AMP AMPW 400 User manual
Save this manual for future reference.
PN: 110820-01 Rev. 0
Do not store or use gasoline or other
ammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instrucons.
• If you cannot reach your gas supplier,
call the re department.
Installaon and service must be performed
by a qualied installer, service agency or the
gas supplier.
WARNING: If the information in these
instrucons is not followed exactly, a re
or explosion may result causing property
damage, personal injury or death.
Commercial Condensing Water Heater
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Thermal Solutions Products, LLC www.thermalsolutions.com
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
400-1000L MBH Water Heater Indoor/Outdoor
Water Heater Models
AMPW 400
AMPW 500
AMPW 650
AMPW 800
AMPW 1000L
Boiler Model: Serial Number:
Installation Date: System Type:
Heating Contractor: Phone/Email:
Address:
2 AMPW 400-1000L I&O Manual
Table of Contents
A. Local Codes 5
B. Warranty 5
C. Shipment Damage 5
D. Connecting Gas Supply Line 5
E. Appliance Operation 5
F. Gas Leakage (If you detect or smell gas...) 5
G. Maintenance 5
I. Factory Test and Inspections 6
J. Disclaimers and Local Codes 6
A. Unpacking and Inspection 12
B. Check Equipment 12
C. Installation and Operation Manual 12
A. General 13
B. Appliance Mounting 14
C. Outdoor Installation 14
D. AMP 400-1000L Stacking 15
E. Clearances 16
F. Clearances (French) 16
G. Closet and Alcove Installation 16
A. General Venting Guidelines 17
B. Venting Design Requirements 17
C. General Termination 18
D. Field Installation 19
E. Venting for Outdoor Installation 19
F. General Termination 26
G. Terminal Installation 28
J. Multiple Appliance Terminations 32
K. Removing Existing Appliance 33
L. Special Installation Requirements for Massachusetts 33
A. Condensate trap 35
B. Condensate Neutralizer Installation 36
C. Common Condensate pump/Sump 36
AMPW 400-1000L I&O Manual 3
Table of Contents
A. General Piping Guidelines 37
B. Factory Supplied Outlet Manifold 38
C. Standard Piping Components 39
D. Scalding 40
E. Water Quality 41
F. Temperature Rise and Heat Exchanger Head Loss 42
G. Pump Selection 43
A. Guidelines and Requirements 47
B. Field Connecting Gas Supply 47
C. Gas Pressure Switches 49
A. General. 50
B. Power Requirements 50
C. Appliance Wiring 50
D. Routing Field Connections 50
E. System and Circulation Pump Wiring 51
A. Check System Setup 56
B. Start the AMP 56
D. Field Conversion of Gas Type 59
E. Pump Control 60
F. Check Thermostat Operation 60
H. Testing of Controls and Safety Devices 60
A. General Maintenance 62
B. Monthly Inspection 62
C. Annual Inspections and Service 62
D. Restarting after Prolong Shutdown 65
4 AMPW 400-1000L I&O Manual
-
CAUTIONCAUTION
NOTICENOTICE
!
!
!
AMPW 400-1000L I&O Manual 5
A. Local Codes
B. Warranty
Table 20
C. Shipment Damage
D. Connecng Gas Supply Line
E. Appliance Operaon
Table 4
F. Gas Leakage (If you detect or smell gas...)
G. Maintenance
H. Product Idencaon Label
6 AMPW 400-1000L I&O Manual
II(continued)
I. Factory Test and Inspecons
J. Disclaimers and Local Codes
the Naonal Fuel Gas Code, NFPA 54/ANSI Z223.1,
and/ or CSA B149.1 Natural Gas and Propane Code
Standard for
Controls and Safety Devices for Automacally Fired
Boilers, ANSI/ ASME CSD-1
-
!
!
AMPW 400-1000L I&O Manual 7
water heaters are not
Specication AMPW Models
400 500 650 800 1000L
Fuel NG or LP NG or LP NG or LP NG or LP NG or LP
Max. Water Temp. (°F)1210 210 210 210 210
Max. Working Pres. (psi) 160 160 160 160 160
Standard Safety Relief
Valve (psi) 150 150 150 150 150
Water Vol. (gal) 3.8 4.3 5.6 6.6 8.1
Heat Transfer Area (sq. ft.) 34.8 39.1 52.2 60.9 75.4
Approx. Shipping Weight (lb) 460 470 530 560 600
1Appliance will go into hard lockout if temperature exceeds 200 0F.
400 40 400 392 475 98
500 50 500 490 594 98
650 65 650 637 772 98
800 80 800 784 950 98
1000L 100 1000 980 1188 98
Ratings shown are for installations at sea level and elevations up to 2000 ft.
factory.
Dimensions (in.) AMPW Model
400 500 650 800 1000L
Gas Inlet 3/4 3/4 1 1 1
Water Outlet Pipe 2 2 2 2 2
Water Inlet Pipe 2 2 2 2 2
Air Intake 4 4 6 6 6
Vent Outlet 4 4 6 6 6
Condensate Drain 1 1 1 1 1
Drain Line 3/4 3/4 3/4 3/4 3/4
Electrical Conduit Holes 7/8 7/8 7/8 7/8 7/8
8 AMPW 400-1000L I&O Manual
III(continued)
38 1
2
"
45"
33 1
2
"
25 5
8
"
26 3
8
"
Front View
1 7
8
"
36 1
2
"
5
8
"
5 1
2
"
1 7
8
"
46
1
4
"
2 1
2
"
Side View
4 1
8
"
9 1
4
"
5 7
8
"
12 1
4
"
19 3
4
"
10"
26 1
2
"
27 3
4
"
35 1
8
"
9 7
8
"
6 1
4
"
2 7
8
"
Rear View
LAMPW 400-500 dimensional for manual
AMPW 400-1000L I&O Manual 9
III(continued)
45"
38 1
2
"
33 1
2
"
25 5
8
"
26 3
8
"
Front View
1 7
8
"
5
8
"
52 3
8
"
7 1
8
"
1 7
8
"
60 3
4
"
Side View
9 1
4
"
10"
5 7
8
"
12 1
4
"
35 1
8
"
9 7
8
"
6 1
4
"
27 3
4
"
26 1
2
"
19 3
4
"
4 1
8
"
3 1
4
"
Back View
LAMPW 650-1000 dimensional for manual
10 AMPW 400-1000L I&O Manual
1. Communicaon Interface (ConcertTM Control)
2. Main appliance control
3. Front control box
4. Rear control box
5. ON/OFF switch
6. Main gas valve
7. Gas and Air Mixer/Venturi
8. Blower
9. BluejetRBurner
10. Ignion electrode
11. High gas pressure switch
Table 28
12. Low gas pressure switch
Table 28
13. Outlet/Hot water connecon
14. Water ow switch
Table 21
15. Gas supply connecon
Table 28 for
16. Inlet/Cold water connecon
17. Hot/outlet water temperature sensor
18. Cold/Inlet water temperature sensor
19. Low water cut o (LWCO)
20. Temperature and pressure gauge
21. Temperature and pressure safety relief valve
22. Condensate drain trap
23. Minimum combuson air proving switch
24. Blocked vent switch
25. Combuson air lter box
26. Exhaust vent connecon
to Table 6
27. Heat Exchanger
12 AMPW 400-1000L I&O Manual
A. Unpacking and Inspecon
B. Check Equipment
16
C. Installaon and Operaon Manual
NOTICENOTICE
-
-
-
!
Front panel with
display cover
Side panel
with louvers
Rear intake cover
AMPW 400-1000L I&O Manual 13
A. General
Naonal Fuel Gas
Code, ANSI Z223.1/NFPA 54, and/or Natural Gas
and Propane Installaon Code, CAN/CSA B149.1.
Standard for
Controls and Safety Devices for Automacally Fired
Boilers, ANSI/ASME CSD-1.
Table 4
NOTICENOTICE
-
-
-
!
14 AMPW 400-1000L I&O Manual
C. Outdoor Installaon
Contaminants to Avoid:
(CFC’s)
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Anti-static fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms.
Adhesives used to fasten building products and
other similar products
Excessive dust and dirt
Areas likely to have contaminants:
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
New building construction
Remodeling areas
Garages with workshops
VI(continued)
CAUTIONCAUTION
!
B. Appliance Mounng
AMPW 400-1000L I&O Manual 15
VI(continued)
D. AMP 400-1000L Stacking
shown in
Rear Right
Front Right
C
D
Front Left
Rear Left
Rotated Display
16 AMPW 400-1000L I&O Manual
E. Clearances
found in
F. Clearances (French)
G. Closet and Alcove Installaon
VI(continued)
NOTICENOTICE
Minimum
Clearance
Front
(In.)
Rear
(In.)
Right
(In.)
Left
(In.)
Top
(In.)
Serviceability
(Indoor
Installation)
24 24 0* 0* 0
Serviceability
(Outdoor
Installation)
24 36 0* 0* 0**
To
Combustible
Construction
00000
* Leave 24" clearance on at least one side.
**
H. Side by Side and 0" Clearance Installaon
24 in
AMPW 400-1000L I&O Manual 17
A. General Venng Guidelines
aonal
Fuel Gas Code, ANSI Z223.1/NFPA 54
in Table 11
B. Venng Design Requirements
1. Engineered Venng Method (recommended)
WARNINGWARNING
!
found in Table 10
2 2ranges are shown in
Table 30
e. Manifolded venng
2. Equivalent length method:
Table 6
NOTICENOTICE
-
18 AMPW 400-1000L I&O Manual
VII(continued)
C. General Terminaon
NOTICENOTICE
CAUTIONCAUTION
I
!
AMPW 400-1000L I&O Manual 19
D. Field Installaon
VII(continued)
E. Venng for Outdoor Installaon
WARNINGWARNING
-
-
!
Drain Cap
Boot Tee
36" Straight
90° Elbow
Termination Tee
NOTICENOTICE
20 AMPW 400-1000L I&O Manual
NOTICENOTICE
VII(continued)
Component
Combuson Air Vent
Equivalent
Length Per
Piece
xQuantity =
Subtotal
Equivalent
Length
Equivalent
Length
Per Piece
xQuantity =
Subtotal
Equivalent
Length
Straight Pipe x = A x = D
90° Elbow x = B x = E
45° Elbow x = C x = F
Combustion Air Total
Equivalent Length =Vent Total
Equivalent Length =
Notes:
1. Total equivalent length cannot exceed maximum equivalent length shown in Table 6.
2. Combustion air and vent terminations do not count towards total equivalent length.
AMP
Model
Combustion Air Length Vent Length
Pipe Dia.
in. (mm)
Minimum
eq. ft. (m)
Maximum
eq. ft. (m)
Pipe Dia.
in. (mm)
Minimum
eq. ft. (m)
Maximum
eq. ft. (m)
400 4 (100) 0 100 (30) 4 (100) 5 (1.5) 100 (30)
500 4 (100) 0 100 (30) 4 (100) 5 (1.5) 100 (30)
650 6 (150) 0 100 (30) 6 (150) 5 (1.5) 100 (30)
800 6 (150) 0 100 (30) 6 (150) 5 (1.5) 100 (30)
1000L 6 (150) 0 100 (30) 6 (150) 5 (1.5) 100 (30)
NOTE:
Contact factory for assistance on maximum vent length applications.
This table applies to all listed vent/combustion air system options.
Diameter 4 in. (100 mm) 6 in. (150 mm)
90°Elbow 5 ft. (1.5 m) 8 ft. (2.4 m)
45° Elbow 2 ft. (0.6 m) 3 ft. (1 m)
This manual suits for next models
5
Table of contents
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