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Esteem 399 Low NOx
User Manual
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AERCO Esteem 399 Low NOx User Manual

Installation, Operation & Maintenance Manual (IOMM)
GF-135
OMM-0089_0A
USER MANUAL
Installation, Oper atio n and M ainte nan ce
Natural Gas or Propane Gas Modulating & Condensing Hot Water Boiler:
06/19/2014
Page 1 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
AERCO Document Conventions
NOTE
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
DISCLAIMER
The information contained in this manual 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 m erchantability 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 these materials.
AERCO Technical Support:
(Mon–Fri, 8am-5pm EST)
1 (800) 526-0288
In this document, some types of information are presented as shown in the following examples:
Message Type Example and Description
NOTES
CAUTIONS
WARNINGS
NOTE messages indicate specific information related to the
surrounding contextual information, and highlighted for special attention.
CAUTION!
CAUTION messages inform of pot ential probl em s rel ating to
the functioning of equipment, safety to persons, harm to the environm ent, and/or damage to property or equipm ent.
WARNING!
WARNING messages warn of potential dangerous situations
that may result in serious injury and/or death to persons or animals. Text is red within a red box.
How Instructions are Presented
1. Instructions are shown in a blue box with an underlined title.
2. All text, excepting in accompanying illustrations, is colored
INSTRUCTIONS
blue.
3. All procedures are listed in steps starting with “1.”, and using letters [a), b), c), etc.] to indicate sub-steps.
4. Steps that are continued on the next page have a “(Cont.)” append ed to the instruction title.
Page 2 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
CHAPTER 1: SAFETY PRECAUTIONS .............................................................................................. 9
1.1 WARNINGS & CAUTIONS ..................................................................................................................................... 9
1.2 EMERGENCY SHUTDOWN .................................................................................................................................. 10
1.3 PROLONGED SHUTDOWN .................................................................................................................................. 11
CHAPTER 2: INSTALLATION .......................................................................................................... 15
2.1 CODE COMPLIANCE ........................................................................................................................................... 15
2.2 DETERMINING PRODUCT LOCATION ................................................................................................................. 15
2.3 BOILER REPLACEMENT ....................................................................................................................................... 16
2.4 RECOMMENDED CLEARANCES .......................................................................................................................... 16
2.5 RESIDENTIAL GARAGE INSTALLATIONS .............................................................................................................. 17
2.6 BOILER FREEZE PROTECTION FEATURE.............................................................................................................. 17
CHAPTER 3: COMBUSTION AIR AND VENTING ............................................................................ 19
3.1 COMBUSTION AIR CONTAMINATION ................................................................................................................ 19
3.2 POTENTIAL CONTAMINATING PRODUCTS ......................................................................................................... 19
3.2.1 Areas Likely to Contain Contaminating Products ....................................................................................... 20
3.3 VENTILATION AND COMBUSTION AIR REQUIREMENTS - DIRECT VENT ............................................................ 20
3.4 VENTILATION AND COMBUSTION AIR REQUIREMENTS - CATEGORY IV ........................................................... 21
3.5 METHODS OF SUPPLYING COMBUSTION AIR TO A CONFINED SPACE - CATEGORY IV ...................................... 21
3.5.1 INDOOR COMBUSTION AIR......................................................................................................................... 22
3.5.2 OUTDOOR COMBUSTION AIR ..................................................................................................................... 23
3.5.2.1 Option 1: One Permanent Opening to Outside ................................................................................... 23
3.5.2.2 Option 2: Two Permanent Openings to Outside.................................................................................. 24
3.6 COMBINATION OF INDOOR AND OUTDOOR COMBUSTION AIR ....................................................................... 25
3.6.1 Outdoor Opening(s) Location ..................................................................................................................... 25
3.6.2 Outdoor Opening(s) Size ............................................................................................................................. 25
3.7 COMBUSTION AIR AND VENT PIPING ................................................................................................................ 25
3.8 REMOVAL OF AN EXISTING BOILER FROM A COMMON VENT SYSTEM .............................................................. 26
CHAPTER 4: UNIT PREPARATION.................................................................................................. 29
4.1 HANDLING INSTRUCTIONS................................................................................................................................. 29
4.2 WALL MOUNTING INSTALLATION...................................................................................................................... 29
4.3 WALL MOUNTING GUIDELINES.......................................................................................................................... 29
4.4 STUD WALL INSTALLATION ................................................................................................................................ 30
4.5 BOILER MOUNTING............................................................................................................................................ 30
CHAPTER 5: BOILER PIPING .......................................................................................................... 31
5.1 GENERAL PIPING REQUIREMENTS ..................................................................................................................... 31
5.2 PRESSURE RELIEF VALVE .................................................................................................................................... 31
5.3 BOILER AIR VENT................................................................................................................................................ 32
5.4 LOW WATER CUTOFF DEVICE ............................................................................................................................ 32
5.5 ADDITIONAL LIMIT CONTROL ............................................................................................................................ 33
5.6 BACKFLOW PREVENTER ..................................................................................................................................... 33
5.7 BOILER SYSTEM PIPING APPLICATIONS ............................................................................................................. 33
5.8 EXPANSION TANK AND MAKEUP WATER .......................................................................................................... 33
5.8.1 Diaphragm Expansion Tank ........................................................................................................................ 34
5.8.2 Closed-Type Expansion Tank ...................................................................................................................... 34
5.9 CIRCULATOR ...................................................................................................................................................... 34
5.10 SIZING PRIMARY PIPING .................................................................................................................................. 34
5.11 DOMESTIC HOT WATER SYSTEM PIPING ........................................................................................................ 34
Page 3 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
5.12 SYSTEM PIPING - ZONE CIRCULATORS ............................................................................................................. 34
5.13 SYSTEM PIPING - ZONE VALVES ....................................................................................................................... 35
5.14 SYSTEM PIPING - THROUGH BOILER ................................................................................................................ 35
5.15 SYSTEM PIPING - RADIANT HEATING ............................................................................................................... 35
5.16 SYSTEM PIPING—SPECIAL APPLICATIONS ....................................................................................................... 36
5.17 SYSTEM PIPING—MULTIPLE UNITS INSTALLATION ......................................................................................... 36
CHAPTER 6: INSTALLING VENT, AIR INTAKES, AND DRAIN ....................................................... 43
6.1 INSTALLING VENT AND COMBUSTION AIR INTAKE............................................................................................ 43
6.2 INSTALLING CONDENSATE DRAIN ASSEMBLY .................................................................................................... 43
CHAPTER 7: GAS PIPING ................................................................................................................ 45
7.1 GAS SUPPLY PIPING CONNECTION .................................................................................................................... 45
7.2 NATURAL GAS .................................................................................................................................................... 46
7.2.1 Pipe Sizing - Natural Gas ............................................................................................................................. 46
7.2.2 Natural Gas Supply Pressure Requirements ............................................................................................... 47
7.3 PROPANE GAS .................................................................................................................................................... 47
7.3.1 Pipe Sizing – Propane Gas ........................................................................................................................... 47
7.3.2 Propane Gas Supply Pressure Requirements.............................................................................................. 48
CHAPTER 8: INTE RNAL WIRING..................................................................................................... 51
8.1 GENERAL REQUIREMENTS ................................................................................................................................. 51
8.2 FUSE LOCATIONS ............................................................................................................................................... 51
8.2.1 EZ-SETUP Controller Module Fuses Location.............................................................................................. 51
8.2.2 Line Voltage Fuses Location ........................................................................................................................ 52
CHAPTER 9: EXTERNAL WIRING ................................................................................................... 55
9.1 INSTALLATION COMPLIANCE ............................................................................................................................. 55
9.2 LINE VOLTAGE CONNECTIONS ........................................................................................................................... 55
9.3 CIRCULATOR WIRING ......................................................................................................................................... 56
9.4 ALARM WIRING.................................................................................................................................................. 57
9.5 LOW VOLTAGE CONNECTIONS .......................................................................................................................... 57
9.6 THERMOSTAT WIRING ....................................................................................................................................... 57
9.7 OUTDOOR SENSOR WIRING ............................................................................................................................... 58
9.8 DOMESTIC HOT WATER WIRING ....................................................................................................................... 58
9.9 ADDITIONAL BOILER LIMITS ............................................................................................................................... 58
9.10 EXTERNAL MODULATION CONTROL ................................................................................................................ 58
9.11 SYSTEM SENSOR WIRING ................................................................................................................................. 58
9.12 CASCADE WIRING ............................................................................................................................................ 59
9.13 MODBUS WIRING ............................................................................................................................................ 59
CHAPTER 10: BASIC EZ-SET CONTROLLER OPERATION ........................................................... 65
10.1 EZ-SET CONTROLLER INTRODUCTION.............................................................................................................. 65
10.2 EZ-SET CONTROLLER FEATURES AND FUNCTIONS........................................................................................... 65
10.3 CONTROLLER NAVIGATION .............................................................................................................................. 66
10.4 HOME SCREEN ................................................................................................................................................. 68
10.5 MAIN MENU .................................................................................................................................................... 70
10.6 EZ SETUP ................................................................................................................................................... 71
10.7 HEATING EZ SETUP ............................................................................................................................... 71
10.7.1 Select CH Demand (Default: Switch & Outdoor Reset) ............................................................................ 71
10.7.2 CH1 Setpoint (Default: 180°F [82°C]) ........................................................................................................ 72
Page 4 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
10.7.3 CH2 Setpoint (Default: 140°F [60°C]) ........................................................................................................ 72
10.7.4 Select CH1 Reset Curve (Default: Finned Tube Baseboard) ...................................................................... 72
10.7.5 Select CH2 Reset Curve (Default: Low Mass Radiant) .............................................................................. 72
10.7.6 Set Warm Weather Shutdown Temperature (Default: OFF) .................................................................... 73
10.8 DOMESTIC HOT WATER EZ SETUP ....................................................................................................... 74
10.8.1 Select DHW Demand (Default: Switch) ..................................................................................................... 74
10.8.2 Boiler DHW Setpoint (Default: 186°F [86°C])............................................................................................ 74
10.8.3 DHW Storage Setpoint (Default: 140°F [60°C]) ......................................................................................... 75
10.8.4 DHW Priority Timeout (Default: Off) ........................................................................................................ 75
10.9 EZ SETUP RESET .................................................................................................................................... 76
10.10 DISPLAY EZ SETUP ............................................................................................................................. 76
10.11 CH/DHW OPERATION ........................................................................................................................ 77
10.12 BOILER INFORMATION ............................................................................................................................. 77
10.12.1 Boiler Information Logging ..................................................................................................................... 79
10.13 LOCKOUT HISTORY......................................................................................................................................... 80
10.13.1 Lockout Details ....................................................................................................................................... 80
CHAPTER 11: START-UP PREP ARATION ...................................................................................... 85
11.1 CHECK BOILER SYSTEM WATER CHEMISTRY .................................................................................................... 85
11.1.1 Water pH Level 6.0 to 8.0 ......................................................................................................................... 85
11.1.2 Water Hardness Less Than 7 Grains ......................................................................................................... 85
11.1.3 Chlorinated Water .................................................................................................................................... 85
11.1.4 Flush Boiler to Remove Sediment ............................................................................................................. 85
11.1.5 Check and Test Antifreeze ........................................................................................................................ 86
11.1.6 Use of Antifreeze in the Boiler System ..................................................................................................... 86
11.2 BOILER CLEANING ............................................................................................................................................ 86
11.2.1 Cleaning an Old Boiler and System ........................................................................................................... 86
11.2.2 Cleaning of New Boiler/System: ............................................................................................................... 87
11.2.3 Filling the Boiler System ........................................................................................................................... 87
11.3 CHECK LOW WATER CUT-OFF DEVICE ............................................................................................................. 87
11.4 CHECK FOR GAS LEAKS ..................................................................................................................................... 88
11.5 CHECK THERMOSTAT CIRCUIT ......................................................................................................................... 88
11.6 INSPECTION OF CONDENSATE DRAIN ASSEMBLY ............................................................................................ 89
CHAPTER 12: START-UP PROCEDURES ....................................................................................... 91
12.1 FINAL CHECKS BEFORE START-UP .................................................................................................................... 91
12.2 ESTEEM START-UP ........................................................................................................................................... 91
12.3 OPERATING INSTRUCTIONS (READ BEFORE OPERATING BOILER) .................................................................. 91
12.3.1 Troubleshooting Start-Up Problems ......................................................................................................... 93
12.4 INSPECTION OF THE ESTEEM BOILER AND SYSTEM......................................................................................... 93
12.4.1 Boiler Piping inspection ............................................................................................................................ 93
12.4.2 Vent Piping and Combustion Air Piping inspection .................................................................................. 93
Page 5 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
12.4.3 Gas Piping Inspection................................................................................................................................ 94
12.4.4 Flame Pattern and Combustion Verification ............................................................................................ 94
12.4.5 Measure and Verify Input Rating - Natural Gas Only................................................................................ 96
12.4.6 High Temperature Limit Testing ............................................................................................................... 97
CHAPTER 13: OUTDOOR RESET CONTROL .................................................................................. 99
13.1 OUTDOOR TEMPERATURE SENSOR INSTALLATION ....................................................................................... 100
13.2 OUTDOOR TEMPERATURE SENSOR WIRING ................................................................................................. 101
CHAPTER 14: EXTERNAL MODULATING CONTROL ................................................................... 103
14.1 WIRING THE EXTERNAL MODULATING CONTROLLER ................................................................................... 103
14.2 EZ-SETUP CONTROLLER PROGRAMMING FOR EXTERNAL 0-10V SIGNAL ...................................................... 103
14.3 EXTERNAL PROGRAMMING OF 0-10V MODULATING CONTROL ................................................................... 103
CHAPTER 15: CHECK-OUT PROCEDURES .................................................................................. 105
CHAPTER 16: MAINTENANCE SCHEDULE .................................................................................. 107
16.1 SERVICE TECHNICIAN MAINTENANCE ........................................................................................................... 107
16.1.1 General Maintenance ............................................................................................................................. 107
16.1.2 Poor Performance Maintenance ............................................................................................................ 107
16.1.3 Owner Maintenance ............................................................................................................................... 107
CHAPTER 17: MAINTENANCE PROCEDURES ............................................................................. 109
17.1 REPORTED PROBLEMS ................................................................................................................................... 109
17.2 SURROUNDING AREA INSPECTION ................................................................................................................ 109
17.3 BURNER AREA INSPECTION ........................................................................................................................... 109
17.4 SYSTEM PIPING INSPECTION .......................................................................................................................... 110
17.5 CLEAN CONDENSATE DRAIN ASSEMBLY ........................................................................................................ 110
17.6 VENTILATION AIR OPENINGS INSPECTION .................................................................................................... 110
17.7 VENT AND COMBUSTION AIR PIPING INSPECTION........................................................................................ 110
17.8 BOILER SYSTEM INSPECTION ......................................................................................................................... 111
17.9 EXPANSION TANK INSPECTION ...................................................................................................................... 111
17.10 BOILER RELIEF VALVE INSPECTION .............................................................................................................. 111
17.11 IGNITION ELECTRODE INSPECTION .............................................................................................................. 112
17.12 IGNITION WIRING AND GROUND WIRING INSPECTION .............................................................................. 112
17.13 CONTROL WIRING INSPECTION ................................................................................................................... 112
17.14 CONTROL SETTINGS INSPECTION ................................................................................................................ 112
17.15 PERFORM START-UP AND CHECKOUT PROCEDURES .................................................................................. 112
17.16 BURNER FLAME INSPECTION AND TROUBLESHOOTING ............................................................................. 113
17.17 FLAME SIGNAL INSPECTION ......................................................................................................................... 114
17.18 COMBUSTION LEVELS INSPECTION.............................................................................................................. 114
17.19 FLUE GAS TEMPERATURE CHECK ................................................................................................................ 114
17.20 HEAT EXCHANGER CLEANING...................................................................................................................... 115
17.21 REVIEWING MAINTENANCE REQUIREMENTS WITH OWNER ...................................................................... 115
17.22 Handling Previously Fired Combustion Chamber Insulation ....................................................................... 116
CHAPTER 18: EZ-SETUP CONTROLLER OPERATION AND SETTINGS ..................................... 117
18.1 ENTERING THE INSTALLER ACCESS CODE ...................................................................................................... 117
18.2 USING THE INSTALLER MENU ........................................................................................................................ 118
18.3 CH and DHW SETTINGS MENU ................................................................................................................ 121
18.3.1 Heating Operation (Default: Enabled) .................................................................................................... 121
18.3.2 Demand Type (Default: Switch & Outdoor Reset) .................................................................................. 122
Page 6 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
18.3.3 Absolute Max CH Setpoint (Default: 188°F [87°C]) ................................................................................. 123
18.3.4 CH1 Maximum Setpoint (Default: 180°F [82°C])..................................................................................... 123
18.3.5 CH1 Minimum Setpoint (Default: 120°F [49°C]) ..................................................................................... 124
18.3.6 Reset Curve Coldest Day (Default: 0°F [-18°C])....................................................................................... 124
18.3.7 Reset Curve Warmest Day (Default: 64°F [18°C]) ................................................................................... 124
18.3.8 CH2 Circuit (Default: Enabled) ................................................................................................................ 125
18.3.9 CH2 Maximum Setpoint (Default: 140°F [60°C])..................................................................................... 125
18.3.10 CH2 Minimum Setpoint (Default: 80°F [27°C]) ..................................................................................... 125
18.3.11 Warm Weather Shutdown (Default: Off).............................................................................................. 126
18.3.12 Pump Constant Circulation (Default: Disabled) .................................................................................... 126
18.3.13 CH Post Pump Time (Default: 1 Minute)............................................................................................... 127
18.3.14 Freeze Protection (Default: Enabled) ................................................................................................... 128
18.3.15 Frost Protection Setpoint (Default: -22°F [-30°C]) ................................................................................ 129
18.3.16 Parallel Shift Value (Default: 0°F [0°C]) ................................................................................................. 129
18.3.17 CH Call Blocking (Default: 1 Minute)..................................................................................................... 130
18.3.18 System Pump (Default: CH1/CH2) ........................................................................................................ 130
18.4 DHW SETTINGS MENU ....................................................................................................................... 135
18.4.1 DHW Operation (Default: Enabled) ........................................................................................................ 136
18.4.2 Demand Type (Default: Switch) .............................................................................................................. 137
18.4.3 Boiler DHW Setpoint (Default: 186°F [86°C]).......................................................................................... 137
18.4.4 DHW Storage Setpoint (Default: 140°F [60°C]) ....................................................................................... 137
18.4.5 DHW on Differential (Default: 6°F [3°C])............................................................................................... 138
18.4.6 DHW Storage Adder (Default: 46°F [25°C])............................................................................................ 139
18.4.7 DHW Post Pump Time (Default: 1 Minute) ............................................................................................ 139
18.4.8 DHW Priority Timeout (Default: OFF) .................................................................................................... 140
18.4.9 DHW Priority (Default: ENABLED) ......................................................................................................... 140
18.4.10 DHW Call Blocking (Default: 0 Minutes) ............................................................................................. 141
18.4.11 DHW to CH Call Blocking (Default: 1 Minute) ..................................................................................... 141
18.4.12 Antilegionella Function (Default: DISABLED) ...................................................................................... 142
18.5 BOILER SETTINGS MENU ...................................................................................................................... 143
18.5.1 Lockout Temp (Default: 210°F [99°C]) .................................................................................................... 143
18.5.2 Modbus Address (Default: 0=BCST) ........................................................................................................ 144
18.6 RESET ALL SETTINGS MENU ............................................................................................................... 144
18.7 CASCADE MENU AND OPERATING INFORMATION ........................................................................................ 146
18.7.1 Cascade Installation – System Piping ...................................................................................................... 148
18.7.2 Cascade Installation – System Sensor Installation .................................................................................. 148
18.7.3 Cascade Installation – Cascade Communication Cable........................................................................... 149
18.7.4 Cascade Installation – Low Voltage Wiring Connections ........................................................................ 149
18.7.5 Cascade Installation – Line Voltage Wiring Connections ........................................................................ 150
18.8 CASCADE AUTODETECTION MENU ...................................................................................................... 151
18.8.1 Cascade Operation – Lockouts ............................................................................................................... 151
Page 7 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler
OMM-0089_0A Installation, Operation & Maintenance Manual
18.9 CASCADE INFORMATION MENU ......................................................................................................... 158
18.9.1 System Temperature Logging ................................................................................................................. 158
18.9.2 Cascade Settings Menu ................................................................................................................... 159
18.9.3 Stage Delay (Default: 60 Seconds) .......................................................................................................... 160
18.9.4 Minimum firing Rate (Default: 30%) ....................................................................................................... 160
18.9.5 Boiler Enabling Algorithm ....................................................................................................................... 161
18.9.6 Boiler Disabling Algorithm ...................................................................................................................... 161
18.9.7 Maximum Firing Rate (Default: 398 MBH).............................................................................................. 161
18.9.8 CH or DHW Boilers (Default: 0) ............................................................................................................... 162
18.9.9 Automatic Rotation (Default: Enabled) ................................................................................................. 163
18.9.10 CH Proportional Gain (Default: 7) ......................................................................................................... 164
18.9.11 CH Integral Gain (Default: 245) ............................................................................................................. 165
18.9.12 DHW Proportional Gain (Default: 7) ..................................................................................................... 166
18.9.13 DHW Integral Gain (Default: 245) ......................................................................................................... 167
18.9.14 Modbus Address (Default: 0 = BcST) .................................................................................................... 168
18.9.15 Modbus Interface ................................................................................................................................. 169
18.10 MANUAL OPERATION .................................................................................................................................. 171
18.10.1 Fan Parameter .............................................................................................................................. 171
18.10.2 CH CH1 Parameter ........................................................................................................................ 172
18.10.3 DHW Parameter............................................................................................................................ 172
18.10.4 SYS CH2 Parameter ....................................................................................................................... 173
APENNDIX A: PART AND DIMENSIONAL DRAWINGS.................................................................... 175
APENNDIX B: CIRCULATOR PRESSURE LOSS CHARTS .............................................................. 183
Page 8 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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GF-135 Esteem 399 Low NOx Boiler Chapter 1
OMM-0089_0A Installation, Operation & Maintenance Manual Safety Precauti ons

CHAPTER 1: SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

The following general warnings and cautions m ust 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 loc al 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 Installati on 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.
See the last two pages of this chapter for important information regarding installation of units within the Commonwealth of Massachusetts.
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.
• Installation and service m ust be performed by a qualified installer, service agency or the gas supplier.
WARNING!
• Do not use matches, candles, fl am es, or other sources of ignition to check for gas leaks.
• Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents. Perform all installation steps required in these manuals in the proper order given. F ailure t o adhere t o the guid elines within these manuals can result in severe personal injury, death or substantial property dam age.
• Fluids under pressure m ay cause injury to personnel or damage to equipm ent when rel eased. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully decrease all trapped pressures to zero before perform ing maintenance.
• Before attempting to perform any m ainten ance on the unit, shut off all gas and electrical inputs to the unit.
• The exhaust vent pipe of the unit operates under a positive pressure and therefore must be completely sealed to prevent leakage of combustion products into living spaces.
• High electrical voltages are used in this equipment, therefore the cover on the unit’s power box m ust be installed at all times, except during maintenance and servicing.
Page 9 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler Chapter 1
OMM-0089_0A Installation, Operation & Maintenance Manual Safety Precautions
WARNING!
A double-pole switch must be installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and safely disconnect electrical servic e. Do n ot affix switch to unit sheet metal enclosures.
CAUTION!
• Many of the soaps used for gas pipe leak testing are corrosive to m etals. The piping must be rinsed thoroughly with clean water after l eak checks have been completed.
• DO NOT use this boiler if any part has been under water. Call a qualified service technician to inspect and replace any part that 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 appli ance.
DO NOT add cold make up water when the boiler is hot. Thermal shock can cause pot ential cracks in the heat exchanger.
WARNING!
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 fire department.
Please have the unit’s model num ber and the serial num ber 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 fittings not specified by AERCO International.

1.2 EMERGENCY SHUTDOWN

Turn the service sw itch on the Esteem 399 Low NOx control panel to “OFF”
Page 10 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler Chapter 1
OMM-0089_0A Installation, Operation & Maintenance Manual Safety Precautions
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit.
NOTE
The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.
Figure 1-1: Typical Manual Gas Shutoff Valve

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended that the startup procedures and the safety device test procedures in Ch apter 12 of this manual be performed, to verify all system-operating parameters.
If there is an em ergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream from the unit.
The installer must identify the emergency shut-off device to those responsible for oper ation of the boiler.
Page 11 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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GF-135 Esteem 399 Low NOx Boiler Chapter 1
OMM-0089_0A Installation, Operation & Maintenance Manual Safety Precautions
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Comm onwealth of Massachusetts must conform to the foll owing requirements:
• Boiler m ust be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
• Prior to unit op eration, the complete g as train and all connections must be leak tested using a non-corr osive soap.
• The vent t ermination must be located a minimum of 4 feet above grade level. If side-wall venting is used, the installation must conform to the
following requirem ents extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operat ed by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
• INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vent ed gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is inst alled on the fl oor l evel where the g as equipment is to be inst alled. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon m onoxide d etector with an al arm is installed on each additional l evel of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the inst allation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon m onoxide detector w ith alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of com pletion of inst allation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operat ed carbon m onoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented g as fu el ed heating appliance or equipment. The sign
shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or l ocal gas inspector of the side wall horizontally vented gas fuel ed equipment shall not approve the install ation unless, upon inspection, the inspector observes carbon monoxide detectors and signage inst alled in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
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(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. W hen the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all install ation instructions for all Product Approved sid e wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
[End of Extracted Information From 248 CMR 5.08 (2)]
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OMM-0089_0A Installation, Operation & Maintenance Manual Installation

CHAPTER 2: INSTALLATION

2.1 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 boil er to be inst alled by a licensed
•
plumber or gas fitter, and if antifreeze is utilized, the installation of a reduced pressure backflow prevent er device is required in the boiler’s cold water fill or make up wat er supply line.
For installation in Massachusetts all direct vent ed appliances m ust comply with the
•
guidelines as outlined in section 1.3 of Chapter 1.
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
•
CSD-1, when required.
NOTE
The Esteem 399 Low NOx boiler gas manifold and gas controls meet the safe lighting and other p erform ance requirem ents as specified in ANSI Z21.13 latest edition.

2.2 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 is free of any combustible materials, gasoline and other flamm able liquids.
The Esteem boiler is certified for indoor conditioned space only.
WARNING!
Failure to remove or maintain the area free of combustible materials, gasoline and other flamm able liquids or vap ors can result in severe personal injury, death or substantial property damage.
Ensure the Esteem 399 and its controls are protected from dripping or spraying water during normal operation or service.
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The Esteem 399 Low NOx should be installed in a location so that any water leaking from the boiler or piping connections or r elief valve will not cause damage to the ar ea surrounding the unit or any lower floors in the structure.

2.3 BOILER REPLACEMENT

If the Esteem 399 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 qu ality of freeze prot ection within the boiler system.
•
See the warning in section 17.22 Handling Previously Fired Combustion Chamber
•
Insulation.

2.4 RECOMMENDED CLEARANCES

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 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:
Surface Dimension
Top Jacket 24 inches [610 mm]. Front 24 inches [610 mm]. Rear 0 inches Sides 6 inches [153 mm] Bottom Pi ping 24 inches [610 mm].
WARNING!
If the clearances listed above cann ot be m aintained or the enclosure in which the boiler is installed is less than 85 cubic feet, the space m ust be ventilated. See chapter 3 for requirem ents.
NOTE
When maintaining zero clearance or less than recommended clearances, some pr oduct labeling may become hidden and unreadable.
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OMM-0089_0A Installation, Operation & Maintenance Manual Installation
WARNING!
When installing the Esteem boiler in a confined space, sufficient air must be provided for proper combustion and venting and to all ow, under normal oper ating conditions, proper air fl ow around the product to maintain am bient temperatures within safe limits to com ply with the National Fuel Gas Code NFPA 54…Latest Edition.

2.5 RESIDENTIAL GARAGE INSTALLATIONS

When installing the Esteem boiler in a residential garage, the foll owing special precautions per NFPA 54/ANSI Z223.1 must be taken:
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.
•

2.6 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 [8ºC] CH (1) & Auxiliary Boiler Pumps ON
•
42ºF [6ºC] CH (1), Auxiliary Boil er & System Pumps ON, Burner operates at low fire
•
60ºF [15ºC] Freeze protection ends. Burner & all pumps OFF after completing CH
•
Post Pump Tim e.
CAUTION!
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 arrangem ent if it is installed in an unheated space or exposed to water tem peratures of 46ºF or less. See “Chapt er 5 B oiler Piping” for primary/secondary piping examples. See Section 11.1.6 for antifreeze guidelines.
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OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting

CHAPTER 3: COMBUSTI ON AIR AN D VENTING

3.1 COMBUSTION AIR CONTAMINATION

WARNING!
If the Esteem boiler combustion air inlet is located in any area likely t o cause or contain contamination, or if products, which would contaminate the air c annot be removed, the combustion air must be re-piped and term inated to another l ocation. Contaminated combustion air will damage the unit and its burner system , resulting in possible severe p ersonal injury, death or substantial property dam age.
WARNING!
Do not operate the Esteem boiler 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 corrosi on 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 inform ation 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 Chapt er 5 of this installation manual.

3.2 POTENTIAL CONTAMINATING PRODUCTS

Spray cans containing chloro/fluorocarbons
•
Permanent W ave Solutions
•
Chlorinated wax
•
Chlorine—based swimming pool chemicals / cleaners
•
Calcium Chloride for melting ice
•
Sodium Chloride for water soft ening
•
Refrigerant leaks
•
Paint or varnish removers
•
Hydrochl oric acid / muriatic acid
•
Cements and glues
•
Antistatic fabric soft en ers 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
•
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3.2.1 Areas Likely to Contain Contaminating Products

Areas likely to contain potential contaminants are as follows:
• Dry cleaning / laundry areas and establishments
• Beauty sal ons
• 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 with workshop s

3.3 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 boiler, in which the minimum service clearances are maintained (see Rec omm ended Cl earances, section 2.4), no ventilation openings are required.
For Direct Vent, zero clearance install ations involving only the Esteem boiler, the space /
enclosure must have two openings for ventilation. The op enings 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 sp ace with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space m ust be provided with adequate air openings t o 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.
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WARNING!
The space must be provid ed with ventilation com bustion air openings properly sized for all make-up air requirements (exhaust fans, clothes dryers, etc.), which includes the tot al input of all appliances located in the same space as the Esteem unit(s) using
indirect vent ed air. Esteem units installed with direct vent air
inputs are excluded from such consideration because they receive com bustion air directly from the outside, and so additional free
area for the openings is not required. Failure to provide properly
sized openings could result in severe p ersonal inju ry, death or property dam age.
3.4 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, fl ammable vapors and tight housing construction. This practice also promotes higher system efficiency.
In installations where the Esteem boil er shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil), the spac e m ust be provid ed with adequate air openings t o provide ventilation and combustion air t o 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 inst allati ons in Can ada, as referenced in this chapter of the manu al and titled Methods of Supplying Combustion Air to a Space.

3.5 METHODS OF SUPPLYING COMBUSTION AIR TO A CONFINED SPACE - CATEGORY IV

NOTE
The methods listed in this section for accessing Indoor Combustion Air assume that the infiltration rate is ad equate and not less than .40 ACH. For infiltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas Code for additional guidance.
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3.5.1 INDOOR COMBUSTION AIR

Openings used to connect indoor spaces shall be sized and located in accordance with Figure 3-1.
Figure 3-1: 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 one opening shall commence within 12 inches of the bottom of the enclosure. The minimum dim ension of air openings shall be not l ess 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 m ore 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.
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OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting

3.5.2 OUTDOOR COMBUSTION AIR

The minimum dimension of air openings for outdoor combustion air venting shall be not less than 3 inches.
3.5.2.1 Option 1: One Permanent Opening to Outside
Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:
One Permanent Opening Method. See Figure 3-2.
•
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:
Figure 3-2: 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 spac e.
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3.5.2.2 Option 2: Two Permanent Openings to Outside
Two permanent openings, one comm encing 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 outdoor s or spaces that freely comm unicate with the outdoors, as foll ows:
• W here 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 3-3.
Figure 3-3: 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 3-4.
Figure 3-4: All Combustion Air from Outdoors Through Horizontal Ducts
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OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting

3.6 COMBINATION OF INDOOR AND OUTDOOR COMBUSTION AIR

Indoor Openings: Where used, openings connecting the interior spaces shall comply with the Indoor Combustion Air section 3.5.

3.6.1 Outdoor Opening(s) Location

Outdoor opening(s) shall be loc ated in accordanc e with the Outdoor Combustion Air section.

3.6.2 Outdoor Opening(s) Size

Outdoor opening(s) shall be calculated in accordance with the following:
The r atio of the interior spaces shall be the availabl e 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 minim um 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.
WARNING!
Do not install the Esteem boiler into a common vent with other gas or oil appliances. This may cause flue gas spill age or appliance malfunction, resulting personal injury, death, and/or property damage.

3.7 COMBUSTION AIR AND VENT PIPING

WARNING!
Combustion air and vent piping must be sealed gas tight and meet all provided instructions and applicabl e codes, failure t o comply will result in severe personal injury or death.
The Esteem boiler requir es a Category IV venting system, which is designed for pressurized venting and condensate.
The Esteem boiler is certified per ANSI Z21.13 as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance uses uncontaminated indoor or outd oor air (surrounding the appliance) for combustion. A Direct Vent appliance uses uncontaminated outdoor air (piped directly to 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, fl ammable vapors and tight housing construction. This practice also promotes higher system efficiency.
NOTE
Install combustion air and vent pipe as detailed in the Esteem boiler Vent Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for addition vent installation instructions.
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OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting

3.8 REMOVAL OF AN EXISTING BOILER FROM A COMMON VENT SYST EM

WARNING!
Do not install the esteem unit 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 dam age.
NOTE
When an existing boil er 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 rem oval of an existing boiler, the following steps shall be followed with each appliance r em aining connected to the common 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, corrosi on and other deficiencies 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 b athroom exhausts, so they will op erate at maxim um speed. Do not op erate a summer exhaust fan. Close fireplace dam pers.
• Operate the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
• Test for spillage at the draft hood reli ef opening after 5 minutes of m ain burner operation. Use the flame of a match or candle, or sm oke fr om 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, fireplace dampers, and any other gas-burning appliance to their previous condition of use.
• Any improper operation of the comm on venting system should be corrected so the installation conforms with the Nation al Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation c odes. 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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OMM-0089_0A Installation, Operation & Maintenance Manual Comb. Air & Venting
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 l evel where there are bed-room(s), a carbon m onoxide detector and alarm shall be placed in the living area outside the bedroom(s). The car-bon monoxide detector shall comply with NFPA 720 (2005 Edition).
2. A carbon monoxide det ector 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 equipm ent such that only
one service switch services b oth the appliance and the carbon monoxid e detector.
b) Have battery back-up power.
c) Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition).
d) Have been approved and listed by the Nation ally 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. Install ation shall be in strict compliance with the m anufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installati on.
4. A metal or plastic identification plate shall be m ounted at the exterior of the building, four feet directly ab ove the locati on 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”.
NOTE
Installer must provide tag identification plate and ensure the lettering meets code requirements.
For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the b ottom of the vent term inal and the air intake are inst alled above four feet above grade the following requirements must be satisfied:
1. If there is not one already present, on each floor l evel where there are bed-room (s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The car-bon monoxide detector shall comply with NFPA 720 (2005 Edition).
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)
3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used. Install ation shall be in strict compliance with the m anufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation
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OMM-0089_0A Installation, Operation & Maintenance Manual Unit Preparation

CHAPTER 4: UNIT PREPARATION

4.1 HANDLING INS TRUCTIONS

The Esteem 399 Low NOx boil er is generally easier to handle and maneuver onc e removed from the shipping carton. To remove the shipping carton, follow these instructions:
Removing the Esteem Boiler from the Shipping Carton
CAUTION!
Use c are not to lift the unit from, or place th e unit on the front plastic control panel, damage can occur. Use care not t o 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.

4.2 WALL MOUNTING INSTALLATION

The Esteem boiler should be wall mounted using the bracket provided with the boiler. The Esteem boiler 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 unit must be vertically plumbed and capable of supporting a minimum 250 pounds [115 kg]. Failure to com ply with these requirem ents could result in personal injury, death or substantial prop erty dam age.

4.3 WALL MOUNTING GUIDELINES

The boiler is heavy and bulky. A minimum of 2 people is required for mounting the boiler.
•
DO NOT mount or attempt to m ount the wall bracket to hollow sheet rock or lath walls
•
using anchors. Only install boiler to studs or equival ent w ood structure.
The w all-mounting bracket is designed for stud spacing of 12 inch or 16 inch on center.
•
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 m ounting 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.
Page 29 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
GF-135 Esteem 399 Low NOx Boiler Chapt er 4
OMM-0089_0A Installation, Operation & Maintenance Manual Unit Preparation
WARNING!
Use extreme care not to drop the boiler or cause bodily injury while lifting or mounting the boiler onto the bracket. Once mounted veri fy that the boiler is securely attached to the bracket and wall. Failure t o com ply with the above guidelines could r esult in property damage, personal injury or death.

4.4 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 boiler W all Frame kit.
W hen using the wall frame to m ount the boil er reference the kit installation instructions
•
and ensure the fram e is securely fast en ed 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 floor stand.
W all Bracket Installation—Solid Walls
•
Locate the gen eral area of the boil er 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 m ounting slots on the wall.
•
Remove the bracket from the wall and drill a 5/8” diameter by 1-3/8” deep hole positioned
•
in the center of each m ark.
Install the anchors (provided) flush or slightly recessed in the drilled hol es with threaded
•
side facing down.
Reposition the br acket 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.
•

4.5 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 wall-mounting bracket. Ensure the boiler is seated properly
and is secure.
Page 30 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
MC1 06/19/14 Ph.: 800-526-0288
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