AERCO Esteem 399 User Manual
Instruction
No.
AERCO INTERNATIONAL, Inc. Northvale, New Jersey, 07647 USA
User’s
Manual
Esteem 399
GF-125U
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
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
© AERCO International, Inc., 2010
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.
Contents—GF-125U
Warnings and Cautions 1
Emergency Shutdown 2
Prolonged Shutdown 2
Boiler & System Water 2
Chapter 1 Combustion Air 3
Prevention of Contamination 3
Potential Contaminating Products 3
Areas likely to have these products 3
Chapter 2 Maintenance Schedule 4
For the Service Technician 4
For the End User 4
Chapter 3 Maintenance Procedures 5
Daily Maintenance 5
Monthly Maintenance 6
Every 6 Months Maintenance 7
Contents
Chapter 4 Operating Instructions 9
Safety 9
TO TURN OFF GAS TO APPLIANCE 10
Operation 10
Standby Mode 11
Chapter 5 BOILER CONTROL DISPLAY 11
Setting Boiler Parameters 12
Accessing Boiler Information 13
Error (Hard Lockout) Mode 14
Boiler Freeze Protection Feature 14
Appendix A: Replacement Parts 15
Jacket Components 15
Internal Components 16
Burner Components 17
Electronic Components 18
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 maintained in
legible condition. It must be given 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-
B
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.
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.
GF-125U
1
Emergency Shutdown
CAUTION!
DO NOT use this boiler if any part
has been under water. Call a qualifi ed
service technician to inspect and replace any part that has been under-
water.
IMPORTANT
The Installer must identify and indicate the location of the emergency
shutdown manual gas valve to operating personnel.
Emergency Shutdown
If overheating occurs or the gas supply fails
to shut off, DO NOT turn off or disconnect
the electrical supply to the pump. Close the
manual gas shutoff valve (Figure 1) located
external to the unit.
Prolonged Shutdown
After prolonged shutdown, the startup procedures in the Installation and Maintenance
Manual should be followed, to verify all system operating parameters.
Boiler & System Water
• Have the boiler and system water chemistry checked at least annually by a qualified
service technician.
• Do not use petroleum-based cleaning or
sealing compounds in the boiler or system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
• Do not use any product not specifically
designed for boiler / hydronic heating systems. Serious damage to the unit, piping
system, personnel and / or property may
result.
• Continual fresh makeup water will reduce
the life of the Esteem. Addition of oxygen
can cause internal corrosion in the system
components. All leaks in the piping system must be repaired at once to prevent
makeup water.
• Do not add cold water to a hot unit.
Thermal shock can cause premature failure to the boiler heat exchanger.
To shut Down the Unit
Operating Cautions
• Do not block flow of combustion air. If
a blockage should occur and is easily accessible and removable, remove
it. If blockage is not obvious or cannot
be removed, have the unit and system
checked by a qualified service technician.
• Do not allow contaminated air to enter
the unit’s combustion air inlet. See page
3 for details.
• The Esteem is equipped with a low
water cutoff device (LWCO). The boiler
and system piping must be filled and
pressurized to 12 psig prior to startup.
The unit will shut down if the pressure
falls below 10 psig.
Turn the external manual gas valve handle
clockwise to “CLOSE”.
Figure 1: Typical Manual Gas Shutoff Valve
2
GF-125U
Prevention of Contamination
Chapter 1 Combustion Air
Prevention of Contamination
WARNING!
IF THE ESTEEM COMBUSTION AIR INLET IS
LOCATED IN ANY AREA LIKELY TO CAUSE OR
CONTAIN CONTAMINATION, OR IF PRODUCTS,
WHICH WOULD CONTAMINATE THE AIR CAN-
NOT BE REMOVED, THE COMBUSTION AIR
MUST BE RE-PIPED AND TERMINATED TO AN-
OTHER LOCATION. CONTAMINATED COMBUS-
TION AIR WILL DAMAGE THE UNIT AND ITS
BURNER SYSTEM, RESULTING IN POSSIBLE
SEVERE PERSONAL INJURY, DEATH OR SUB-
STANTIAL PROPERTY DAMAGE.
ARNING!DO NOT OPERATE A ESTEEM UNIT
W
IF ITS COMBUSTION AIR INLET OR THE UNIT IS
LOCATED IN OR NEAR A LAUNDRY ROOM OR
POOL FACILITY. THESE AREAS WILL ALWAYS
CONTAIN HAZARDOUS CONTAMINATES.
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 following information. If contaminating chemicals will be present near
the location of the combustion air inlet, the
installer should pipe the combustion air inlet
to another location per the Esteem installation manual.
Potential Contaminating Products
• Spray cans containing chloro/fluorocarbons
• Permanent wave solutions
• Chlorinated wax
• Chlorine - based swimming pool chemicals and spa cleaners
• Calcium chloride used for thawing ice
• Sodium chloride used 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 found in household
laundry rooms
• Adhesives used to fasten building products and other similar products
Areas likely to have these
products
• 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 refinishing areas and establishments
• New building construction
• Remodeling areas
• Garages and workshops
GF-125U
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.
3
For the Service Technician
Chapter 2 Maintenance Schedule
For the Service Technician
On an annual basis, or more frequently if
conditions warrant, 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 trap and fill with
fresh water.
• Check for leaks: water, gas, flue and
condensate.
• Verify flue vent piping and air inlet piping
are in good condition and sealed tight.
• 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 flame pattern (stable and
uniform).
Additional items if combustion or performance is poor:
For the End User
• Ongoing, as local conditions warrant.
• Check the area around the unit.
• Check and remove any blockage from
the combustion air inlet and ventilation
openings.
• Check the temperature/pressure gauge.
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!
FOLLOW THE MAINTENANCE PROCEDURES
GIVEN THROUGHOUT THIS MANUAL. FAILURE
TO PERFORM THE SERVICE AND MAINTENANCE
OR FOLLOW THE DIRECTIONS IN THIS MANUAL
COULD RESULT IN DAMAGE TO THE ESTEEM
OR IN SYSTEM COMPONENTS, RESULTING IN
SEVERE PERSONAL INJURY, DEATH OR SUB-
STANTIAL PROPERTY DAMAGE.
• Clean heat exchanger and flue ways.
• Remove burner assembly and clean
burner head using compressed air only.
Once the maintenance items are completed,
review the service with the owner.
4
GF-125U
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