AER Esteem 399 Manual

Instruction

No.

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

Installation and Maintenance

Manual

Esteem 399

Low NOx

Gas Fired

Boiler

Visit www.aerco.com to View the Latest

Product Manuals and Information.

Printed in U.S.A. REVISED MAY 2010

GF-125

OMM-0048_0A

Telephone Support

(800) 526-0288

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through Friday)

Please have the unit’s model number

and the serial number from the rating la-

bel on the backside of the control panel

when calling about service or trouble-

shooting.

Model #_________________________

Serial #__________________________

AERCO International, Inc.

2ULWDQL'U

%ODXYHO, 1< 

www.aerco.com

The information contained in this document

is subject to change without notice from

AERCO International, Inc.

AERCO makes no warranty of any kind

with respect to this material, including but

not limited to implied warranties of mer-

chantability and fitness for a particular

application. AERCO International is not lia-

ble for errors appearing in this manual. Nor

for incidental or consequential damages

occurring in connection with the furnishing,

performance, or use of this material.

Esteem 399 Low NOx Installation and Maintenance Manual

GF-125

Contents

Chapter 1 Warnings and Cautions 1

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

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

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

Chapter 2 Pre-Installation Items 4

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

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

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

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

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

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

Chapter 3 Combustion Air and Venting 7

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

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

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

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

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

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

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

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

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

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

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

Chapter 4 Unit Preparations 14

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

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

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

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

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

Chapter 5 Boiler Piping 16

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 6 Installing Vent, Air Intake & Drain 27

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

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

Chapter 7 Gas Piping 29

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

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

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

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

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

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

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

Chapter 8 Internal Wiring 33

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

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

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

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

Chapter 9 External Wiring 35

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

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

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

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

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

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

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

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

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

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

Chapter 10 Start-Up Preparation 39

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

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

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

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

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

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

iii

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

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

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

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

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

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

Chapter 11 Start-Up Procedures 42

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

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

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

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

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

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

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

Chapter 12 Operating Instructions 47

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

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

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

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

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

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

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

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

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

Chapter 13 Outdoor Reset Control 54

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

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

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

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

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

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

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

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

Chapter 14 External Modulating Control 58

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

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

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

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

Chapter 15 Check-Out Procedures 60

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

Chapter 16 Installation Record 61

Chapter 17 Maintenance Schedule 62

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

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

Chapter 18 Maintenance Procedures 63

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 19 Troubleshooting 69

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

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

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

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

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

Appendices 87

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

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

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

Installers and operating personnel

MUST, at all times, observe all safety

regulations.

The following general warnings and cautions

must be given the same attention as specific

precautions included in these instructions. In

addition to the requirements included in this

Manual, the installation MUST conform with

local building codes, or, in the absence of

local codes, ANSI Z223.1 (National Fuel Gas

Code Publication No. NFPA-54). Where ASME

CSD-1 is required by local jurisdiction, the

installation must conform to CSD-1.

Where applicable, the equipment must be

installed in accordance with the current

Installation Code for Gas Burning Appliances

and Equipment, CGA B149, and applicable

Provincial regulations for the class. Authorities

having jurisdiction should be consulted before

installations are made.

IMPORTANT

This Instruction Manual is an integral

part of the product and must be main-

tained in legible condition. It must be giv-

en to the user by the installer and kept in

a safe place for future reference.

DANGER!

INDICATES THE PRESENCE OF AHAZARDOUS

SITUATION WHICH, IF IGNORED, WILL RESULT IN

DEATH, SERIOUS INJURY OR SUBSTANTIAL PROP-

ERTY DAMAGE.

WARNINGS!

MUST BE OBSERVED TO PREVENT SERIOUS IN-

JURY OR SUBSTANTIAL PROPERTY DAMAGE.

CAUTIONS!

Must be observed to prevent damage or

loss of operating effectiveness.

NOTICE

Indicates special instructions on instal-

lation, operation or maintenance, which

are important to equipment but not re-

lated to personal injury hazards.

WARNING!

BEFORE ATTEMPTING TO PERFORM ANY MAIN-

TENANCE ON THE UNIT, SHUT OFF ALL GAS AND

ELECTRICAL INPUTS TO THE UNIT.

WARNING!

THE EXHAUST VENT PIPE OF THE UNIT OPER-

ATES UNDER APOSITIVE PRESSURE AND THERE-

FORE MUST BE COMPLETELY SEALED TO PRE-

VENT LEAKAGE OF COMBUSTION PRODUCTS INTO

LIVING SPACES.

WARNING!

FLUIDS UNDER PRESSURE MAY CAUSE INJURY

OR DAMAGE TO EQUIPMENT WHEN RELEASED.

BESURE TO SHUT OFF ALL INCOMING AND OUT-

GOING WATER SHUT OFF VALVES. CAREFULLY

DECREASE ALL TRAPPED PRESSURES TO ZERO

BEFORE PERFORMING ANY BOILER MAINTE-

NANCE.

WARNING!

DONOT USE MATCHES, CANDLES, FLAMES, OR

OTHER SOURCES OF IGNITION TO CHECK FOR

GAS LEAKS.

GF-125

Chapter 1 Warnings and Cautions

Emergency Shutdown

CAUTION!

Many soaps used for gas pipe leak test-

ing are corrosive to metals. The piping

must be rinsed thoroughly with clean

water after leak checks have been com-

pleted.

CAUTION!

DO NOT use this boiler if any part has

been under water. Call a quali¿ed serv-

ice technician to inspect and replace

any part that has been underwater.

IMPORTANT

The Installer must identify and indicate

the location of the emergency shutdown

manual gas valve to operating person-

nel.

Emergency Shutdown

If overheating occurs or the gas supply fails

to shut off, close the manual gas shutoff valve

(Figure 1) located external to the unit.

Prolonged Shutdown

After prolonged shutdown, it is recommended

that the startup procedures in Chapter 10 of

this manual be performed, to verify all system

operating parameters. If there is an emergen-

cy, turn off the electrical power supply to the

AERCO boiler and close the manual gas valve

located upstream the unit. The installer must

identify the emergency shut-off device.

To shut Down the Unit

Turn the service switch on the Esteem 399

Low NOx control panel to “OFF”

Turn the external manual gas valve handle

clockwise to “CLOSE”.

Figure 1: Typical Manual Gas Shutoff Valve

GF-125

IF YOU SMELL GAS

DANGER!

IF YOU SMELL GAS

• Do Not try to light any appliance

• Do Not touch any electrical switch

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

• Immediately call your gas supplier from a different location.

• Follow the gas supplier’s instructions.

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

IMPORTANT

Installation and service must be per-

formed by a quali¿ed installer, service

agency or the gas supplier.

DANGER!

DONOT USE THIS APPLIANCE IF ANY PART

HAS BEEN UNDER WATER. IMMEDIATELY CALL

AQUALIFIED SERVICE TECHNICIAN TO INSPECT

THE APPLIANCE AND TO REPLACE ANY PART OF

THE CONTROL SYSTEM WHICH HAS BEEN UNDER

WATER.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS

SUPPLY FAILS TO SHUT OFF, TURN OFF THE

MANUAL GAS CONTROL VALVE EXTERNAL TO

THE APPLIANCE.

WARNING

DO NOT ADD COLD MAKE UP WATER WHEN THE

BOILER IS HOT. THERMAL SHOCK CAN CAUSE

POTENTIAL CRACKS IN THE HEAT EXCHANGER.

CAUTION

Avoid electrical shock by disconnecting

the electrical supply prior to performing

maintenance when servicing the boiler:

WARNING

PRIOR TO INSTALLING THIS PRODUCT READ ALL

INSTRUCTIONS INCLUDED IN THIS MANUAL AND

ALL ACCOMPANYING MANUALS/DOCUMENTS.

PERFORM ALL INSTALLATION STEPS REQUIRED

IN THESE MANUALS IN THE PROPER ORDER GIV-

EN. FAILURE TO ADHERE TO THE GUIDELINES

WITHIN THESE MANUALS CAN RESULT IN SEVERE

PERSONAL INJURY, DEATH OR SUBSTANTIAL

PROPERTY DAMAGE.

Please have the unit’s model number and the

serial number from the rating label, on the

backside of the control panel when inquiring

about service or troubleshooting.

AERCO International accepts no liability for

any damage resulting from incorrect installa-

tion or from the use of components or ¿ttings

not speci¿ed by AERCO International.

GF-125

Chapter 2 Pre-Installation Items

Code Compliance

This product must be installed in accordance

to the following:

• All applicable local, state, national and

provincial codes, ordinances, regulations

and laws.

• For installations in Massachusetts, code

requires the boiler to be installed by a

licensed plumber or gas ¿tter, and if anti-

freeze is utilized, the installation of a re-

duced pressure backÀow preventer device

is required in the boiler’s cold water ¿ll or

make up water supply line.

• For installation in Massachusetts all direct

vented appliances must comply with the

guidelines as outlined on page 13.

• The National Fuel Gas Code NFPA54/

ANSI Z 223.1 - Latest edition.

• National Electric Code ANSI/NFPA 70.

• For installations in Canada -“Installation

Code for Gas Burning Equipment” CGA/

B149.1 or B149.2 Canadian Electrical

Code Part 1 CSA C22.1.

Standards for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-

1, when required.

NOTICE

The Esteem 399 Low NOx boiler gas

manifold and gas controls meet the

safe lighting and other performance re-

quirements as speci¿ed in ANSI Z21.13

latest edition.

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 com-

bustion air/vent piping to be routed directly

through the building and terminate properly

outside with a minimum amount of length and

bends.

Ensure the area chosen for the installation of

the Esteem 399 Low NOx is free of any com-

bustible materials, gasoline and other flam-

mable liquids.

WARNING

FAILURE TO REMOVE OR MAINTAIN THE AREA

FREE OF COMBUSTIBLE MATERIALS, GASOLINE

AND OTHER FLAMMABLE LIQUIDS OR VAPORS

CAN RESULT IN SEVERE PERSONAL INJURY,

DEATH OR SUBSTANTIAL PROPERTY DAMAGE.

Ensure the Esteem 399 Low NOx and its con-

trols are protected from dripping or spraying

water during normal operation or service.

The Esteem 399 Low NOx should be installed

in a location so that any water leaking from the

boiler or piping connections or relief valve will

not cause damage to the area surrounding the

unit or any lower floors in the structure.

GF-125

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