Thermal Solutions AMPW 400 User manual
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PN: 110820-01 Rev. 5, 4/23
Commercial Condensing Water Heater
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Thermal Solutions Products, LLC www.thermalsolutions.com
INSTALLATION, OPERATION, AND
MAINTENANCE MANUAL
399-1000 MBH Water Heater Indoor/Outdoor
Water Heater Models
AMPW 400
AMPW 500
AMPW 650
AMPW 800
AMPW 1000L
Model: Serial Number:
Installation Date: System Type:
Heating Contractor: Phone/Email:
Address:
WARNINGWARNING
WARNING: If the informaon in these instrucons
is not followed exactly, a re or explosion may
result causing property damage, personal injury
or death.
DANGERDANGER
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 qualified installer, service agency or the gas
supplier.
2 AMPW 400-1000L I&O Manual
Table of Contents
A. Local Codes 4
B. Warranty 4
C. Shipment Damage 4
D. Connecting Gas Supply Line 4
E. Gas Leakage (If you detect or smell gas...) 5
F. Maintenance 5
H. Factory Test and Inspections 5
I. Disclaimers and Local Codes 5
A. Unpacking and Inspection 9
B. Check Equipment 9
C. Installation and Operation Manual 9
A. General 12
B. Appliance Mounting 13
C. Outdoor Installation 13
D. AMP 400-1000L Stacking 14
E. Clearances 15
F. Clearances (French) 15
G. Closet and Alcove Installation 15
A. General Venting Guidelines 16
B. Venting Design Requirements 16
C. Field Installation 17
E. PVC Venting 19
F. Venting for Outdoor Installation 19
G. General Termination 20
I. Multiple Appliance Terminations 27
J. Terminal Installation 27
K. Polypropylene Venting 29
M. Removing Existing Appliance 32
N. Special Installation Requirements for Massachusetts 33
A. Condensate trap 34
B. Condensate Neutralizer Installation 34
AMPW 400-1000L I&O Manual 3
Table of Contents
C. Common Condensate pump/Sump 35
A. General Piping Guidelines 35
B. Factory Supplied Relief Valve Package 36
C. Standard Piping Components 37
D. Scalding 38
E. Water Quality 39
F. Temperature Rise and Heat Exchanger Head Loss 40
G. Pump Selection 41
A. Guidelines and Requirements 45
B. Field Connecting Gas Supply 45
C. Gas Pressure Switches 47
A. General. 48
B. Power Requirements 48
C. Appliance Wiring 48
D. Routing Field Connections 48
E. System and Circulation Pump Wiring 49
A. Check System Setup 54
B. Start the AMP 54
D. Field Conversion of Gas Type 57
E. Pump Control 58
F. Check Thermostat Operation 58
H. Testing of Controls and Safety Devices 58
A. General Maintenance 60
B. Monthly Inspection 60
C. Annual Inspections and Service 60
D. Restarting after Prolong Shutdown 63
4 AMPW 400-1000L I&O Manual
A. Local Codes
B. Warranty
Table 21
C. Shipment Damage
D. Connecng Gas Supply Line
DANGERDANGER
WARNINGWARNING
DANGERDANGER
AMPW 400-1000L I&O Manual 5
DANGERDANGER
Table 4
E. Gas Leakage (If you detect or smell gas...)
DANGERDANGER
F. Maintenance
G. Product Idencaon Label
DANGERDANGER
II(continued)
H. Factory Test and Inspecons
I. 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
WARNINGWARNING
6 AMPW 400-1000L I&O Manual
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 Pressure 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 40 399 391 475 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. at minimum
Dimensions (in.) AMPW Model
400 500 650 800 1000L
Gas Inlet 3/4 3/4 1 1 1
Water Outlet Pipe (FNPT) 2 2 2 2 2
Water Inlet Pipe (MNPT) 2 2 2 2 2
Air Intake 4 4 6 6 6
Vent Outlet 4 4 6 6 6
Condensate Drain (PVC) 1 1 1 1 1
Drain Line (FNPT) 3/4 3/4 3/4 3/4 3/4
Electrical Conduit Holes 7/8 7/8 7/8 7/8 7/8
AMPW 400-1000L I&O Manual 7
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
8 AMPW 400-1000L I&O Manual
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
AMPW 400-1000L I&O Manual 9
A. Unpacking and Inspecon
B. Check Equipment
Figure 3
shown in Figure 15
Figure 1 and Figure 2
C. Installaon and Operaon Manual
Front panel with
display cover
Side panel
with louvers
Rear intake cover
DANGERDANGER
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. BluejetR Burner
R
10. Ignion electrode
11. High gas pressure switch
12. Low gas pressure switch
13. Outlet/Hot water connecon
14. Water ow switch
Table 22
15. Gas supply connecon
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 relief valve
22. Condensate drain trap
23. Minimum combuson air proving switch
24. Blocked vent switch
25. Combuson air lter box
26. Heat Exchanger
27. Heat Exchanger Drain
28. Exhaust Vent Connecon
to
29. Condensate Drain Connecon
30. Combuson Air Intake Connecon
12 AMPW 400-1000L I&O Manual
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 5
Table 4
WARNINGWARNING
AMPW 400-1000L I&O Manual 13
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)
WARNINGWARNING
B. Appliance Mounng
14 AMPW 400-1000L I&O Manual
VI(continued)
D. AMP 400-1000L Stacking
DANGERDANGER
shown in Figure 5
Stacking Brace
Self-Drilling Screws
Rotated Display
(optionally field installed)
1
AMPW 400-1000L I&O Manual 15
E. Clearances
found in Table 5
F. Clearances (French)
G. Closet and Alcove Installaon
VI(continued)
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
WARNINGWARNING
16 AMPW 400-1000L I&O Manual
A. General Venng Guidelines
aonal
Fuel Gas Code, ANSI Z223.1/NFPA 54 or Natural
in
B. Venng Design Requirements
1. Engineered Venng Method
WARNINGWARNING
found in Table 12
2 2ranges are shown in
Table 31
e. Manifolded venng
2. Equivalent length method:
AMPW 400-1000L I&O Manual 17
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)
C. Field Installaon
18 AMPW 400-1000L I&O Manual
WARNINGWARNING
VII(continued)
Make Stainless Steel Brand Polypropylene Brand
DuraVent FasNSeal PolyPro
Heat Fab Saf-T Vent EZ Seal* -
Z-Flex (Nova Flex Group) Z-Vent Z-DENS
Centrotherm - InnoFlue SW Rigid
Note: Included appliance connection is a 3-in-1 adapter that permits Stainless Steel, Polypropylene, or CPVC.
Adapting to Z-DENS requires 4" increaser 2ZDI44 or 6" adapter 2ZDCPVCG6.
Adapting to InnoFlue requires 4" adapter ISAALE0404 or 6" adapter ISAALE0606
AMP Model Vent
Diameter (in.) Style Heat Fab Part #
Saf-T Vent
DuraVent Part #
FasNSeal
400
500 4
Tee 9490TEE FSTT4
90° Elbow 9414TERM -
Straight 9492 -
23° Elbow - FSBS4
650
800
1000L 6
Tee 9690TEE FSTT6
90° Elbow 9614TERM -
Straight 9692 -
23° Elbow - FSBS6
AMP Model Vent
Diameter (in.) Style DuraVent Part #
PolyPro Centrotherm Part #
InnoFlue
Z-Flex Part #
Z-DENS
400
500 4
Tee 4PPS-TTBL ISTT0420 2ZDTT4
Elbow 4PPS-E90BC - 2ZDE487UV
Straight 4PPS-12BC ISEP04 2ZDES4
Screen 4PPS-BG IASPP04 2ZDES4
650
800
1000L 6
Tee 6PPS-TTBC ISTT0620 2ZDTT6
Elbow 6PPS-E90BC - 2ZDE687
Straight 6PPS-12BC - 2ZDES6
Screen 6PPS-BG IASPP06 2ZDES6
At Maximum Input Rate At Minimum Input Rate
AMP
Model Flue Gas Flow, ACFM @
35% Excess Air, 180 0F
Combustion Air, SCFM
@ 35% Excess Air,
60 0F
Flue Gas Flow, ACFM @
35% Excess Air, 180 0F
Combustion Air, SCFM
@ 35% Excess Air,
60 0F
400 113 92 11 9
500 141 115 14 11
650 183 149 18 15
800 226 184 23 18
1000L 282 212 28 23
Note: Flow rates are based on the combustion of natural gas.
AMPW 400-1000L I&O Manual 19
D. Room Air for Combuson
E. PVC Venng
F. Venng for Outdoor Installaon
VII(continued)
Drain Cap
Boot Tee
36" Straight
90° Elbow
Termination Tee
20 AMPW 400-1000L I&O Manual
VII(continued)
G. General Terminaon
in Table 13
Vent & Intake
Materials Vent
Option
Penetration
Through Structure Termination Parts Table Reference
Figure
Two Pipe
Stainless Steel vent
Galvanized Steel or
PVC intake
1Intake Horizontal Sidewall 90° elbow
Table 10
Figure 9
Vent Horizontal Sidewall Tee or 45° elbow
2Intake Horizontal Sidewall 90° elbow -
Vent Vertical Roof Tee or straight
3Intake Vertical Roof Tee or 2 90° elbows Figure 10
Figure 11
Vent Vertical Roof Tee or straight
Two Pipe
Polypropylene vent
Galvanized Steel or
PVC intake
4Intake Horizontal Sidewall 90° elbow
Table 11
Figure 9
Vent Horizontal Sidewall Tee or 45° elbow
5Intake Horizontal Sidewall 90° elbow -
Vent Vertical Roof Tee or straight
6Intake Vertical Roof Tee or 2 90° elbows Figure 10
Figure 11
Vent Vertical Roof Tee or straight
Two Pipe
CPVC vent
Galvanized Steel or
PVC intake
7Intake Horizontal Sidewall 90° elbow
-
Figure 9
Vent Horizontal Sidewall Tee or 45° elbow
8Intake Horizontal Sidewall 90° elbow -
Vent Vertical Roof Tee or straight
9Intake Vertical Roof Tee or 2 90° elbows Figure 10
Figure 11
Vent Vertical Roof Tee or straight
SS, PP,
or CPVC vent
Room air intake
10 Vent Horizontal Sidewall Tee or 45° Elbow Table 10
Table 11 -
11 Vent Vertical Roof Tee or straight
This manual suits for next models
4
Table of contents
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