Thermal Solutions AMP 1000 User manual
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PN: 108588-01 REV.: 1
Condensing Hydronic Boiler
Models: AMP 1000, 1250, 1500 & 2000
Boiler Mode:
Serial Number:
Installation Date:
Heating Contractor:
WARNING: Improper installation, adjustment, alteration, service or
maintenance can cause property damage injury, or loss of life. For
-
vice agency or the gas supplier. This boiler requires a special venting
system. Read these instructions carefully before installing.
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Thermal Solutions Products, LLC, 1175 Manheim Pike, Lancaster, PA 17601 www.thermalsolutions.com
2
TABLE OF CONTENTS
I 4
II 5-6
A. Local Codes
B. Warranty
C. Shipment Damage
D. Boiler Operation
E. Gas Leakage (If you detect or smell gas...)
F. Maintenance
G. Freeze Protection Fluids
I. Factory Test and Inspections
J. Disclaimers and Local Codes
III 7-8
IV 10-13
V 14
A. Unpacking and Inspection
B. Check Equipment
C. Installation and Operation Manual
VI 15-17
VII 18-32
A. General Guidelines 18
B. Field Installation 23
C. Polypropylene Venting 25
D. Optional Room Air For Combustion 26
E. Removing Existing Boiler 28
F. Multiple Boiler Installation 30
G. Common Venting Requirements 31
H. Special Installation Requirements for Massachusetts 30
VIII 33-34
A. Condensate Trap Installation
B. Condensate Neutralizer Installation
C. Common Condensate Pump/Sump
IX 35-42
A. Required System Pressure 35
35
C. Factory Supplied Water Manifold 35
D. Temperature Rise and Boiler Head Loss 36
E. Standard Installation Requirements 37
F. Water Quality and Treatments 38
G. Oxygen Contamination 39
41-42
X 43-45
A. Guidelines and Requirements
3
XI 46-50
A. General 46
B. Power Requirements 46
C. Boiler Wiring 46
D. Line Voltage Connection 47
E. Low Voltage Connection 47
XII 51-55
A. Check Heating System 51-54
B. Start Boiler 51
C. Test Safety Limits Controls 54-55
XIII 56-60
A. Inspect Boiler Area 57
B. Inspect Boiler Interior 57
C. Monthly Inspection 57
D. Annual Inspections and Service 57-59
E. Restarting After prolong Shutdown 60
XIV 61
XV 62
APPENDIX A-TABLES 63
APPENDIX B-FIGURES 64
65
APPENDIX D-INLET, OUTLET WATER AND FLUE OUTLET
TEMPERATURE SENSOR RESISTANCE-VOLTAGE CHART 66
APPENDIX E-VENT AND COMBUSTION AIR PRESSURE DROP DATA 67
TABLE OF CONTENTS
4
The following terms are used throughout this manual to bring attention to the presence of hazards of vari-
ous risk levels, or to important information concerning product life.
It is critical all personnel read and adhere to all information contained in DANGER, WARNING, and CAUTIONS.
All DANGERS, WARNINGS, and CAUTIONS are for reference and guidance purpose, and, therefore, do not sub-
stitue for strict adherence to applicable jurisdictional and professional codes and regulations.
Indicatesanimminent hazardous situation which, if notavoided,
willresultindeath, seriousinjuryorsubstantialpropertydamage.
Indicates a potentially hazardous situation which, if not avoided,
could result in death, serious injury, or substiantial property
damage.
Indicatesa potentiallyhazardoussituation which,ifnotavoided,
may result in moderate or minor injury, or property damage.
Indicates special instructions on installation, operation, or
maintenance which are important but not related to personal
injury hazards.
DANGER
WARNING
CAUTIONS
NOTICE
5
1. This unit shall be installed in accordance with
those installation regulations enforced in the
areawheretheinstallation is tobe made. These
regulations shall be carefully followed in all
cases. Authorities having jurisdiction shall be
consulted prior to installation.
2. This unit must be installed and serviced by a
3. The City of New York requires a Licensed
Master Plumber to supervise the installation
of this product.
4. TheCommonwealthof Massachusettsrequires
this product to be installed by a Licensed
Plumber or Gas Fitter.
1. This product has a limited warranty, a copy
of which is shipped with the unit. It is the
responsiblity of the installing contractor to
ensure all controls are correctly installed and
are operating properly.
2. Factory warranty does not apply to units
improperly installed or improperly operated.
3. Heat exchanger failure due to lime (scale)
build-up in the heat exchanger is not covered
under the manufacturer’s warranty.
4. Itistheresponsibilityofthe customertoensure
water hardness level conforms to Table 15.
1. Upon receiving the unit, inspect for signs of
shipping damages. If the unit has been hit or
otherwise mishandled, immediately notify
the carrier.
2. Verify total number of factory supplied items,
as per the packing slip, with received parts.
1. Connect supply gas line to the boiler via the
groundjointunioninside the boiler(seeFigure
19).
2. Use two wrenches when tightening gas piping
attheunionconnection, onewrenchtoprevent
the boiler gas line crom turning.
3. Failure to prevent the gas line from turning
could damage gas line components: blower
and gas valve.
1. This appliance MUST NOT be installed in any
are likely to be present or, in an environment
that contain corrosive contaminants (see
Table 4).
2
combustion or ventilation air from or to the
boiler.
3. Do not operate unit if any part has been under
water. Any appliance that has been under
water must be replaced. Water damage to the
unit can be extensive and present numerous
safety hazards.
1. Do not try to light any appliance.
2. Do not touch any electrical switch; do not use
any phone in the building.
3. Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instruction.
4. If you cannot reach your gas supplier, call the
1. To avoid electrical shock, ensure all electrical
connectionsareunpoweredbeforeattempting
installationor serviceofelectricalcomponents
or connections.
2. Lockout all electrical boxes with padlock once
power is turned off.
3. To prevent severe burns, allow the boiler to
cool before performing maintenance.
1. DONOTUSEautomativeantifreezeorEthylene
glycol. Ethylene glycol is toxic and can attack
gaskets and seals used in hydronic systems.
2. Useonlyinhibitedpropyleneglycolesolutions,
systems.
1. A nameplate, in accordance with the ASME
code Section IV, is permanently attached to
the heat exchanger.
2. To access the nameplate, remove front jacket
panel from boiler.
6
are performed by factory trained service
personnel on each unit. The factory emissions
report is posted on the back of the front jacket
panel for troubleshooting and maintenance
reference.
2. Inaddition,thefollowingtestsand inspections
are performed to ensure the appliance meets
ourhighestsafetyandperformancestandards:
Operating test
Construction inspection
Electrical components inspection
Crating inspection.
1. Installationmustconformto the requirements
of the authority having jurisdiction. In the
absence of such requirements, installation
must conform to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, and/ or CAN/CGA B149
Installation Codes. Where required by the
authority having jurisdiction, the installation
must conform to the Standard for Controls and
Safety Devices for Automatically Fired Boilers,
ANSI/ ASME CSD-1.
2. Installation, start-up, and maintenance of this
equipment can be hazardous and requires
personnel. Do not install, operate, service
or repair any components of this equipment
all requirements and procedures.
3. This instruction manual is an integral part
of the product and must be retained by the
person in charge of the appliance operation,
and service and maintenance.
(continued)
7
forced hot water or heating with indirect domestic
hot water heating systems, where supply water
temperature does not exceed 210°F. These boilers
have special coil type stainless steel heat exchangers,
constructed, tested and stamped per
Section IV ‘Heating Boilers’ of ASME Boiler and
Pressure Vessel Code, which provide a maximum
heat transfer and simultaneous protection against
not designed for use in gravity hot water space
amount of dissolved oxygen (swimming pool water
heating, direct domestic hot water heating, etc.).
Fuel Natural Gas Natural Gas Natural Gas Natural Gas
Max. Water Temperature (°F)1210 210 210 210
Max. Working Pressure (psi) 160 160 160 160
Standard Safety Relief Valve (psi)250 50 50 50
Boiler Water Volume (gal.) 10.96 10.96 12.97 16.72
Heat Transfer Area (sq. ft.) 91.6 91.6 109.79 142.0
Approx. Shipping Weight (lb.) 780 780 1050 1150
Boiler will go in hard lockout if temperature exceed 210 °F.
Optional 30, 60, 75, 100, and 125 psi safety relief valves are available for all models.
Max.
AMP 1000 200 1000 970 843 97 97
AMP 1250 250 1250 1213 1055 97 97
AMP 1500 300 1500 1455 1265 97 97
AMP 2000 400 2000 1940 1687 97 96.9
Ratings shown are for installations at sea level and elevations up to 2000 ft. at minimum
vent length. For high altitude installations above 2000 ft. consult factory.
8
(continued)
A 45.5 45.5 66-1/8 66-1/8
B 54 54 74-5/8 74-5/8
C 60-1/4 60-1/4 79-3/8 79-3/8
D 34-1/4 34-1/4 34-1/4 34-1/4
E 13-3/8 13-3/8 13-3/8 13-3/8
F 42-3/4 42-3/4 42-3/4 42-3/4
G 36-1/8 36-1/8 36-1/8 36-1/8
H 19-1/4 19-1/4 16-1/2 16-1/2
I 6-7/8 6-7/8 11-7/8 11-7/8
J 14-5/8 14-5/8 13-1/4 13-1/4
K 8-1/2 8-1/2 8-1/2 8-1/2
L 40-1/2 40-1/2 40-1/2 40-1/2
M 44-3/8 44-3/8 44-3/8 44-3/8
N 9-1/4 9-1/4 9-1/4 9-1/4
O 4-7/8 4-7/8 4-7/8 4-7/8
P 13-3/8 13-3/8 13-3/8 13-3/8
Q 6-1/8 6-1/8 8-1/2 8-1/2
R 10-1/8 10-1/8 10-1/8 10-1/8
S 23-1/2 23-1/2 23-1/2 23-1/2
T 32-1/4 32-1/4 32-1/4 32-1/4
Gas Inlet 1 1 1.25 1.25
Supply Pipe Size 3 3 3 3
Return Pipe Size 2-1/2 2-1/2 2-1/2 2-1/2
Air Intake 8 8 8 8
Vent Outlet 8 8 8 8
Condensate Drain 1 1 1 1
Drain Line 3/4 3/4 3/4 3/4
CENTER OF GRAVITY
X-COG 18-3/4 16-5/8 18-7/8 18-7/8
Y-COG 16-5/8 16-5/8 24-7/8 24-7/8
Z-COG 21-5/8 21-5/8 21-1/4 21-1/4
9
10
TM
The AMP boiler series is equipped with Concert Boiler ControlTM display which provides easy access for
viewingandadjusting boiler operationalparameters, monitoringhistorical performancecharacteristics
and annunciating boiler alarm/lockout conditions.
It receives and processes input signals from safety switches and sensors to modulate main burner
The control box is designed to allow easy acess to safety components and PCB boards for service and
troubleshooting purposes.
The OFF position interrupts power to the unit.
The blower is designed for pre-mix application and delivers combustion air and gas to the burner at
a desired ratio over the modulation range.
R
RBurner is mounted on the burner door with eight M4 x 10
scews.
The ionization electrode provides electrical spark for ignition. The ignitor assembly is installed on the
burner door with two M4 x 10 torx screws.
condition.
If the temperature at the burner door reaches over 320 0F, the thermal fuse will interrupt power to the
The high gas pressure switch monitors supply gas pressure and shuts off the electrical control circuit
when pressure rises above the set point (see Table 21).
The low gas pressure switch monitors supply gas pressure and shuts off the electrical control circuit
in the event a low gas pressure condition occurs (see Table 21).
Outlet manifold with Victaulic grooved connection conveys supply water from the boiler to the system.
11
Provides a means of connection for incoming gas line to the boiler’s gas train assembly. See Table 21 for
set point.
The unit comes with an integrated Low Water Cut Off (LWCO) probe and rest box. LWCO safeguards the
heat exchanger from inadequate water level. The LWCO has a manual reset button.
Provides real time supply water temperature and pressure readings.
The safety relief valve protects the heat exchanger from an over pressure condition. Refer to Table 2 for
standard factory supplied relief valve sizes and optional sizes for all models.
drain line.
It ensures adequate combustion air is supplied to the combustion chamber for stable and complete
ignition.
of vent piping.
It provides pathway for combustion air to enter the ignition system by a means of negative pressure
(suction) generated by the blower.
The vent pipe conveys combustion products to a safe point of discharge. The unit is equipped with a
(continued)
12
(continued)
13
(continued)
14
1. Move boiler to approximate installation
location.
2. Remove all crate fasteners.
3. Lift and remove outside container.
4. Account for all loose shipped items.
5. Remove boiler cardboard positioning
sleeves on shipping skid.
6. The boiler can be moved to its permanent
location via a fork lift or an overhead cran
attached to the lift lugs.
7. Theliftlugsarelocated nexttotheinlet/outlet
water connections.
8. The boiler can be removed from the pallet
using a lift truck from the side, front or rear
of the boiler.
WARNING
Failure to assure the truck forks are long
enough to extend at least half way through the
boiler’s base will result in the boiler tipping
off the lift truck and potentially falling. This
will result in severe personal injury, death, or
substantial property damage.
Do not operate this appliance if any part has
been underwater. The possible damage to a
numerous safety hazards. Any appliance that
has been underwater must be replaced.
NOTICE
Do not drop, bump, or lean an object against
the boiler in order to avoid damaging the heat
exchanger or critical components.
1. Upon receiving the equipment, check for
signs of shipment damage.
2. Pay particularattentiontopartsaccompanying
the appliance which may show sign of being
hit or otherwise mishandled.
3. Verifytotalnumberofpiecesshownonpacking
slip with those actually recieved. In case there
is damage or a shortage, immediately notify
the carrier.
1. The instruction manual enclosed with the
unit is an integral part of the product and
must be retained by the person in charge of
the appliance. Please read the instructions
contained in this manual carefullly as they
provide important information regarding
the safe installation, use and servicing of this
appliance.
15
A.Installation must conform to the requirements
of the authority having jurisdiction or, in the
absence of such requirements, to the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or
Natural Gas and Propane Installation Code, CAN/
CSA B149.1. Where required by the authority
havingjurisdiction,the installation must conform
to the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
B.
combustible
carpeting.
C. Provide clearance between boiler jacket and
combustible material in accordance with local
listed clearances from combustible material and
recommendedserviceclearance. Recommended
service clearance may be reduced but should not
be less thean clearances to combustible.
D. Protect gas ignition system components from
water (dripping, spraying,rain,etc.)during boiler
operation and service (circulator replacement,
condensate trap, control replacement, etc.).
E. Provide combustion and ventilation air in
accordance with applicable provisions of local
building codes, or: USA - National Fuel Gas Code,
ANSI Z223.1/NFPA 54, Air for Combustion and
Ventilation; Canada - Natural Gas and Propane
Installation Code, CAN/CSA-B149.1, Venting
Systems and Air Supply for Appliances.
F. The boiler should be located so as to minimize
the length of the vent system. Ensure air intake
pipe termination away from areas that may
contaminate combustion air (see Table 4). In
particular, avoid areas near chemical products
removers, cleaning solvents and detergents.
Avoidareascontainingsawdust, loose insulation
NOTICE
Due to the low water content of the boiler, mis-
sizing of the boiler with regard to the heating
system load will result in excessive boiler
cycling and accelerated component failure.
Thermal Solutions DOES NOT warrant failures
caused by mis-sized boiler applications.
DO NOT oversize the boiler to the system.
Multiple boiler installations greatly reduce the
likelihood of boiler oversizing.
Avoid operating this boiler in an environment
wall dust, etc. are present. If boiler is operated
under these conditions, the burner interior
and ports must be cleaned and inspected daily
to insure proper operation.
Ensure all labels on the boiler are fully visible
at all times for the purpose of maintenance and
inspections.
WARNING
Apply supplied dielectric grease to gasket inside
vent connector. Failure to apply the grease
installation or gasket deterioration due to
condensate exposure.
Adequate combustion and ventilation air must
be provided to assure proper combustion.
Install combustion air intake per Section IV
“Venting”.
Installation of this boiler should be undertaken
only by trained and skilled personnel from
instructions exactly. Improper installation,
adjustment, service, or maintenance can cause
property damage, personal injury or loss of life.
Do not change or modify any boiler accessories
or parts or jump-out any safety limit devices.
16
G. General.
1. AMP boilers are intended for installation in an
pan to prevent any leaks or safety relief valve
discharge resulting in property damage.
2. AMP boilers are not intended to support
external piping and venting. All external
piping and venting must be supported
independently of the boiler.
3. AMP boilers must be installed on a level
surface to prevent condensate from backing
up inside the boiler. Refer to Table 2 for boiler
approximate shipping weight.
4. Boiler Installation:
a. For basement installation provide a solid
notlevelwatermaybeencountered around
boiler.Floormustbe able tosupportweight
of boiler, water and all additional system
components.
b. Provide adequate space for condensate
piping or a condensate pump, if required.
(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
Antistatic 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 establish-
ments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
(continued)
17
(continued)
Rear
Rear
AMP 1000 Open 6 6 10 6 6 22 6 24 24 20 18
AMP 1250 Open 6 6 10 6 6 22 6 24 24 20 18
AMP 1500 Open 6 6 10 6 6 22 6 24 24 20 18
AMP 2000 Open 6 6 10 6 6 22 6 24 24 20 18
18
a. Install vent system in accordance with
National Fuel Gas Code, ANSI Z223.1/NFPA
54 or Natural Gas and Propane Installation
Code,CAN/CSAB149.1InstallationCodefor
Canada, or, applicable provisions of local
building codes.
boiler. Category II vent is required when
common venting multiple units. Refer to
SectionH"CommonVentingRequirements."
c. The vent pipe serves to expel products of
combustion to a safe point of discharge
and air intake pipe serves to deliver
combustion air from outdoors (Refer part
E "Optional Room Air for Combustion Air.")
The following vent/combustion system
materials are approved for use with the
AMP boilers.
WARNING
Failure to vent this boiler in accordance with
these instructions could cause products of
combustion to enter the building resulting in
severe property damage, personal injury or
death.
Do not locate vent termination under a deck, or
where exposed to prevailing winds.
Donotlocatecombustionairterminationwhere
volatile vapors or other chemicals are present
(seeTable4). Severeboilercorrosionand failure
will result.
Do not interchange vent systems or materials
Do not apply thermal insulation to vent pipe or
Do not use a barometric damper; draft hood or
vent damper with this boiler.
Atmospheric venting is prohibited.
a. Do not exceed maximum vent/combustion
air lengths listed in Table 7. Vent and
combustionairlengthrestrictionsarebased
onequivalentlengthofventandcombustion
air pipe (total length of straight pipe plus
b. Do not include vent/combustion air
terminal in equivalent feet calculations.
Usevent/combustionair equivalentlength
worksheet provided in Table 9.
c. See Table 5 for recommended clearance to
service and combustible materials.
Standard-
Factory
Supplied
Vent Two-Pipe AL 29-4C Vertical or Horizontal
Air Intake Two-Pipe PVC/ Galvanized steel Vertical or Horizontal
Option 1 Vent Two-Pipe, Rigid Polypropylene Vertical or Horizontal
Air Intake Two-Pipe, Rigid PVC, Galvanized steel Vertical or Horizontal
Option 2 Vent Two-Pipe, Rigid CPVC Vertical or Horizontal
Air Intake Two-Pipe, Rigid PVC/Galvanized steel Vertical or Horizontal
Note: For "Option 1" refer to Table 10 for polypropylene vent adapter.
WARNING
Moisture and ice may form on surface around
vent termination.
To prevent deterioration, surface must be in
good repair (sealed, painted, etc.).
Do not allow low spots in the vent where con-
densate may pool.
diameters.
All vent and combustion air pipe must be
sealed and airtight.
Alteration of the boiler vent connection is
prohibited.
19
(continued)
Equivalent
Length Per
Piece
x Quantity =
Subtotal
Equivalent
Length
Equivalent
Length Per
Piece
x Quantity =
Subtotal
Equivalent
Length
Straight Pipe x = A D
90° Elbow x = B E
45° Elbow x = C F
Combustion Air Total
Equivalent Length
= Vent Total
Equivalent Length
Notes:
1. Total equivalent length cannot exceed maximum equivalent length shown in Table 7.
2. Use elbow equivalent lengths provided in Table 8.
3. Combustion air and vent terminations do not count towards total equivalent length.
Pipe Dia.
(ft.)
Minimum
(ft.)
Maximum
(ft.)
Pipe Dia.
(ft.)
Minimum
(ft.)
Maximum 1
(ft.)
AMP 1000
8 0 100 8 3 100
AMP 1250
AMP 1500
AMP 2000
1 Up to 200 feet maximum when drawing combustion air from inside.
Applies to all listed vent/combustion air system options.
NOTE: Contact factory for assistance for changing RPM for Max. vent applications.
Nominal Diameter 8
90° Elbow 10
45° Elbow 10
AMP 1000 8 ISSA0808 8PPS-08PVCM-8PPF
AMP 1250 8 ISSA0808 8PPS-08PVCM-8PPF
AMP 1500 8 ISSA0808 8PPS-08PVCM-8PPF
AMP 2000 8 ISSA0808 8PPS-08PVCM-8PPF
20
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