiler return temperature sensor and wiring, ensure it is secure and in good con-

Temperature Sensor

E 36

Control module detects the flue temperature sensor as “open”, which is typically an improper or

missing connexion at the sensor.

Boiler Return

Temperature sensor

E 37

• Replace the sensor if problem persists.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

continues, contact AERCO International Technical Support for additional assistance.

• Reset the boiler control module and retry ignition sequence and boiler operation. If problem

Flue Temperature

Sensor

E 40

• Isolate the boiler from the boiler system piping and drain the boiler heat exchanger. Flush

• Heat exchanger flue ways may need cleaning. See Chapter 18 Maintenance Procedures for

Internal Failure

Control module

detects the flue tem-

perature exceeding

E 44

replace as needed.

• Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition,

the boiler.

the 250ºF limitation of

GF-125

Page 90

a secure connection. Replace the blower assembly if problem is not resolved.

continues, contact AERCO International Technical Support for additional assistance.

• Reset the boiler control module and retry ignition sequence and boiler operation. If problem

Flue Temperature

Sensor

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If problem

continues, contact AERCO International Technical Support for additional assistance.

Internal Failure • Reset the boiler control module and retry ignition sequence and boiler operation. If problem

35Vdc at the connector between the black and white wires (pin 1 & 5).

• If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure

• Disconnect the 35V dc connector at the blower. Restart the boiler sequence and check for

Blower Assembly Control module does not detect proper blower operation during a call for heat.

of damage. If the wire harness inspection does not resolve the problem, contact AERCO

International Technical Support for additional assistance.

• If 35Vdc is not present at the connector, inspect the wiring harness for any visible signs

E 52

84 GF-125

E 60

E 61

E 65

Please have the unit’s model number and the serial number from the rating label on the backside of the control panel when calling

about service or troubleshooting.

Telephone Support

(800) 526-0288

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through Friday)

Model #_________________________

Serial #__________________________

Page 91

Appendices

Appendix A: Replacement Parts

Figure 28: Esteem 399 Low NOx Jacket Components

Item Part # Description

1 38027 Display Control Panel

2 34028 Base Panel

3 37051 Front Jacket Panel

5 37052 Side Jacket Panel (Left and Right)

6 37053 Top Jacket Panel

7 37054 Top Jacket Access Panel

8 37055 Control Cover Panel

9 33113 Wall Mounting Bracket with 1 Hardware

38028 (Left)

38029 (Right)

Display Control Panel Extensions (Not Shown)

GF-125

Page 92

Figure 29: Esteem 399 Low NOx Internal Components

Item Part # Description

1 28191 Heat Exchanger Body 2 38030 Vent Outlet Adapter 3 38031 Combustion Air Inlet Adapter 4 61022 Supply & Return NTC Sensor (NTC1, NTC2) 5 61023 Flue NTC Sensor (NTC5) 6 60013 LWCO Pressure Device 7 22123 Condensate Drain Assembly 8 22124 Boiler Piping - Return Assembly 9 22125 Boiler Piping - Supply Assembly

10 67003 Pressure Gauge and Fitting

GF-125

Page 93

Figure 30: Esteem 399 Low NOx Burner Components

Item Part # Description

1 83025 Combustion Chamber Insulation 2 24230 Burner Head with Gasket 3 36059 Burner Plate 4 58026 Blower with Gasket 5 92078 Gas Valve 6 -- Venturi 7 63086 Ignition Cable 8 58027 Igniter with Gasket

9 58028 Sight Glass Assembly (Glass, Gasket and Bracket) 10 -- Propane Orifice - Not Shown 11 -- Burner Plate Gasket - Not Shown 12 22126 Gas Valve Piping 13 22127 Gas Supply Piping

GF-125

Page 94

Figure 31: Esteem 399 Low NOx Electronic Components

Item Part # Description

1 64061 Esteem 399 Low NOx Control Module

2 64062 Transformer with Surge Protection

3 64063 Esteem 399 Low NOx Control Module Display

Appendix B: Unit Speciﬁ cations

Fuel Natural Gas

Input

Output

Net IBR Rating Combustion Efficiency 94.1% Thermal Efficiency 95.1% Shipping Weight 225 lbs./ 102 Kg

Esteem 399 Low NOx output rating is based on the thermal efficiency.

399,000 379,000 330,000

1. Input and output ratings are shown for sea level applications. The Esteem 399 Low NOx automatically derates the input at approximately 2% for every 1,000 Ft. of altitude. No alterations to the boiler or burner system is required.

2. The IBR rating is based on a piping and pick up allowance of 1.15. This allowance should be sufficient for the standard radiation requirements for a building load.

GF-125

Page 95

Appendix B: Unit Speciﬁ cations

Figure 32: Front View Esteem 399 Low NOx

GF-125

Page 96

Appendix B: Unit Specifications

Figure 33: Side View Esteem 399 Low NOx

GF-125

Page 97

Appendix C: Pressure Drop Comparison Tables

Graph 3: Pressure Loss Through Boiler - Grundfos Circulators

Graph 2: Pressure Loss Through Boiler - Taco Circulators

• Note: Minimum allowable ﬂ ow rate at full input: 19 gpm

GF-125

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AERCO Esteem 399 Installation and Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual