AERCO Esteem Boiler with EZ-Set Controller User Manual
User manual, Gf-135
Installation, Operation & Maintenance Manual (IOMM)
GF-135
OMM-0089_0A
USER MANUAL
Installation, Operation and Maintenance
GAS FIRED BOILER
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
Table of contents
Document Outline
- CHAPTER 1: SAFETY PRECAUTIONS
- CHAPTER 2: installation
- CHAPTER 3: COMBUSTION AIR AND VENTING
- 3.1 COMBUSTION AIR CONTAMINATION
- 3.2 POTENTIAL CONTAMINATING PRODUCTS
- 3.3 VENTILATION AND COMBUSTION AIR REQUIREMENTS - DIRECT VENT
- 3.4 VENTILATION AND COMBUSTION AIR REQUIREMENTS - CATEGORY IV
- 3.5 METHODS OF SUPPLYING COMBUSTION AIR TO A CONFINED SPACE - CATEGORY IV
- 3.6 COMBINATION OF INDOOR AND OUTDOOR COMBUSTION AIR
- 3.7 COMBUSTION AIR AND VENT PIPING
- 3.8 REMOVAL OF AN EXISTING BOILER FROM A COMMON VENT SYSTEM
- CHAPTER 4: UNIT PREPARATION
- CHAPTER 5: BOILER PIPING
- 5.1 GENERAL PIPING REQUIREMENTS
- 5.2 PRESSURE RELIEF VALVE
- 5.3 BOILER AIR VENT
- 5.4 LOW WATER CUTOFF DEVICE
- 5.5 ADDITIONAL LIMIT CONTROL
- 5.6 BACKFLOW PREVENTER
- 5.7 BOILER SYSTEM PIPING APPLICATIONS
- 5.8 EXPANSION TANK AND MAKEUP WATER
- 5.9 CIRCULATOR
- 5.10 SIZING PRIMARY PIPING
- 5.11 DOMESTIC HOT WATER SYSTEM PIPING
- 5.12 SYSTEM PIPING - ZONE CIRCULATORS
- 5.13 SYSTEM PIPING - ZONE VALVES
- 5.14 SYSTEM PIPING - THROUGH BOILER
- 5.15 SYSTEM PIPING - RADIANT HEATING
- 5.16 SYSTEM PIPING—SPECIAL APPLICATIONS
- 5.17 SYSTEM PIPING—MULTIPLE UNITS INSTALLATION
- CHAPTER 6: Installing Vent, Air Intakes, AND Drain
- CHAPTER 7: GAS PIPING
- CHAPTER 8: INTERNAL WIRING
- CHAPTER 9: EXTERNAL WIRING
- 9.1 INSTALLATION COMPLIANCE
- 9.2 LINE VOLTAGE CONNECTIONS
- 9.3 CIRCULATOR WIRING
- 9.4 ALARM WIRING
- 9.5 LOW VOLTAGE CONNECTIONS
- 9.6 THERMOSTAT WIRING
- 9.7 OUTDOOR SENSOR WIRING
- 9.8 DOMESTIC HOT WATER WIRING
- 9.9 ADDITIONAL BOILER LIMITS
- 9.10 EXTERNAL MODULATION CONTROL
- 9.11 SYSTEM SENSOR WIRING
- 9.12 CASCADE WIRING
- 9.13 MODBUS WIRING
- CHAPTER 10: Basic EZ-SET Controller Operation
- 10.1 EZ-SET CONTROLLER INTRODUCTION
- 10.2 EZ-SET CONTROLLER FEATURES AND FUNCTIONS
- 10.3 CONTROLLER NAVIGATION
- 10.4 HOME SCREEN
- 10.5 MAIN MENU
- 10.6 EZ SETUP
- 10.7 HEATING EZ SETUP
- 10.7.1 Select CH Demand (Default: Switch & Outdoor Reset)
- 10.7.2 CH1 Setpoint (Default: 180 F [82 C])
- 10.7.3 CH2 Setpoint (Default: 140 F [60 C])
- 10.7.4 Select CH1 Reset Curve (Default: Finned Tube Baseboard)
- 10.7.5 Select CH2 Reset Curve (Default: Low Mass Radiant)
- 10.7.6 Set Warm Weather Shutdown Temperature (Default: OFF)
- 10.8 DOMESTIC HOT WATER EZ SETUP
- 10.9 EZ SETUP RESET
- 10.10 DISPLAY EZ SETUP
- 10.11 CH/DHW OPERATION
- 10.12 BOILER INFORMATION
- 10.13 LOCKOUT HISTORY
- CHAPTER 11: START-UP PREPARATION
- CHAPTER 12: Start-Up Procedures
- CHAPTER 13: Outdoor Reset Control
- CHAPTER 14: External Modulating Control
- CHAPTER 15: Check-Out Procedures
- CHAPTER 16: Maintenance Schedule
- CHAPTER 17: Maintenance Procedures
- 17.1 REPORTED PROBLEMS
- 17.2 SURROUNDING AREA INSPECTION
- 17.3 BURNER AREA INSPECTION
- 17.4 SYSTEM PIPING INSPECTION
- 17.5 CLEAN CONDENSATE DRAIN ASSEMBLY
- 17.6 VENTILATION AIR OPENINGS INSPECTION
- 17.7 VENT AND COMBUSTION AIR PIPING INSPECTION
- 17.8 BOILER SYSTEM INSPECTION
- 17.9 EXPANSION TANK INSPECTION
- 17.10 BOILER RELIEF VALVE INSPECTION
- 17.11 IGNITION ELECTRODE INSPECTION
- 17.12 IGNITION WIRING AND GROUND WIRING INSPECTION
- 17.13 CONTROL WIRING INSPECTION
- 17.14 CONTROL SETTINGS INSPECTION
- 17.15 PERFORM START-UP AND CHECKOUT PROCEDURES
- 17.16 BURNER FLAME INSPECTION AND TROUBLESHOOTING
- 17.17 FLAME SIGNAL INSPECTION
- 17.18 COMBUSTION LEVELS INSPECTION
- 17.19 FLUE GAS TEMPERATURE CHECK
- 17.20 HEAT EXCHANGER CLEANING
- 17.21 REVIEWING MAINTENANCE REQUIREMENTS WITH OWNER
- 17.22 Handling Previously Fired Combustion Chamber Insulation
- CHAPTER 18: EZ-SETUP CONTROLLER OPERATION AND SETTINGS
- 18.1 ENTERING THE INSTALLER ACCESS CODE
- 18.2 USING THE INSTALLER MENU
- 18.3 CH and DHW SETTINGS MENU
- 18.3.1 Heating Operation (Default: Enabled)
- 18.3.2 Demand Type (Default: Switch & Outdoor Reset)
- 18.3.3 Absolute Max CH Setpoint (Default: 188 F [87 C])
- 18.3.4 CH1 Maximum Setpoint (Default: 180 F [82 C])
- 18.3.5 CH1 Minimum Setpoint (Default: 120 F [49 C])
- 18.3.6 Reset Curve Coldest Day (Default: 0 F [-18 C])
- 18.3.7 Reset Curve Warmest Day (Default: 64 F [18 C])
- 18.3.8 CH2 Circuit (Default: Enabled)
- 18.3.9 CH2 Maximum Setpoint (Default: 140 F [60 C])
- 18.3.10 CH2 Minimum Setpoint (Default: 80 F [27 C])
- 18.3.11 Warm Weather Shutdown (Default: Off)
- 18.3.12 Pump Constant Circulation (Default: Disabled)
- 18.3.13 CH Post Pump Time (Default: 1 Minute)
- 18.3.14 Freeze Protection (Default: Enabled)
- 18.3.15 Frost Protection Setpoint (Default: -22 F [-30 C])
- 18.3.16 Parallel Shift Value (Default: 0 F [0 C])
- 18.3.17 CH Call Blocking (Default: 1 Minute)
- 18.3.18 System Pump (Default: CH1/CH2)
- 18.4 DHW SETTINGS MENU
- 18.4.1 DHW Operation (Default: Enabled)
- 18.4.2 Demand Type (Default: Switch)
- 18.4.3 Boiler DHW Setpoint (Default: 186 F [86 C])
- 18.4.4 DHW Storage Setpoint (Default: 140 F [60 C])
- 18.4.5 DHW on Differential (Default: 6 F [3 C])
- 18.4.6 DHW Storage Adder (Default: 46 F [25 C])
- 18.4.7 DHW Post Pump Time (Default: 1 Minute)
- 18.4.8 DHW Priority Timeout (Default: OFF)
- 18.4.9 DHW Priority (Default: ENABLED)
- 18.4.10 DHW Call Blocking (Default: 0 Minutes)
- 18.4.11 DHW to CH Call Blocking (Default: 1 Minute)
- 18.4.12 Antilegionella Function (Default: DISABLED)
- 18.5 BOILER SETTINGS MENU
- 18.6 RESET ALL SETTINGS MENU
- 18.7 CASCADE MENU AND OPERATING INFORMATION
- 18.8 CASCADE AUTODETECTION MENU
- 18.9 CASCADE INFORMATION MENU
- 18.9.1 System Temperature Logging
- 18.9.2 Cascade Settings Menu
- 18.9.3 Stage Delay (Default: 60 Seconds)
- 18.9.4 Minimum firing Rate (Default: 30%)
- 18.9.5 Boiler Enabling Algorithm
- 18.9.6 Boiler Disabling Algorithm
- 18.9.7 Maximum Firing Rate (Default: 398 MBH)
- 18.9.8 CH or DHW Boilers (Default: 0)
- 18.9.9 Automatic Rotation (Default: Enabled)
- 18.9.10 CH Proportional Gain (Default: 7)
- 18.9.11 CH Integral Gain (Default: 245)
- 18.9.12 DHW Proportional Gain (Default: 7)
- 18.9.13 DHW Integral Gain (Default: 245)
- 18.9.14 Modbus Address (Default: 0 = BcST)
- 18.9.15 Modbus Interface
- 18.10 MANUAL OPERATION
- Apenndix A: Part AND DIMENSIONAL Drawings
- Apenndix B: CIRCULATOR PRESSURE LOSS CHARTS
- Please complete one (1) form for each unit at the site and return to AERCO for warranty validation within 30 days of start-up. For your convenience, this information can be faxed to (845) 580-8090 or sent via US mail to: AERCO International, Inc., 1...
- Completed By:______________________________________________ Date:___________
- LOCATION
- Installation Name: __________________________________ SST Technician:_____________________
- Street Address: ___________________________________ Company:__________________________
- City, State, Zip: ___________________________________ Phone#:___________________________
- AERCO Sales Rep.: _________________________________ Unit Serial#: _______________________
- GENERAL INSTALLATION
- Number of units at site: ______ ______ ______ _______ _______ _______
- GAS SUPPLY
- Type of Gas Supply: Natural Gas Propane Gas
- Is an external gas supply regulator installed within two to six feet of the unit? …….......... Yes No
- What are the make and model number of the external gas supply regulator? Make: _____________
- Model: _____________
- What is the static gas supply pressure to the external supply regulator? …….___________________
- If this is a lock-up style external regulator, what is the size of the orifice? ……___________________
- What is the supply regulator’s outlet spring range? …………………………….. ___________________
- The external gas supply vent regulator lines are: Individually Run Manifolded together with other regulator vent lines.
- What is the BTU content of the gas? ___________________________________________________
- What is the size of the gas supply header _______________________________________________
- What is the length of gas pipe from the main meter? _______________________________________
- STARTUP RECORD FOR ESTEEM 399 BOILER - (Continued)
- Venting
- Combustion Air
- Boiler Installation
- Combustion Settings
- CO2: _______________% Measured Rate of Input: _________________ Btu/hr
- O2: _______________%
- CO: _______________ppm