Installation, Operation & Maintenance Manual (IOMM)
GF-135
OMM-0089_0A
USER MANUAL
Installation, Oper atio n and M ainte nan ce
GAS FIRED B OILE R
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
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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
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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
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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
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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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GF-135 Esteem 399 Low NOx Boiler Chapter 1
OMM-0089_0A Installation, Operation & Maintenance Manual Safety Precautions
(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 Safety Precautions
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GF-135 Esteem 399 Low NOx Boiler Chapt er 2
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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GF-135 Esteem 399 Low NOx Boiler Chapt er 2
OMM-0089_0A Installation, Operation & Maintenance Manual Installation
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.
Page 16 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 Chapt er 2
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.
Page 17 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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OMM-0089_0A Installation, Operation & Maintenance Manual Installation
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GF-135 Esteem 399 Low NOx Boiler Chapt er 2
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
•
Page 19 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 Chapt er 2
OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting
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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GF-135 Esteem 399 Low NOx Boiler Chapt er 2
OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting
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.
Page 21 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 Chapt er 2
OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting
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.
Page 22 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 Chapt er 2
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.
Page 23 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 Chapt er 2
OMM-0089_0A Installation, Operation & Maintenance Manual Combustion Air/Venting
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
Page 24 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 Chapt er 2
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.
Page 25 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 Chapt er 2
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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GF-135 Esteem 399 Low NOx Boiler Chapt er 3
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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GF-135 Esteem 399 Low NOx Boiler Chapt er 3
OMM-0089_0A Installation, Operation & Maintenance Manual Comb. Air & Venting
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GF-135 Esteem 399 Low NOx Boiler Chapt er 4
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.
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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.
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GF-135 Esteem 399 Low NOx Boiler Chapt er 5
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
CHAPTER 5: BOILE R PIPING
5.1 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 boiler from the system piping.
•
WARNING!
Use a two wrench method when tightening piping onto the boiler
connections. Use one wrench to prevent the boiler piping from
turning/twisting. Failure to support the boiler piping and
connections in this m anner c ould cause damage to the boiler and
its components.
5.2 PRESSURE RELIEF VAL VE
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
•
be piped using the PRV connection as shown in Figure 5-1.
o avoid p otential w ater d am age to the sur rounding area or potential scalding hazard due
• T
to the oper ation of the relief valve, the discharge piping:
o Must be connected to the discharge outlet of the reli ef valve and directed to a safe
place of disposal.
o Length should be as short and direct as possible. The size of the discharge lin
s
hould not be reduced, maintain the sam e size as the outlet of the relief valve.
o Should be directed downward towards the floor at all times. The piping should
terminate at l east 6 inches [153 mm] above any drain connection to allow clear
visibility of the discharge.
o 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.
boiler is supplied with a 45 psi pressure relief valve and must
e
o Should not be subject to conditions where freezing could occur.
o Should not contain any shut-off valves or obstructions. No shut-off valve should b
piped between the boiler and relief valve.
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e
GF-135 Esteem 399 Low NOx Boiler Chapt er 5
(Field Supplied)
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
Figure 5-1: Pressure Rel ief valve and Boiler Drain Valve Installation
5.3 BOILER AIR VENT
This boiler is supplied with a special automatic air vent that will provide reliable oper ation in
purging air from the boiler. The hygroscopic cap supplied with the automatic air vent MUST
remain tight at all times on the air vent body. The hygroscopic cap has a m em brane which
expands upon contact with water and seals the air vent until the membrane dries up due to new
air forming in the air vent.
• Make sure to fully tighten the cap on the air vent on initial installation.
• Never loosen the hygroscopic cap to allow air to escape the air vent. Air will exit with the
cap fully tightened in place.
• If the hygroscopic cap is not fully tightened, water m ay leak from the cap. Simply tighten
the cap securely.
5.4 LOW WATER CUTOFF DEVICE
The Esteem boiler 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 l ocal cod es if a L ow W ater Cutoff Device is required. If so, det ermine if this device
meets the requirements of the local cod es.
WARNING!
The Esteem boiler control system senses the system water
temperatures entering and exiting the heat exchanger to provide
protection against low water c onditions where local codes and
jurisdiction do not accept a pressure device for low water
protection, they may accept these integral control functions as a
means of providing low water protection.
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OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
5.5 ADDITIONAL LIMIT CONTROL
If a separate LW CO device is required by cert ain l ocal jurisdictions or when the b oiler is
installed above the system piping, the foll owing guidelines must be followed:
The LW CO device m ust be designed for water install ations, electrode probe-type is
•
recomm ended.
The LWCO device must be installed in a tee connection on the boiler supply piping above
•
the boiler.
W iring of the LW CO device to the Esteem boiler is done directly onto the 24V terminal
•
strip. See Figure 8-3 for available term inals for an external lim it (manual or auto reset).
If the installation is to com ply with ASME or Canadian requirements, an additional high
tem perature limit may be needed. Consult local cod e requirements to determ ine compliance.
The limit should be installed as follows:
Install the limit in the boiler supply piping between the boil er and any isolation valve.
•
Consult heat exchang er for maxim um set point of limit.
•
For wiring of the limit, see Figure 8-3 for 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.
5.6 BACKFLOW PREVENTER
Use a backflow prev ent er v alv e in the make-up wat er s upply to the unit as required by local codes .
5.7 BOILER SYSTEM PIPING APPLICATIONS
NOTE
It is recommended on all piping applications to utilize a primary/secondary
piping arrangem ent as a means to provide freeze protection of the boiler,
which is an integr al function of the boiler contr ol. Maint ain the minimum
boiler flow rate (see the charts in Figure B-1 and B-2 in Appendix B). For
other piping arrangements, consult the Engineering Department at AERCO
International or consult other approved/recognized design arrangements.
NOTE
On piping applications utilizing a single zone or other recognized piping
design arrangem ents, it is rec omm ended that the inst aller uses flow/check
valves with weighted seats at or near the applianc e to prevent gravity
circulation.
5.8 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 boiler and the system volume and temperature.
WARNING!
Undersized expansion tanks will cause system water to be lost
through the pressure reli ef valve and cause additional m akeup
water to be added to the system . Eventual boiler heat exchanger
failure can result due to this exc essive m akeup water addition.
The expansion tank must be located as shown in Figure 5-3 and Figure 5-4 when using a
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OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
primary/secondary piping arrangement or as per recognized design methods. Refer to the
expansion tank manufacturer instructions for additional installation d etails.
Connect the expansion tank t o 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.
5.8.1 Diaphragm Expansion Tank
Always install an automatic air vent on the top of the air separator t o remove residual air from
the system.
5.8.2 Closed-Type Ex pansion 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 exp ansion tank to all ow air within the system to rise.
WARNING!
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 t o be vented from the system resulting in a waterlogged expansion tank.
5.9 CIRCULATOR
The Esteem boiler must be supplied with a Central Heating (CH) circulator. The circulator when
wired directly to the Esteem boiler will allow for domestic hot water priority and to provid e
circulation for the freeze protection feature of the boiler control. See the charts in Figures B-1
and B-2 in Appendix B for pressure drop and minimum flow rate through the boiler.
5.10 SIZING PRIMARY PIPING
See Figur e 5-5 through Figure 5-10 on the following pages for recommended piping
arrangem ents based on various applications. Size the piping and system com ponents required
in the space heating system, using recognized design methods.
5.11 DOMES TIC HOT WATER SYSTEM PIPING
See Figure 5-5 through Figure 5-9 on the following pages for rec omm ended 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 W iring.
5.12 SYSTEM PIPING - ZONE CIRCULATORS
Connect the Esteem boiler to the system piping as shown in Figure 5-5 when zoning with zone
circulators.
The install er must provide a separate circulator for each zone of space h eating as well as the
boiler circulator.
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GF-135 Esteem 399 Low NOx Boiler Chapt er 5
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
NOTE
To ensure an adequate fl ow rate through the Esteem boiler, the
boiler supply and return piping size must be a minimum 1-1/2
inches.
5.13 SYSTEM PIPING - ZONE VALVES
Connect the Esteem boiler to the system piping as shown in Figure 5-6 when zoning with zone val ves.
The primary / secondary piping ensures that the boiler loop has sufficient flow.
5.14 SYSTEM PIPING - THROUGH BOILER
In new or retrofit applications in which primary/secondary arrangement is not used, the Esteem boiler
all ows this fl exibility du e t o a lower boiler pressure drop, see the charts in Figure B-1 and B-2 in
Appendix B.
Figure 5-7 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 5-8 illustrat es a sin gle zone utilizing the boil er circulat or as the system circulat or.
5.15 SYSTEM PIPING - RADIANT HEATING
The heat exchanger design of the Esteem 399 Low NOx boiler allows operation in a condensing
mode. This feature requir es no return water tem perature regulation in radi ant heating
applications.
The design and construction of the Esteem heat exchanger allows the installation of the boiler
on systems with non-oxygen barrier tubing.
CAUTION
DO NOT install a water storage tank along with the unit in
systems with non-oxygen barrier tubing. Failure to comply
could result in premature failure of the storage tank.
A high temperature limit 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 boiler is connected to a
domestic hot wa ter s ys tem , whi ch requi r e s a high pr imary supply wate r tem perature.
Size the system piping and circulator to provide the flow needed for the radiant system.
NOTES
• To ensure an adequate fl ow rate through the Esteem 399 Low
NOx boiler, the boiler supply and return piping size must be a
minimum of 1-1/2” (inches).
• The addition of the high temperature limit is important if the
Esteem boiler is connected to a d om estic hot water syst em,
which requires a high primary supply water temperature.
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GF-135 Esteem 399 Low NOx Boiler Chapt er 5
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
5.16 SYSTEM PIPING—SPECIAL APPLICATIONS
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.
5.17 SYSTEM PIPING—MULTIPLE UNITS INSTALLATION
Use a balanc ed manifold system as the primary / secondary connecti on to the space heating
piping as shown in Figure 5-9.
Maintain a minimum of 6 inches [153 mm] of clearance between units to allow for servicing.
Refer to Figure 5-3 and Figure 5-4 to install air separat or and expansion tank.
For the space heating piping refer t o the applications m entioned in this manual or use
recognized design methods.
NOTE
The boiler system piping shown must be a “closed” system to
avoid any contamination and potential failure of any components
in the system.
Figure 5-2: Piping Diagram Component Legend
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GF-135 Esteem 399 Low NOx Boiler Chapt er 5
5 feet of piping) toward
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
Figure 5-3: Near Boiler Piping – Diaphragm Expansion Tank
NOTE
Pitch horizontal piping
upwards (1” of pipe per
expansion tank.
Page 37 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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Figure 5-4: Near Boiler Piping – Closed Type Expan sion Tank
GF-135 Esteem 399 Low NOx Boiler Chapt er 5
NOTE
Smart.
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
Figure 5-5: System Piping – Zoning with Zone Circulators
The boiler system piping
shown must be a “closed”
system to avoid any oxygen
contamination and potential
failure of the outer tank of the
Page 38 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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Figure 5-6: System Piping – Zoning with Zone Valves
GF-135 Esteem 399 Low NOx Boiler Chapt er 5
pressure drop and provide
adequate flow through the
boiler system.
pressure drop and provide
adequate flow through the
NOTE
Smart.
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
NOTE
NOTE
Verify CH circulator is properly
sized to overcome the system
Manifold mounted valve
actuators may be used in
lieu of zone valves.
Figure 5-7: System Piping – Multiple Zone Valve with Single System/Boiler Circulator
The boiler system piping
shown must be a “closed”
NOTE
Verify CH circulator is properly
sized to overcome the system
boiler system.
system to avoid any oxygen
contamination and potential
failure of the outer tank of the
Figure 5-8: System Piping – Single Zone System with Single System/Boiler Circulator
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GF-135 Esteem 399 Low NOx Boiler Chapt er 5
9 for information on wiring
18 for configuring the
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
NOTE
See section 9.12 in Chapter
and section 18.8 in Chapter
boilers using the built-in
Cascade function.
Figure 5-9: Syst em P ip i ng – Multiple Esteem Boiler Piping – Secondary/Primary
Page 40 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 Chapt er 5
1 = Esteem 399 Low NOx Boiler
5 = Zone Valve
5 = Zone Valve
9 = Automatic Air Vent
Diagram Legend
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
Figure 5-10: CH Syste m Pipi ng – Radiant / Low Temperature Heating
2 = CH Circulator
3 = Flow/Check Valve
4 = Isolation Valve
Page 41 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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6 = Drain/Purge Valve
7 = Pressure Relief Valve
8 = Air Separator
10 = Diaphragm Expans ion T ank
11 = Automatic Fill Valve
12 = System Circulator
13 = High Temp. Limit Control
GF-135 Esteem 399 Low NOx Boiler Chapt er 5
OMM-0089_0A Installation, Operation & Maintenance Manual Boiler Piping
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GF-135 Esteem 399 Low NOx Boiler Chapt er 6
OMM-0089_0A Installation, Operation & Maintenance Manual Vents, Intake & Drain
CHAPTER 6: INSTALLING VENT, AIR IN TAKES, AND
DRAIN
6.1 INSTALLING VENT AND COMBUSTION AIR INTAKE
WARNING!
The Esteem 399 Low NOx boiler must be vented and supplied with combustion air as instructed
in the Esteem boiler Vent Application Guide (GF-125V or GF-125CV), which is included in the
boiler installation envelope. Once installation is complete, inspect the vent and combustion air
system thoroughl y to ensure systems are airtight and comply with the instructions given in the
venting guide and are within all requirements of applicable codes. Failure to com ply with all
installation requirements can cause severe personal injury or death.
6.2 INSTALLING CONDENSATE DRAIN ASSEMBLY
Locate the condensate drain assembly and install as described below.
Installing the Condensate Drain Assembly
WARNING!
Before operating the Esteem boil er, the condensat e drain
assembly MUST be filled with water at the fill plug, or else flue
gases will escape creating a dangerous situation. It is
recommended to fill the plug at this time, though it may be done
any tim e prior to boiler operation.
1. Remove the ret aining nut (with rubber seal) from the condensate drain assem bly and slide
this nut over the heat exchanger condensate drain nipple (Fig. 6-1, left im age). Confirm that
the metal wash er is placed above the two rubber gaskets as shown in Figure 6-1, right
image. Place the condensate drain assem bly to the nipple and slide down retaining nut and
tighten to the assembly. Hand tighten only!
Drain Outlet
Figure 6-1: Condensate Drain Assembly
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GF-135 Esteem 399 Low NOx Boiler Chapt er 6
OMM-0089_0A Installation, Operation & Maintenance Manual Vents, Intake & Drain
Installing the Condensate Drain Assembly (Cont.)
WARNING!
Ensure the condensate drain assembly contains the plastic seated
ball. If the ball is lost or missing, do not install and replace entire
assem bly with new one.
2. Remove the compression nut (with rubber seal) from the drain outlet (Fig. 6-1).
3. Using 3/4” x 2’ flexible PVC tube provided, slide the compression nut and rubber seal over
the pipe
NOTE
The use of 3/4” PVC or CPVC pipe is also acceptable. If 3/4” pipe
is used, de-burr and cham fer pipe to allow m ating onto the drain
assem bly.
4. Thread the rubber seal into the com pression nut to ease install ation of the pipe to the drain
assem bly.
5. Seat the pipe onto the drain assembly and tighten the compression nut. Hand tight only!
NOTES
• The installer may opt to use 13/16” ID tubing in lieu of rigid
piping.
• The drain line m aterials 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 certified PVC or CPVC pipe,
fittings and cement/primer.
6. Continue the pipe from the drain assembly to a floor drain or condensate pump.
NOTE
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 overflow switch to prevent
property damage from potential condensate spillage.
7. The Esteem boiler will typically produce a condensat e that is considered slightly acidic with
a pH content below 3.0. Install a neutralizing filter if required by authority having jurisdiction.
WARNING!
The condensate drain must remain filled and unobstructed and
all ow unrestricted flow of condensate. The condensate sh ould not
be subject to conditions where freezing could occur. If the
condensate is subjected to freezing or becomes obstructed, it can
leak, resulting in pot ential water damage to the boiler and
surrounding area.
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GF-135 Esteem 399 Low NOx Boiler Chapter 7
OMM-0089_0A Installation, Operation & Maint enance Manual Gas Piping
CHAPTER 7: GAS PIPING
7.1 GAS SUPPLY PIPING CONNECTION
Install the gas piping as described below.
Connecting the Gas Supply Piping
NOTE
The gas supply piping must be installed in accordance to all local,
state and national codes and utility requirem ents.
Figure 7-1: Reco mm en de d Ga s Supp ly Pip ing
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 7-1. For Canadi an
installations the main shutoff valve must be tagged and identified by the installer.
3. Install a sediment trap (drip leg) on the g as supply lin e prior to connecting to the Esteem
boiler gas train as shown in Figure 7-1.
4. Support the gas piping using hangers. Do not support the piping by the unit or its
com ponents.
5. Purge all air from the gas supply piping.
6. Before placing the boiler into operation, test all connections for leaks.
7. Close the manual shutoff valve during any pressure test with less than 13” W.C..
8. Disconnect the Esteem boiler and its gas valve from the gas supply piping during any
pressure test greater than 13” W.C..
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OMM-0089_0A Installation, Operation & Maint enance Manual Gas Piping
Connecting the Gas Piping (Cont.)
WARNING!
Do not check for gas l eaks with an open flame. Use a gas detection
device or bubbl e test. Failure to check for gas leaks can cause
severe personal injury, death or substantial property dam age.
9. 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.
WARNING!
• Failure t o apply pipe dope as detail ed above can result in severe
personal injury, death or substanti al property damage.
• 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 turning and the second to
tighten adjacent piping. Failure to support the boiler gas piping
connection could damage the gas line components.
7.2 NATURAL GAS
7.2.1 Pipe Sizing - Natural Gas
Refer to Table 7-1 for schedule 40 metallic pipe length and diameter requirements for natural
gas, based on rated Esteem 399 Low NOx boiler input (divide by 1,000 to obtain cubic feet per
hour).
• Table 7-1 is based on Natural Gas with a specific 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.
Table 7-1: Natural Gas Piping Sizing
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
Page 46 of 188 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0089_0A
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Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hou r
(based on 0.60 specific gravity, 0.30” W .C. pressure drop)
GF-135 Esteem 399 Low NOx Boiler Chapter 7
OMM-0089_0A Installation, Operation & Maint enance Manual Gas Piping
7.2.2 Natural Gas Supply Pressure Requirements
Pressure required at the gas valve inlet supply pressure port:
•
o
Maximum 13” W.C. at flow or no flow conditions to the burner.
o
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.
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 attem pt 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
adjustm ent. Attem pts by the installer t o adjust or measure the g as
valve outlet pressure could result in damage to the valve, causing
potential severe personal injury, death or substantial property
damage.
NOTE
The natural gas orifice for th e Esteem 399 Low NOx boiler is 0.339” (8.6
mm).
7.3 PROPANE GAS
7.3.1 Pipe Sizing – Propane Gas
Contact the local propane gas supplier for recommended sizing of piping, tanks and 100%
lockup gas regulat or.
WARNING!
The unit is shipped with a propane conversion kit, which is located
on the t op of the unit in the instruction packet. This kit includes all
the nec essary parts and instructions to perform the conversion
from natural gas to propane gas. If this conversion kit is missing,
please contact AERCO Technical Support before installing the
Esteem boiler to use propane g as.
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 conversi on lab el.
If there is a conflict or doubt on the burner set up, r em ove the gas
valve and check for the propane orifice (Figure 7-2). Failure to
ensure proper burner setup could result in severe personal injury,
death or substantial property d am age.
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7.3.2 Propane Gas Supply Pressure Requirements
1. Adjust the propane supply regulator provided by the gas supplier for 13” W.C. maxim um
pressure.
2. Pressure required at the gas valve inlet supply pressure port:
• Maximum 13” W.C. at flow or no flow conditions to the burner.
• 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.
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 suitabl e for natural gas and propane and requires no field
adjustment. Attempts by the installer 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.
WARNING!
Prior to start up, ensur e the unit is set to fire propane. Check the
rating label for the type of fuel. Check the gas valve for propane
conversi on label. If there is a conflict or doubt on the burner set up,
remove the gas valve and check for the prop ane orifice. See Figure
7-2. Failure to ensure proper burner setup could result in severe
personal injury, death or substantial property dam ag e.
NOTE
The propane orifice required for the Esteem 399 Low NOx boiler is
0.264” (6.7 mm).
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GF-135 Esteem 399 Low NOx Boiler Chapter 7
VENTURI
COVER SCREW
GAS VALVE
GAS INLET
OR PROPANE)
GASKET
THROTTLE SCREW
(RED PLASTIC SLEEVE)
INLET PRESSURE PORT
BLOWER
ASSEMBLY
OMM-0089_0A Installation, Operation & Maint enance Manual Gas Piping
ORIFACE
(NATURAL GAS
OFFSET PRESSURE
Figure 7-2: Gas Valve and Component Locations
(With Gas Valve Shown Separated From the Blower Assembly)
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GF-135 Esteem 399 Low NOx Boiler Chapter 8
OMM-0089_0A Installation, Operation & Maint enance Manual Internal Wiring
CHAPTER 8: INTERNAL WIR ING
WARNING!
ELECTRICAL SHOCK HAZARD. For your safety, disconnect
electrical power supply to the unit before servicing or m aking any
electrical connections to avoid possible el ectric shock hazard.
Failure to do so can cause severe personal injury or death.
WARNING!
Prior to servicing, label all wires before disc onnecting. Wiring errors
can cause improper and dangerous operation. V erify proper w iring
and operation after servicing.
8.1 GENERAL REQUIREMENTS
W iring 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 m inimum.
The Esteem boiler 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.
8.2 FUSE LOCATIONS
8.2.1 EZ-SETUP Contr oller Mod ule Fus es Location
The control module contains two (2) internal replaceabl e 5A fuses, as shown in Figure 8-1.
Figure 8-1: Control Modul e Fu se Lo cati on
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GF-135 Esteem 399 Low NOx Boiler Chapter 8
2.5A
23,24,25
CH2 /System Pump
2.5A
26,27,28
Auxiliary Boiler Pump
Fuse Locations
OMM-0089_0A Installation, Operation & Maint enance Manual Internal Wiring
8.2.2 Line Voltage Fuses Location
Additional fuses are also located on the line voltage term inals as shown in Figure 8-2.
Fuse S ize Terminals Purpose
2.5A 29,30,31 DHW Pump / Diverter Valve
2.5A 32,33,34 CH1 Pump/Diverter Valve
8.0A 35,36,37 Power Supply
2.5A 38,39,40 Alarm
Figure 8-2: Line Voltage Fuse Locations
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OMM-0089_0A Installation, Operation & Maint enance Manual Internal Wiring
Figure 8-3: Esteem Boiler Internal Wiring Diagram
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GF-135 Esteem 399 Low NOx Boiler Chapt er 9
OMM-0089_0A Installation, Operation & Maintenance Manual External Wiring
CHAPTER 9: EXTE RNAL WI RIN G
9.1 INSTALLATION COMPLIANCE
All field wiring made during installation must comply with:
National Electrical Code NFPA 70 and any other national, state, pr ovincial or local codes
•
or requirem ents.
In Canad a, CSA C22.1 Canadian Electrical Code Part 1, and any other local codes.
•
WARNING!
ELECTRICAL SHOCK HAZARD. Before m aking any el ectrical
connections to the unit, disconnect electrical power supply at the
service panel. Failur e to comply can cause severe personal injury
or death.
NOTE
The line voltage terminals ar e l ocated on the right set of t erminals
23 through 40. The low voltage t erminals are l ocated on the left set
of terminals 1 through 22.
9.2 LINE VOLTAGE CONNECTIONS
To connect line voltage electrical power to the unit, perform the following.
Connecting Line Voltage to the Esteem Boiler
1. Connect a dedicated 120 VAC/15A service to the line voltage terminal strip on the wiring
panel below the Esteem boiler control module, as shown in Figure 8-3.
2. Route the incoming 120 VAC power wire through the provided openings in the bottom jacket
panel.
3. The unit is provided with a service switch located on the front pan el, check local code
requirem ents for compliance.
NOTE
If local codes or conditions require an additional service switch, the
installer m ust install a fused disconnect for 15 amp (minimum)
service switch.
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GF-135 Esteem 399 Low NOx Boiler Chapter 9
Auxiliary
Boi ler Pump
System
Pump
ON
ON
OMM-0089_0A Installation, Operation & Maint enance Manual External Wiring
9.3 CIRCULATOR WIRIN G
To wire the circulator, perform the following.
Wiring the Circulator
1. Reference Tabl e 9-1 to det ermine the appropriate circulator connections required. The
circulator connections used will depend on the syst em s piping layout.
Table 9-1: Circular Operation Default Settings
Call CH (1) Pump DHW Pump
CH 1 or CH 2 Call
DHW Call OFF (Note 1)
ON
OFF (Note 1)
ON
ON
OFF (Note 1)
NOTE 1
Domestic Hot Water Priority can be disabled in the Installer Menu
which allows the CH (1) and DHW circulators to operate at the
same tim e. Consult Chapter 10, B asic Esteem Controls, for m ore
inform ation.
NOTES
• The system circulator can also been en abled during a DHW Call
in the Installer Menu. Consult Section 10, Basic Esteem
Controls, for m ore information.
• Each circulator is individually fused with a 2.5A fuse located in
the terminal strip. The total combined amp draw of the CH (1),
DHW, and Auxiliary Boiler Circulators must not exceed 3 am ps at
any time for the Esteem boiler. Use an isol ation relay to lower the
total com bined amp draw if exceeding these limits.
2. Connect the CH circulator to the line volt ag e term inal strip on the wiring panel bel ow the
Esteem control module, as shown in Figure 8-3. The CH circulator is enabled during a CH 1
or CH 2 call. This circulator is used to supply heat to the central/space heating loop.
3. Connect the DHW circulator to the line voltage term inal strip on the wiring panel below the
4. Connect the Auxiliary Boiler circulator to the line voltage terminal strip on the wiring panel
5. Connect the System circulator to the line voltage terminal strip on the wiring pan el bel ow the
Esteem control module, as shown in Figure 8-3. The DHW circulator is enabled during a
DHW call. This circulator is used to supply heat to an indirect hot water heater.
below the Esteem control module, as shown in Figure 8-3. The auxiliary boiler circulator is
enabled during a CH or a DHW call. This circulator is typically used in r etrofit applications
where the CH and DHW systems are connected to a common boiler supply.
Esteem control module, as shown in Figure 8-3 The system circulator is enabled during a
CH1 or CH2 call with the factory default settings. This circulator is typically used to circulate
water in the secondary CH loop when zoning with zone valves.
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9.4 ALARM WIRING
The alarm contact closes when ever the Est eem is in a soft or hard lockout. This dry contact can
be connected t o an external monitoring system or other indicator to al ert the operator that the
Esteem is locked out.
Connect the external monitoring device to the line voltage terminal strip on the wiring panel
below the Esteem control module, as shown in Figure 8-3.
NOTE
The alarm contact is fused with a 2.5A fuse located in the terminal
strip. An isolation relay is required if the external monitoring device
draws more than 2.5A.
9.5 LOW VOLTAGE CONNECTIONS
Line and Low Voltage wiring should be separated to prevent possible electrical noise on the low
voltage circuits. Line and Low Voltage wiring should use separate electrical knockouts on the
Esteem cabinet and should remain separat ed inside the Esteem.
CH and DHW call connections to the Esteem require a dry contact with no external voltag e
present. Ensure n o external voltage is pr esent on each set of wires before connecting to the
Esteem . If external voltage is present, the use of an isolation relay is required to prevent
damage to the Esteem EZ-SETUP controller.
9.6 THERMOSTAT WIRING
The Esteem EZ-SETUP Controller has two thermostat call inputs for m ultiple zone / temperature
systems. This allows each call to have its own outdoor reset curve and m aximizes the efficiency
of the system .
WARNING!
Simultaneous CH1 and CH2 calls will result in the Esteem boiler
operating at the high est target t emperature. The use of a mixing
device on the lower temperature zones may be required to protect
the lower tem perature zones from damage.
Wire a thermostat to the Esteem unit as follows.
Wiring the Thermostat to the Esteem Boiler
1. Connect the room thermostat or dry contact end switch to the low voltage term inal strip on
the wiring panel below the Esteem control module, as shown in Figure 8-3.
2. Follow thermostat manufacturer’s instructions for proper installation. Therm ostat should b e
located on an inside wall away from any heat or cold influences such as drafts, lights,
firepl aces, etc.
3. Set the therm ostat anticipator (If applicable) as follows:
• Set for 0.2 amps when wired directly to the Esteem.
• Set to match the electrical power requirements of the connected device when wired to
zone relays or other devices. Refer to the relay m anufacturer’s specifications and the
therm ostat instructions for addition al information on anticipator setting.
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9.7 OUTDOOR SENSOR WIRING
The Outdoor Reset function and Warm Weather Shutdown (WWSD) features require the
connection of the included outdoor temperature sensor. See Chapt er 13 for outdoor sensor
installation and setup.
9.8 DOMESTIC HOT WATER WIRING
The Domestic Hot W ater terminals can accept either a call from an aquastat (switch) or
tem perature sensor. Use of the included indirect water heater sensor is recommended.
Connect the DHW aquastat or temperature sensor to the low volt ag e term inal strip on the wiring
panel below the Esteem control module, as shown in Figure 8-3.
9.9 ADDITIONAL BOILER LIMITS
Additional boiler limits (High Limit, LWCO, etc.) can be wired into either the Manual Reset Lim it
or Auto Reset Limit terminals of the Esteem. These limit connections will provide a “hard”
lockout requiring a manual reset of the Esteem or a “soft” lockout in which the Esteem will
automatically reset when the limit resets.
NOTE
Manual Reset Limit and Auto Reset Limit connections to the
Esteem require a dry contact with no external voltag e present.
Ensure no external volt-age is present on each set of wires befor e
connecting to the Esteem. If external voltage is present, the use of
an isolation relay is required to prevent damage to the controller.
Remove the factory installed jum per wire on the Manu al Reset or Auto Reset terminals that will
accept the additional b oiler limit.
Connect the additional boiler limit to the l ow volt age terminal strip on the wiring panel below the
Esteem control m odule, as shown in Figure 8-3.
9.10 EXTERNAL MODULATION CONTROL
The Esteem firing rate can be controlled by an external modulating boiler controll er. See
Chapter 14, External Modulating Control, for external modulation signal wiring and setup.
9.11 SYSTEM SENSOR WIRING
An optional system temperature sensor can be pl aced on the central heating loop to c ontrol th e
temperature in the central heating loop instead of the boiler l oop. When connected, the Esteem
will automatically modulate to maintain the target temperature in the central heating loop. The
boiler supply temperature sensor will continue to be used as a high temperature limit.
WARNING!
Locate the system temperature sensor where it can accurately
measure the supply temperature to the heating system. Inaccurate
system temperature readings could lead to overheating or under
heating resulting in property damage.
Connect the system temperature sensor to the l ow voltage term inal strip on the wiring panel
below the Esteem control module, as shown in Figure 8-3.
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9.12 CASCADE WIRING
The EZ-SETUP controller includes the ability to operat e up to six boilers together as one without
the need for external controllers. Consult Chapter 10, Basic Controller Operation, for more
inform ation.
9.13 MODBUS WIRING
The EZ-SETUP controller includes the ability to communicate with building management
systems (BMS) through a Modbus interface. Con sult Section 10, Basic Controller Operation, for
more inform ation.
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Figure 9-1: Multiple Zone Field Wiring Using Zone Valves
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GF-135 Esteem 399 Low NOx Boiler Chapt er 9
OMM-0089_0A Installation, Operation & Maintenance Manual External Wiring
Figure 9-2: Multiple Zone Field Wiring Using Zone Circulators
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Figure 9-3: Esteem 399 Wiri ng - Zoning with Zone Circulators
Figure 9-4: Esteem 3 99 W ir i ng - Zoning with Zone Valves
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Figure 9-5: Esteem 3 99 W ir i ng – Multiple Zone Valve with Single System/Boiler Circulator
Figure 9-6: Esteem 3 99 W ir i ng – Single Zone System with Single System/Boiler Circulation
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GF-135 Esteem 399 Low NOx Boiler Chapter 10
Installer Button
Navigation Buttons
ON/OFF Switch
Menu Display
Pressure Gauge
OMM-0089_0A Installation, Operation & Maint enance Manual EZ-SET Controller
CHAPTER 10: BASIC EZ-SET CONTROLLER OPERATION
NOTE
This chapter describes the g eneral operation of the EZ-SET
controller. See Chapter 18 for in-depth information concerning
controller installer setup, operation, and menus.
10.1 EZ-SET CONTROLLER INTRODUCTION
The Esteem Boiler Managem ent System is designed to be flexibl e yet easy to use. The
controller monitors and controls the Esteem boiler to operat e as efficiently as possible. The
controller monitors the boil er supply, return and flue gas temperatures and operates the igniter,
gas valve and blower and uses this inform ation to modulat e the boil er’s firing rat e to m aintain the
required setpoint. All controller features are easy to use through a graphical display where
inform ation is presented either graphically or in plain English, so code charts are not required.
Figure 10-1 shows an image of the EZ-SET controller front panel, including menu display,
navigation buttons, ON/OFF switch, Installer button, and temperature g auge.
10.2 EZ-SET CONTROLLER FEATURES AND FUNCTIONS
The EZ-SET controller offers many advanced control options, which may be adjusted for vari ou s
applications to achieve optim um boiler efficiency and operation, and includes:
• Two central / space heating (CH) call inputs with separate outdoor reset curves.
• Domestic Hot Water (DHW) call input with optional priority.
• EZ Setup feature allows the installer to quickly customize the EZ-SET controller for each
installation.
• Cascade function allows up to six boilers to operate togeth er in a single heating system.
• Modbus interface for integrating with building management systems.
These advanced features are adjustable in the Installer Menu after entering an access
code.
Figure 10-1: EZ-SET Control ler Front Panel Features
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10.3 CONTROLLER NAVIGATION
Navigation is per form ed through four arrow buttons UP, DOWN, LEFT, RIGHT with a center OK
button for making selections and entering information. The INSTALLER button (the small round
button) provides the installing contractor with full access to all available features aft er entering a
password. Refer to Chapter 18 of this manual for Install er level m enu functions.
Figure 10-2: EZ-SET Controller Navigation Buttons
The Main Menu can be entered from the Home Screen by pressing the OK button. The menu
system utilizes icons to represent each selection. The current selected menu is displayed as a
reversed image with a text description shown at the top of the display. Menus can be entered by
highlighting the desired icon and pressing the OK button. The Home Screen ( ) icon at the
bottom of each screen r eturns to the Hom e Screen when selected. The Previ ous Screen ( )
icon at the bottom of each screen returns to the previous screen when selected.
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Figure 10-3: Controller Menu Structure
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GF-135 Esteem 399 Low NOx Boiler Chapter 10
The status line displays the current operating state of the Esteem boiler.
See Table 10-1, for a list of all status line messages.
OMM-0089_0A Installation, Operation & Maint enance Manual EZ-SET Controller
10.4 HOME SCREEN
The Home Screen presents status information in a very user friendly way so that the current
state of the boiler can be quickly accessed.
Figure 10-4: EZ-SETUP Controller Home Screen Menu
The screen backlight will illuminate when any button is pressed and remain illuminated for five
minutes. Press the UP or DOW N buttons to turn on the backlight while at the Home Screen
without making any changes. The screen c ontrast can be adjust ed at the Home Screen by
pressing and holding the OK button then pressing and holding the LEFT arrow along with the OK
button. The contrast can then be increased by pressing the UP button or decreased by pressing
the DOW N button while holding in the OK button and LEFT arrow. All buttons must be released
and the procedure performed again to switch between increasing and decreasing contrast.
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CH Demand
DHW Burner Delay
OMM-0089_0A Installation, Operation & Maint enance Manual EZ-SET Controller
Table 10-1: EZ-SET Controller Status Line Messages
Status Lin e Mes sag e Description
Standby
DHW Demand
CH / DHW Demand
DHW Priority
Priority Timeout
External Demand
Slave Operation
Manual Operation
CH Burner Delay
CH Setpoint Reached
DHW Setpoint Reached
CH Post Pump
DHW Post Pump
Freeze Protection
Boiler Protection
Indicates that the Esteem is ready to respond when a demand is
received.
A central heating call has been received.
A domestic hot water call has been received.
Central heating and domestic hot water calls are being received
simultaneously. Both calls are being satisfied simultaneously because
domestic hot water priority has been disabled.
Central heating and domestic hot water calls are being received
simultaneously. Domestic hot water call is being satisfied first because
it has priority over central heating calls.
Central heating and domestic hot water calls are being received
simultaneously. The domestic hot water priority time limit has been
exceeded. Priority will now switch back and forth between central
heating and domestic hot water calls until one call is satisfied.
An external modulation call has been received.
The Esteem is responding to a call from the master Esteem boiler in a
cascade system.
The burner or circulators have manually been enabled in the Installer
Menu.
The burner will not fire until the call blocking time has elapsed.
The burner will not fire until the call blocking time has elapsed.
The burner is not fired because the supply/system water temperature
exceeds the setpoint. The central heating circulator continues to
operate and the burner will fire again once the supply/system water
temperature drops below the setpoint.
The burner is not fired because the supply/system water temperature
exceeds the setpoint. The domestic circulator continues to operate
and the burner will fire again once the supply/system water
temperature drops below the setpoint.
The central heating circulator is running to remove heat from the
Esteem at the completion of a call.
The domestic hot water circulator is running to remove heat from the
Esteem at the completion of a call.
The burner is fired because the freeze protection feature has been
activated. Freeze protection will end once the supply/system water
temperature is raised to 60ºF [16ºC].
The burner firing rate is being reduced because of an excessive
difference between the boiler supply and return temperatures. The
firing rate will begin increasing once the temperature difference is less
than 45ºF [25ºC].
Lockout Description
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The lockout which currently has the Esteem shut down is displayed.
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10.5 MAIN MENU
The Main Menu can be entered from the Home Screen by pressing the OK button. The menu
system utilizes icons to represent each selection. The currently selected menu is displ ayed as a
reversed image with a text description shown at the top of the display. Menus can be ent ered by
highlighting the desired icon and pressing the OK button.
Figure 10-5: EZ-SETUP Controller Main Menu
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10.6 EZ SETUP
Navigation: Home Screen > Main Menu > EZ Setup
The EZ Setup menus provide a simple way to quickly customize the controller for each
installation. EZ Setup prompts the user to m ake sel ections which allows the Esteem 399 boiler
to be setup very quickly without searching through long lists of settings and manually making
adjustments.
10.7 HEATING EZ SETUP
Navigation: Home Screen > Main Menu > EZ Setup > Heating EZ Setup
Heating EZ Setup allows the installer to quickly customize the central heating settings for the
application.
10.7.1 Select CH Demand (Default: Switch & Outdoor Reset)
Select CH Demand pr om pts the installer t o select how a CH Demand is generated. Press th e
UP or DOW N buttons to select the CH Dem and type then press the OK button to store th e
setting. The Select CH Demand options are:
• Sw itch & Outdoor Reset: This option is only displayed when the outdoor temperature
sensor is connected. A central h eating call from a thermostat or zone panel will enabl e
the Esteem and the setpoint will vary with the outdoor temperature for central heating
calls.
• Switch & Setpoint: This option is only displayed when the outdoor tem perature sensor is
not connected. A central heating call from a therm ostat or zone panel w ill enable the
Esteem and the setpoint will be fixed for central heating calls
• Constant & Outdoor Reset: This option is only displayed when the outdoor temperature
sensor is connected. The Esteem will maintain set-point without an external call from a
therm ostat or zone panel. The set-point will vary with the outdoor temperature for central
heating calls.
• Constant & S etpoint: The Esteem will maintain setpoint without an external call from a
therm ostat or zone panel. The setpoint will be fixed for central heating calls.
• 0-10V Modulation Signal: This option allows the Esteem firing rate to be controlled by
an external contr ol system.
OR
Figure 10-6: Select CH Demand Menu (with Outdoor Sensor & W it hou t)
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10.7.2 CH1 Setpoint (Default: 180°F [82°C])
CH1 Setpoint prompts the installer to enter the fixed setpoint for a CH1 heating call when a
Setpoint option is chosen in Select CH Demand. Press the LEFT or RIGHT buttons to adjust the
CH1 Setpoint then press the OK button to store the setting.
Figure 10-7: Select CH1 Setpoint Menu (Same as CH2 Setpoint Menu)
10.7.3 CH2 Setpoint (Default: 140°F [60°C])
CH2 Setpoint prom pts the installer to ent er the fixed setpoint for a CH2 heating call when a
Setpoint option is chosen in Select CH Demand. Press the LEFT or RIGHT buttons to adjust the
CH2 Setpoint then press the OK button to store the setting.
10.7.4 Select CH1 Reset Curve (Default: Finned Tube Baseboard)
Select CH1 Reset Curve pr om pts the installer to select an outdoor reset curve for a CH1 heating
call when an Outdoor Reset option is chosen in Select CH Dem and. Outdoor reset curve
presets are available to cover most applications. Th e outdoor reset curve can also be adjusted
to any desir ed settings in the Install er Menu. Press the UP or DOW N buttons to select the
outdoor reset curve appropriate for the type of heating system then press the OK button to stor e
the setting.
10.7.5 Select CH2 Reset Curve (Default: Low Mass Radiant)
Select CH2 Reset Curve pr om pts the installer to sel ect an outdoor reset curve for a CH2 heating
call when an Outdoor Reset option is chosen in Select CH Dem and. Outdoor reset curve
presets are available to cover most applications. Th e outdoor reset curve can also be adjusted
to any desir ed settings in the Install er Menu. Press the UP or DOW N buttons to select the
outdoor reset curve appropriate for the type of heating system then press the OK button to stor e
the setting.
Figure 10-8: Select CH1 Reset Curve Menu (Same as CH2 Reset Curve Menu)
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GF-135 Esteem 399 Low NOx Boiler Chapter 10
High Mass Radiant
Finned Tube B as eboard
120ºF [49ºC]
180ºF [82ºC]
Radiators
Fan Coil
OMM-0089_0A Installation, Operation & Maint enance Manual EZ-SET Controller
Table 10-2: Outdoor Reset Preset Selections
Preset Minimum Setpoint Maximum Setpoint
Low Mass Radiant 80ºF [27ºC] 140ºF [60ºC]
80ºF [27ºC] 120ºF [49ºC]
Cast Iron Baseboard 100ºF [38ºC] 170ºF [77ºC]
120ºF [49ºC] 170ºF [77ºC]
140ºF [60ºC] 180ºF [82ºC]
10.7.6 Set Warm Weather Shutdow n Temperature (Default: OFF)
Warm W eather Shutdown prompts the installer to enter an optional outd oor temperature at which
to disable th e central heating function. The Esteem will continue t o respond to a domestic hot
water call or a 0-10VModulation Signal when the outdoor temperature exceeds the W arm
Weather Shutdown Temperature setting. Press the LEFT or RIGHT buttons to adjust the Warm
Weather Shutdown Temperature then press the OK button to store the setting. The W arm
Weather Shutdown icon ( ) is displayed on the home screen when the outdoor temperature
reaches the Warm Weather Shutdown Temperature.
Figure 10-9: Set Warm We ath er Sh utdown Te mp er ature M enu
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10.8 DOMESTIC HOT WATER EZ SETUP
Navigation: Home Screen > Main Me nu > EZ Set up > DHW EZ Setup
Domestic Hot W ater EZ Setup allows the installer to quickly custom ize the domestic hot water
settings for the application.
10.8.1 Select DHW Demand (Default: Switch)
Select DHW Demand prom pts the installer to select the type of device which will generate a
DHW call. Press the UP or DOWN buttons to select the DHW Dem and type then press the OK
button to store the setting. The Select DHW Demand options are:
• Switch: A domestic hot water c all from an aquastat or dry contact switch will enabl e the
Esteem with a fixed setpoint for a dom estic hot water call.
• Sensor: This option requires the use of Indirect W ater Heater Sensor 69107. The
Esteem will monitor the DHW storage temperature and generate a domestic hot water
call when the temperature drops bel ow the DHW Storage Setpoint by 6ºF [3ºC].
Figure 10-10: Select DHW Demand Menu
10.8.2 Boiler DHW Setpoint (Default: 186°F [86°C])
Boiler DHW Setpoint prompts the installer to enter the fi xed boiler setpoint temperature during a
Domestic hot water call when the Switch option is chosen in Select DHW Dem and. Press the
LEFT or RIGHT buttons to adjust the Boiler DHW Setpoint then p ress the OK button to store the
setting.
Figure 10-11: Boiler DHW Setpoint Menu
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10.8.3 DHW Storage Setpoint (Default: 140°F [60°C])
DHW Storage Setpoint prompts the installer to enter the domestic hot water storage setpoint
tem perature when the Sensor option is chosen in Select DHW Dem and. Press the LEFT or
RIGHT buttons to adjust the DHW Storage Setp oint then press the O K button to store the
setting.
Figure 10-12: DHW Stor ag e Setpo int M enu
NOTE
The Boiler DHW Setpoint will automatically be set 46°F [25°C]
higher than the DHW Storage Setpoint setting.
10.8.4 DHW Priority Timeout (Default: Off)
DHW Priority Tim eout prompts the installer to enter an optional time limit that a dom estic hot
water call has priority over a central heating call. Press the LEFT or RIGHT buttons to adjust the
DHW Priority Timeout then press the OK button to store the setting.
Figure 10-13: DHW Priority Timeout Menu
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10.9 EZ SETUP RESET
Navigation: Home Screen > Main Me nu > EZ Set up > EZ Setup Reset
EZ Setup Reset allows the installer t o reset all EZ Setup settings back to the original factory
defaults. Follow the on screen instructions to reset all EZ Setup settings back to the original
factor y defaults.
Figure 10-14: EZ Setup Reset Menu
10.10 DISPLAY EZ SETUP
Navigation: Home Screen > Main Me nu > EZ Set up > Display EZ Setup
Display EZ Setup allows the installer to select the type of temper ature units displayed as well as
the language used for all text. Press the UP or DOW N buttons to select then press the OK
button to store the setting.
Figure 10-15: Display EZ Setup (Temperature Units Select) Menu
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10.11 CH/DHW OPERATION
Navigation: Home Screen > Main Me nu > CH / DHW Operation
CH / DHW Operation pr ovides a simple way to disabl e either the central heating or domestic hot
water functions of the Esteem. Operation can be enabled and disabled by selecting the central
heating or domestic hot water icon then pressing the OK button to toggle between enabled an d
disabled. An icon with an X through it indicates that function has been disabled. The disabled
icon is also displayed on the home screen when a function has been disabled.
Figure 10-16: Heating Enabled Menu
10.12 BOILER INFORMATION
Navigation: Home Screen > Main Me nu > Boiler Inform a t ion > Boiler Information
Boiler Inform ation provides real time operating information of the Esteem boiler. Each line
contains an information item followed by its current value. Six inform ation items ar e displayed on
the screen at one time. Press the UP or DOW N buttons to scroll through additional inform ation
item s. See Table 10-3 on the next page for a list of all inform ation item s.
Figure 10-17: Boiler Information Menu
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Table 10-3: Information Displayed Using Boiler Information Menu
Information I tem Description
Boiler Status
Displays the current operating state of the Esteem . This is the
same as the status line on the hom e screen.
Heating Call Displays if a central heating call is present.
DHW Call Displays if a domestic hot water call is present
Boiler F iring Ra t e Displays the current firing rate of the Esteem.
Flame Ionization Current Displays the current flame ionization current from the igniter.
Boi ler Setpoint Displays the current setpoint of the Esteem.
Boiler Supply Temperature Displays the current supply temperature of the Esteem.
Boiler Return Temperature Displays the current return temperature of the Esteem .
Boiler Flue Temperature Displays the current flue tem peratur e of the Esteem.
Outdoor Temperature Displays the current outdoor temperature.
DHW Storage Temperature
External Modulation Signal
CH Ignit ion s
Displays the current DHW storage temperature when Indirect
Water Heater Sensor 69107 is installed.
Displays the current external m odulation signal being rec eived
from an ext ernal controller.
Displays the number of central heating ignitions since the unit
was installed. This counter increases in increments of twenty.
CH Runtime
DHW Ign it ion s
DHW Runtime
Displays the number of hours the Esteem has run for a central
heating call since the unit was installed.
Displays the number of domestic hot water ignitions since the
unit was installed. This counter increases in increments of
twenty.
Displays the number of hours the Esteem has run for a
domestic hot water call since the unit was installed.
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10.12.1 Boiler Infor mat ion Logg ing
Some information items include a logging function which records one sample every 12 minutes
to produce a graph of the last 24 hours. Select the inform ation item in Boiler Information then
press the OK button to view its graph. The following items have a logging function:
• Boiler Firing Rate
• Flame Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Tem perature
• Outdoor Temperature
• DHW Storage Temperature
• External Modulation Signal
Figure 10-18: Boiler Information Menu
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10.13 LOCKOUT HISTORY
Navigation: Home Screen > Main Menu > Boiler Information > Lockout History
Lockout History records the last eight lockouts. Each line contains a lock-out description
followed by how long ago the lockout occurred. Six lock-outs are displ ayed on the screen at on e
time. Press the UP or DOW N buttons to scroll through additional lockouts. See Tables 10-4 and
10-5 for a list of lockouts and descriptions.
Figure 10-19: Lockout History Menu
10.13.1 Lockout Details
Som e information items are recorded at the time of a lockout to aid in di agnosing the cause of
the lockout. Select the lockout description in Lockout History then press the OK button to view
the recorded information. Press the UP or DOWN buttons to scroll through the recorded
inform ation. The following information items are recorded at the time of a l ockout:
• Boiler Status
• Heating Call
• Domestic Call
• Boiler Firing Rate
• Flame Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Temperature
• Outdoor Temperature
• System Temperature
Figure 10-20: Lockout Details Menu
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Figure 10-21: Lockout Screen Information
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Table 10-4: Manual Reset Hard Lockout Descriptions
Code Locko ut Message Description
E1 Failed Ignition The burner failed to light after 5 ignition attem pts.
E2 False Flame A flam e is being detected prior to ignition.
E3 High Boiler Temperature Boiler temperature exceeds 212°F [100ºF]
E5 Blower Speed
Blower is not at correct speed or sp eed signal is not
being received by control module.
E8 Flame Circuit Error Flam e circuit test failed.
E9 Gas Valve Circuit Error Gas valve circuit test failed.
E13 Reset Limit Reached Resets are limited to 5 every 15 minutes.
E15 Sensor Drift Supply or return sensor reading has drifted.
E16 Supply Sensor Stuck Supply sensor reading is not changing.
E17 Return Sensor Stuck Return sensor reading is not changing.
E18 Sensor Failure Supply or return sensor reading changed very rapidly.
E21 Internal Control Fault A / D conversi on error.
E30 Supply Sensor Shorted
E31 Supply Sensor Open
E43 Return Sensor Shorted
A short circuit has been detected in the boiler supply
tem perature sensor circuit.
An open circuit has been detected in the boiler supply
tem perature sensor circuit.
A short circuit has been detected in the boiler return
tem perature sensor circuit.
E44 Return Sensor Open
An open circuit has been detected in the boiler return
tem perature sensor circuit.
E80 Return > Supply Return temperature is higher than supply temperature.
E87 External Lim it Open An external manual reset limit has opened.
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E25
Internal Control Fault
CRC check error.
A short circuit has been detected in the DHW temperature
E76
E81
Sensor Drift
Supply and return temperatures are not equal.
An open circuit has been detected in the system
A short circuit has been detected in the outdoor
E94
Internal Display Fault
Display m em ory error.
An open circuit has been detected in the outdoor
E97
Casc ade Mismatch
Cascade configuration has changed.
E98
Casc ade Bus Error
Communication with other boilers has been lost.
Communication between boiler display and control module
OMM-0089_0A Installation, Operation & Maint enance Manual EZ-SET Controller
Table 10-5: Automatic Reset Soft Lockout Descriptions
Code Lock out Message Description
E7 High Flue Temperature Flue temperature exceeds high limit.
E12 Internal Control Fault EEPROM misconfiguration.
E32 DHW Sensor Short ed
E33 DHW Sensor Open
E34 Low Voltage
sensor circuit.
An open circuit has been detected in the DHW
tem perature sensor circuit.
Line voltage has fall en below an acceptable operating
level.
E37 Low W ater Water level has fallen below an acceptable operating level.
E45 Flue Sensor Shorted
E46 Flue Sensor Open
A short circuit has been detected in the boiler flue
tem perature sensor circuit.
An open circuit has been detected in the boiler flue
tem perature sensor circuit.
External Lim it Open An external automatic reset boiler limit has open ed.
E89 Incorrect Setting A parameter setting is outside the settings range.
E90 Firmware Mismatch
E91 System Sensor Shorted
E92 System Sensor Open
Control module and display firm ware versions are
incompatible.
A short circuit has been detected in the system
tem perature sensor circuit.
tem perature sensor circuit.
E93 Outdoor Sensor Shorted
tem perature sensor circuit.
E95 Supply Sensor Error Supply sensor reading is invalid.
E96 Outdoor Sensor Open
E99 Controller Bus Error
tem perature sensor circuit.
has b een lost.
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GF-135 Esteem 399 Low NOx Boiler Chapter 11
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CHAPTER 11: START-UP PREPARATION
NOTE
Requirem ents bel ow m ust be m et for warranty coverage of Esteem
heat exchangers. A thorough cleaning of any existing system,
using approved heating syst em cleaning agents is required prior to
installation of the Esteem boiler. System should be treated with an
approved inhibitor after filling for long term protection.
11.1 CHECK BOILER SYSTEM WATER CHEMISTRY
WARNING!
Do not use petroleum -based cleaning or sealing compounds in the
boiler system . Damage to seals and gaskets in the sys-tem
components could occur, resulting insubstantial property damage.
NOTE
System water including additives must be practically non-toxic ,
having a toxicity rating or Class of 1, as listed in Clinical Toxicology
of Comm ercial Products.
11.1.1 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.
If the pH does not meet this requirement, do not operate the Esteem or leave the unit filled until
the condition is corrected.
11.1.2 Water Hardness Less Than 7 Grains
For areas with unusually hard water (hardness above 7 grains) consult a water treatm ent
com pany.
11.1.3 Chlorinated Water
Do not use the Esteem 399 to heat a swimming pool or spa directly.
Maintain the chlorine level of the water at levels considered safe for drinking.
11.1.4 Flus h Boiler to Remove Sediment
The installer m ust flush the boiler system to remove any sediment to allow proper operation of
the Esteem 399.
Flush the systems until the water runs clean and is free of sediment.
For zon ed 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.
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11.1.5 Check and Test Antifreeze
For boiler system s containing antifreeze solutions, follow the antifreeze manufacturer’s
instructions in verifying the inhibitor level and to ensur e the fluid characteristics are within
specification requirem ents.
Due to the degradation of inhibitors over tim e, antifreeze fluids must be peri odically repl aced.
Refer to the manufacturer of the antifreeze for additional instructions.
11.1.6 Use of Antifreeze in the Boiler System
WARNING!
Never use automotive antifreeze, ethylene glyc ol antifreeze, or
undiluted antifreeze, in the primary system as fr eeze protection.
This can cause severe personal injury, death or substantial
property damage.
Determine the antifreeze fluid quantity using the system water cont ent vol um e and foll owing the
antifreeze manufacturer instructions.
The water volume of the Esteem 399 Low NOx boiler is approximately 7 gallons [26 L].
Remember to include the volume of the expansion tank.
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.
NOTE
Massachusetts Cod e requires the installation of a backflow
preventer if antifreeze is used.
Ensure the concentrati on of antifreeze to water does not exceed a 50/50 ratio.
NOTE
System water, including additives, m ust be practically non-toxic ,
having a toxicity rating or Class of 1, as listed in Clinical Toxicology
of Comm ercial Products.
11.2 BOILER CLEANING
11.2.1 Cleaning an Old Boiler and System
Perform the following to clean an old boiler and system.
Cleaning an Old Boiler and System
1. Drain the existing system.
2. Fill system with fresh water and cleaner.
3. Place existing boiler in operation and run all zones.
4. Follow manufacturer’s instructions for proper cleaner concentration and proper cleaning time.
5. Thoroughly drain and flush system with fresh water after cleaning.
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11.2.2 Cleaning of New Boiler/System:
Perform the following to clean a new boiler and syst em .
Cleaning a New Boiler and System
1. Install new boiler and flush system with clean er water to rem ove any debris.
2. Fill system with fresh water and proper amount of inhibitor.
3. Verify pH and inhibitor level per inhibit or manufacturer’s specs; add inhibitor if necessary.
11.2.3 Filling the Boiler System
Perform the following to fill the boiler system.
Filling the Boiler System
1. Close the boiler drain valve locat ed on the bottom of the unit and any manual or automatic air
vent in the system.
2. Open all syst em isolati on valves.
3. Fill the boiler system to correct system pressur e. Correct pressure will vary with each
application.
NOTE
Typical residential system fill pressure is 12 psi. System pressure
will increase when syst em temperature increases. Oper ating
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 continual makeup water to b e
added to the boiler. Continual makeup water will cause mineral
buildup within the heat exchanger, reducing the heat transfer,
causing possible heat buildup and eventual heat exchanger failure.
11.3 CHECK LOW WATER CUT-OFF DEVICE
The Esteem boiler is provided with a factory installed LWCO device that m easures 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 A-2 in Appendix A for location of the LWCO (Item 6).
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11.4 CHECK FOR GAS LEAKS
WARNING!
Prior to start-up and during initial operation, smell near the floor
and around the unit for gas odor ant 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 propane to make its presence detectable. In some
cases the odor ant can fad e and the gas may n o l onger have an
odor. Prior to start-up of the unit and periodically after start-up have
the propane supplier check and verify the odorant level.
11.5 CHECK THERMOSTAT CIRCUIT
Perform the following to check the thermostat circuit.
Checking the Thermostat Circuit
1. Disconnect the external thermost at wires from the low voltage terminal strip.
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.
4. There should NEVER be voltage measured at the wire ends.
5. If voltage is measured at the panel under any condition, check and correct the external
wiring.
NOTE
In systems using 3-wire zone valves, back-feed of voltage to the
unit is a common problem . Use an isolation relay to prevent
voltage from the external circuit entering the Esteem control panel.
6. Reconnect the external therm ostat wires to the low voltage term inal strip.
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11.6 INSPECTION OF CONDENSATE DRAIN ASSEMBLY
Inspect the condensate drain assembly as follow.
Inspecting the Condensate Drain assembly
1. Inspect and ensure the Condensate Drain Assembly is properly installed as shown in
Figure 6-1 of Ch apter 6.
2. Remove the plug from the Condensat e Drain Assem bly and fill with fresh water.
WARNING!
The condensate drain assembly must be filled with water when the
Esteem boiler is in operation. The condensate drain assembly
prevents flue gas em issions from entering the condensat e line.
Failure to ensure trap is filled with water could result in severe
personal injury or death.
3. Re-Install the plug into the condensate dr ain assembly.
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
CHAPTER 12: START-UP PROCEDURES
12.1 FINAL CHECKS BEFORE START-UP
• Read Chapt er 10 regarding basic operation of the EZ-SETUP controll er and refer to
Chapter 18 for initial installation and in-depth operation of the Boiler Management
System.
• Verify the Esteem 399 and the boiler system are full of water and all system components
are correctly set for oper ation, including the minim um flow rate through the boiler (see
Appendix A).
• Verify Start-up Preparation items outlined in Chapter 11 have been completed.
• Verify all electrical connections are correct and securely fast ened.
• Inspect vent and combustion air piping for signs of det erioration from corrosion, physical
damage or sagging. Verify combustion air and vent piping are intact and correctly
installed and supported. Reference the Esteem boiler vent supplement.
• Verify burner configuration - Propane only.
o Check for proper lab eling on the gas valve and the rating label for propan e
configuration.
o If there is doubt on the burner configuration, remove the gas valve and check for
proper propane gas orifice size: 0.264” (6.7 mm) for Esteem 399 Low NOx boiler .
Refer to Figure 7-2 at the end of Chapter 7 for location of the propane gas orifice.
NOTE
For natural gas applications the Esteem 399 requires an orifice in
size of: 0.330” (8.6 mm)
• Ensure the vent Condensate Drain Assembly is filled with water.
12.2 ESTEEM START-UP
To start up the Esteem boiler, perform the following.
Starting Up the Esteem Boiler
1. Press the ON-OFF button located on the front control panel to the OFF position. Turn ON
the electrical supply/service to the unit.
2. Read and follow the Operating Instructions on the next page.
12.3 OPERATING INSTRUCTIONS (READ BEFORE OPERATING BOILER)
WARNING!
If you d o not follow these instructions, a fire or explosion m ay result
causing property dam ag e, personal injury, or loss of life.
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
READ BEFORE OPERATING
A. This appliance does not have a pilot light. It is equipped with an ignition device, which
automatically lights the burner. Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to
the floor, as som e gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appli ance
• Do not touch or operate any el ectric switch
• Do not use any phone in the building
• Immediately call your gas suppli er from a neighbors phone or
from outside with your cell phone and follow the gas supplier’s
instructions.
• Call the fire department if the gas supplier cannot be reached.
C. Use only your hand to turn the gas ball-valve knob. Never use tools. If the knob will not turn
by h and, do NOT try to repair it, but rather call a qualified service technician. Force or
attempted repair may result in a fire or explosi on
D. Do not use this appliance if any p art h as been submerged under wat er. Immediately call a
qualified service t echnician to inspect the appliance and replac e any part of the control
system and any gas control device that has been submerged under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above.
This appliance is equipped with an ignition
device which automatically lights the burner.
DO NOT try to light the burner by hand.
2. Set room thermostat(s) to l owest setting.
Turn the external manual gas valve handle
clockwise to CLOSED position (valve handl e
shall be perpendicular to gas piping).
3. Turn the service switch on the Esteem
control panel to OFF.
4. Remove the front jacket panel on the unit.
5. Turn the external manual gas valve handle
counter clockwise to OPEN position (valve
handle shall be parallel to gas piping).
6. Wait five (5) minutes to clear out any g as. If
you then sm ell gas in the jacket enclosure or
around the unit, STOP! Follow “B” in the
safety inform ation above. If you don’t smell
gas, go to the n ext step.
7. Turn the service switch on the Esteem
control panel to “ON”.
8. Set room therm ostat(s) to desired setting(s).
9. The Esteem control panel display will show a
sequence of numbers (0,1,2,3,etc.) in the left
digit. Sequence digit 3 or 4 indicates the
boiler is firing. Sequence digit 0 means there
is no call for heat (all external thermostats
are satisfied).
10. 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 service t echnician or gas
supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to its lowest setting.
2. Turn off switch on Esteem control panel, and any d ownstream electrical service switches.
3. Close the external manual gas valve clock-wise to OFF position.
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maintenance Manual Start-Up Procedures
12.3.1 Troubleshooting Start-Up Problems
If the Esteem boiler does not start correctly, follow the procedures below to troubleshoot the
problem.
Troubleshooting Start-Up Problems
1. Check for loose el ectrical connections, blown fuses, (on control module and in terminals) or
an open service switch.
2. Verify CH and DHW operation is enabl ed. A radiator or faucet icon with an X through it
indicates that function is disabled.
3. Check continuity across the LW CO device for a closed circuit. See item 6 in Figure A-2 in
Appendix A.
4. Is an external limit control (if applicable) open? Ensure the external limit is reset to the
closed position.
5. Are the gas supply valves open at the unit and meter?
6. Is incoming gas supply pressure at the unit more than 5”W.C. and less than 13” W.C. for
natural or prop ane with all gas appliances ON or OFF.
7. Are the heating thermostats set above room temperature?
If none of these conditions correct the problem, refer to the Esteem boiler Trouble-Shooting
Guide or contact AERCO Technical Services.
12.4 INSPECTION OF THE ESTEEM BOILER AND SYSTEM
12.4.1 Boiler Piping inspection
Inspect the Boiler system piping and com ponents for leaks. If found, shut down the unit and
repair imm ediately.
Purge any remaining air from the syst em piping. Air in the system piping will interfere with
circulation creating heat distribution problems and system noise.
12.4.2 Vent Piping and Combustion Air Piping inspection
Inspect for gas-tight seals at every connection and seam of the venting and combustion air
piping.
WARNING!
Venting system must be sealed gas-tight to prevent flue gas
spillage and potential carbon monoxide emissions, which will result
in severe personal injury or death.
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
12.4.3 Gas Piping Inspection
Inspect around the unit for gas odor following the procedure outlined in the operating instructions
in Section 12.4 at the end of this chapter.
WARNING!
If any gas leaks are found or suspected, shut the unit down
imm ediately. Use a gas d et ection device or bubble test to locate
the source of the gas leak and repair at once. Do not operate the
unit until the leak is corrected. Failure to comply with this procedure
could result in severe personal injury, death or property damage.
12.4.4 Fla me Pattern and Combustion Verification
To verify the flame pattern and combustion, perform the following procedure.
Verifying Correct Flame Pattern and Combustion
1. Verify the flame pattern through the inspection port of the heat exchanger. The flame should
be blue and stable. The flame should be the length of the burner head openings.
WARNING!
The combustion testing and adjustments must be performed by a
qualified installer, service agency or the gas supplier. All
combustion measurements must be performed with calibrated
equipment to ensure proper reading and accuracy.
2. Test for CO2 or O2 and for CO during high firing rate. The combustion readings should be
within the range listed in Table 12-1. The CO level should not exceed 100 ppm when
com bustion is correct. Perform the foll owing procedure to m anually place the burn er into high
fire.
a) Press the round INSTALLER button, as shown in Figure 12-1.
b) Enter the installer access code “054” by using the LEFT and RIGHT buttons to select a
digit and the UP and DOWN buttons to change the digit. Press the OK button to enter
the access code.
c) Press the RIGHT button to highlight the Manual Operation icon then press the OK button.
OK Button
Installer
Button
Figure 12-1: Installer Button (L) & Manual Operation Menu (R)
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
CO2 Max.
10.50%
11.00%
CO Max.
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
Verifying Correct Flame Pattern and Combustion (Cont.)
d) Press the OK button while the FAN icon is highlighted to manually fire the burner and
power the CH circulator.
NOTE
An adequate CH load must be present to dissipate the heat
generated during the combustion test. If an adequate CH load i s
not available, an indirect water heat er can be used to dissipate th e
heat by creating a DHW call which will enable the DHW circulator.
Table 12-1: Recommended Combustion Levels
Combus tion Gases Natural Gas Propane Gas
O2 Min. 2.30% 3.70%
O2 Max. 5.30% 5.20%
CO2 Min. 8.80% 10.00%
100 ppm 100 ppm
e) Press the LEFT and RIGHT buttons to adjust the firing rate from 1% to 100%.Hold down
the LEFT or RIGHT but-ton to rapidly increase or decrease the firing rate.
f) Press the OK button while the FAN icon is highlighted to shut-down the burner.
g) Cycle power to the boil er once com bustion testing is complete to return to normal
operation.
WARNING!
The combustion levels should be measured at high firing rate. If
the combustion levels are outside the range given in Table 12-1 for
the firing rate, shut the boiler down and contact AERCO Technical
Support. Failure t o comply with this requirement could result in
severe personal injury, death, or substantial property dam age.
3. If the combustion levels during high fire (100%) are outside the recommended combustion
settings in Table 12-1, adjust the Throttle Screw (see Figure 12-2) as follows:
• Counter-clockwise rotation: O
• Clock-wise rotation: O
4. Once the combustion level is set at high fire (100%), manually place the boiler into low fire
(1%) mode by pressing the LEFT button to adjust firing rate downward.
5. If the CO2 combustion level during low fire (1%) is not within +/- 0.2 of the combustion level
measured at high fire, adjust the plastic Offset Pressure Screw under the cover screw on
the top of the g as valve (see Figure 12-2).
decreases and CO2 increases
2
increases and CO2 decreases.
2
6. Counter-clockwise adjustment of the Offset Pressure Screw at Low Fire:
• Counter-clockwise rotation: O
• Clock-wise rotation: O
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decreases and CO2 increases
2
increases and CO2 decreases.
2
GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
Venturi
Offset Pressure Screw
Gasket
Orifice
(Natural or
Propane gas)
Gas Valve
Throttle Screw
(Red Plastic Sleeve)
Inlet Gas Pressure Port
Figure 12-2: Gas Valve / Venturi Assembly
12.4.5 Measure and Verify Input Rating - Natural Gas Only
To m easure and verify the input for Natural Gas (Only), perform the following procedure.
Measuring and Verifying Natural Gas Input Rating
1. Ensure the boiler is firing at m aximum firing rate. To manually place the boil er into high fire
mode, refer to instructions in Section 12.3.4 of this chapter.
2. Operate the unit for approxim ately 10 minutes.
3. Turn off all gas appliances within the building, except the Esteem boiler.
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.
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GF-135 Esteem 399 Low NOx Boiler Chapter 12
OMM-0089_0A Installation, Operation & Maint enance Manual Start-Up Procedures
12.4.6 High Temper ature Lim it Testing
To test the high temperature limit function, perform the foll ow ing procedure.
Testing the High Temperature Limit Function
NOTE
The high tem perature limit can be t em porarily lowered from 210ºF
[99ºC] to 102ºF [39ºC] for testing.
1. Press the round INSTALLER button (See Figure 10-1).
2. Enter the installer access code “054” by using LEFT and RIGHT buttons to select a digit and
the UP and DOWN buttons to change the digit. Press the OK button to enter the access
code.
3. Press the OK button while CH & DHW Settings icon is highlighted.
4. Press the DOW N button to highlight the Boiler Settings icon then press the OK button.
5. Press the DOW N button to highlight Lockout Temperature then press the OK button.
6. Press the UP button to highlight 102ºF [39ºC] then press the OK button.
7. Press the DOWN button twice to highlight the Home Screen icon then press the OK
button.
8. Initiate a CH or DHW call and confirm that a High Boiler Temperature lockout occurs onc e
the supply temperature reaches 102ºF [39ºC].
9. Press any ARROW button to return to the Home Screen
10. Press the round INSTALLER button.
11. Press the OK button while the CH & DHW Settings icon is highlighted.
12. Press the DOWN button to highlight the Boiler Settings icon then press the OK button
13. Press the DOWN button to highlight Lockout Temperature, then press the OK button.
14. Press the DOWN button to highlight 210ºF [99ºC] then press the OK button.
15. Press the DOW N button twice to highlight the Home Screen icon then press the OK
button.
16. Press the OK button to reset the lockout and return the unit to service.
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GF-135 Esteem 399 Low NOx Boiler Chapter 13
OMM-0089_0A Installation, Operation & Maint enance Manual Outdoor Reset Control
CHAPTER 13: OUTDOOR RESET CONTROL
The use of the outdoor reset function is required to optimize boil er efficiency. See the important
notice below.
If the outdoor sensor is not installed before turning on the b oiler, an Outdoor Sensor Open err or
(E96) will be displayed. The error will not prevent th e boiler from operating. The error will
automatically reset once the outdoor sensor is install ed or if the outdoor reset function i s
disabled.
Reference section 10.6 for information on disabling the outdoor reset function using the EZ setup
menu. The outdoor reset function can only be disabled if the boiler installation meets on e of the
exceptions listed in the foll owing notice.
IMPORTANT NOTE!
In accordance with Section 325 (f) (3) of the En ergy P olicy and
Conservation Act, this boiler is equipped with a feature that saves
energy by reducing the boiler water temperature as the heating
load decreases. This feature is equipped w ith an override which is
provid ed prim arily to perm it the use of an external energy
management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST
ONE OF THE FOLLOWING CONDITIONS IS TRUE.
• An external energy m anagement syst em is installed that
reduces the boiler water temperature as the heating load
decreases.
• This boiler is not used for any space h eating.
• This boiler is part of a modular or m ultiple boil er system
having a total input of 300,000 BTU/hr. or greater.
• This boiler is equipped with a tankless coil.
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GF-135 Esteem 399 Low NOx Boiler Chapter 13
OMM-0089_0A Installation, Operation & Maint enance Manual Outdoor Reset Control
13.1 OUTDOOR TEMPERATURE SENSOR INSTALLATION
To install the outdoor temper atur e sensor, perform the following procedure.
Installing the Outdoor Temperature Sensor
1. Remove the front cover and mounting screws / anchors from the sensor enclosure.
Figure 13-1: Outdoor Sensor Enclosure and Components
2. When mounting the encl osure, 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 for those buildings, which may have large glass walls or windows on the southern
face.
3. Ensure the sensor enclosure is shielded 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 dam age
or tampering.
5. Avoid mounting the enclosure in areas subjected to excessive moisture.
6. Once an area on the exteri or wall has been determined, follow the manufacturer’s mounting
instructions included with the outdoor sensor.
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