GF-146-P TAG-0074_0B PIPING APPLICATION GUIDE Natural Gas or Propane Modulating & Condensing Boilers and Water Heaters Applies to the following models: Boilers • • • • 399 / 500 / 750 / 1000 AM 399B AM 500B AM 750B AM 1000B Gas-Fired Boilers and Water Heaters Pending Water Heaters • • • • AM 399W AM 500W AM 750W AM 1000W AM 399 Single-Installation Piping Example Pending 04/08/2014 Page 1 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping GF-146-P Application Guide TAG-0074 0B DISCLAIMER The information contained in this manual 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 merchantability and fitness for a particular application.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Table of Contents Table of Contents ..................................................................................... 3 1. MANDATORY REQUIREMENTS ........................................................ 4 2. BOILER QUALITY AND MAINTENANCE........................................... 6 2.1. BOILER WATER CHEMISTRY ........................................................................ 6 2.1.1. Scale and Corrosion ................................
AM Series Piping GF-146-P Application Guide TAG-0074_0B 1. MANDATORY REQUIREMENTS The following are mandatory actions required to ensure proper piping and drainage of the AM Series system. CAUTION! Local codes and authorities should be consulted prior to installation. • AERCO requires that the boiler loop to be de-coupled from the system loop. This can be achieved by one of the following: o Employing primary-secondary piping.
AM Series Piping GF-146-P Application Guide TAG-0074 0B RELIEF VALVE #1 RELIEF VALVE #1 DISCHARGE PIPING RELIEF VALVE #2 RELIEF VALVE #2 DISCHARGE PIPING SEPARATE PIPES LEADING TO POINT OF DISCARGE Figure 1: AM 399/500 Relief Valve Point of Discharge Example CAUTION! Each relief valve must have its own discharge piping all the way to the point of discharge, and must never be manifolded, attached to, or combined with any other piping. Page 5 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping GF-146-P Application Guide TAG-0074 0B 2. BOILER QUALITY AND MAINTENANCE 2.1. BOILER WATER CHEMISTRY 2.1.1. Scale and Corrosion Free oxygen can cause the formation of rust (iron oxides), which degrade metallic materials. Magnetite is formed in un-inhibited water if there is electrolytic action in the presence of oxygen. Sludge is formed when calcium compounds, primarily CaCO3, are heated.
AM Series Piping Application Guide GF-146-P TAG-0074 0B types of metals used in hydronic systems. Elevated salt levels also contribute to higher conductivity levels, another undesirable characteristic in hydronic systems. • Chloride – Chlorides are salts resulting from the combination of the gas chlorine with a metal and are instrumental in accelerating corrosion in the types of metals used in hydronic systems. Chlorides may be introduced into the water naturally.
GF-146-P TAG-0074 0B AM Series Piping Application Guide 2.3. SYSTEM FLUSHING, TREATMENT, AND CLEANSING Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent infusion of containments, including sludge, into the boiler. Section 2.3 provides recommendations for flushing, cleaning, and treating the water used in the AM Series system. IMPORTANT! Cleaning solution and inhibitors used must be compatible with heat exchanger material.
AM Series Piping Application Guide low lying pipework is fully drained. completely emptied. GF-146-P TAG-0074 0B Opening all bleed valves ensures the system will be • A reliable test to determine if a system is clean is if the Total Dissolved Solids (TDS) of the water being drained is within 10% of the make-up water TDS. This indicates that sufficient contamination has been flushed from the system.
AM Series Piping GF-146-P Application Guide TAG-0074 0B TABLE 1: Flow Rate and Pressure Drops AM 399 AM 500 AM 750 AM 1000 Minimum Water Flow (GPM) @ Min. Fire Rate 4 4 4 4 Minimum Water Flow (GPM) @ Max. Fire Rate 7 9 14 18 Maximum Water Flow (GPM) 37 37 55 74 Water Pressure Drop (Ft. of Hd.) at Max. Flow 29 55 41.5 38 14.7 18.4 27.6 36.8 5 17 13 10.5 1-1/4" NPT 1-1/2" NPT 1-1/2" NPT 2" NPT Strainer ∆P (Ft. of Hd.) – (‘Y’ Strainer, 20 mesh) 0.63 0.54 1.22 0.
AM Series Piping GF-146-P Application Guide TAG-0074 0B TABLE 1: Flow Rate and Pressure Drops AM 399 AM 500 AM 750 AM 1000 1-1/4" NPT 1-1/2" NPT 2" NPT 2" NPT Strainer ∆P (Ft. of Hd.) – (‘Y’ Strainer, 20 mesh) 0.41 0.64 0.70 1.25 ∆P (Ft. of Hd.) – (20’ SCH.40, 4 x 90°, 2 x reducing couplings, 2 x Ball Valve) 0.71 1.21 0.92 1.76 Total Primary Loop ∆P (Ft. of Hd.) @ ∆T of 25°F 20.12 56.85 43.13 41.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 2: Water Side Pressure Loss Chart Figure 3: Water Velocity Flow Chart Page 12 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Figure 4: AM BOILER: Electrical Connections Page 13 of 30 AERCO International, Inc. • 100 Oritani Dr.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 5: Water Heater Electrical Junction Box Connections (with Small Storage Tank) Figure 6: Water Heater Electrical Junction Box Connections (with Large Storage Tank) Page 14 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B 2.5. STRAINERS AERCO requires the installation of a Y strainer to keep dirt out of the system and boiler. The strainer should be installed in the return piping with isolation valves to allow for cleaning as necessary. The Y strainer shall have a 20 mesh or finer strainer. Such filter shall protect the boiler from heating system dirt. It should be regularly cleaned to prevent problems. 2.6.
AM Series Piping GF-146-P Application Guide TAG-0074 0B 2.7. AIR VENTING OF THE HEATING SYSTEM The AM Series units come standard with automatic air vents on each of the headers on the rear of the unit (see Figure 6a and 6b). These vents are for the unit only and not the entire heating system. An effective air vent for air removal for the entire heating system must be installed in the highest point of the system piping.
AM Series Piping Application Guide GF-146-P TAG-0074 0B AUTOMATIC AIR VENTS SAFETY RELIEF VALVE PRESSURE AND TEMPERATURE GAUGE HEADER TEMPERATURE SENSOR WATER SUPPLY (OUTLET) CONNECTION HEADERS WATER RETURN (INLET) CONNECTION DRAINING VALVES Figure 6b: AM 750/1000 Rear Panel Connections Page 17 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping GF-146-P Application Guide TAG-0074 0B 2.3.5. Flow Switch A flow switch is required to be installed on every unit (Figure 7). This flow switch is included with the unit and must be field-installed. The flow switch should be installed in a tee on the boiler outlet piping as shown in Figure 7. The paddle of the flow switch may have to be cut to length for the given pipe diameter according to the manufacturer’s instructions.
AM Series Piping Application Guide 3. GF-146-P TAG-0074 0B CONNECTIONS 3.1. PRIMARY-SECONDARY PIPING Primary-secondary piping must be utilized. This can be accomplished by using a common pipe (see Figures 11, 13, 15, 17) or a hydraulic separator. Primary – secondary piping decouples the boiler loop from the system loop, making it independent from system loop pressure fluctuations associated with opening/closing of zone valves or 3-way valves. 3.2.
GF-146-P TAG-0074 0B AM Series Piping Application Guide The AM Series of boilers and water heaters come equipped with a condensate trap and neutralizer tank (see Figure 10). It is crucial that these be filled with water to prevent combustion gases from entering the room and/or gases flowing backwards through the condensate line. A corrugated tube is provided to pipe neutralized condensate to a drain.
AM Series Piping Application Guide 4. GF-146-P TAG-0074 0B PIPING DIAGRAMS NOTES 1) For actual sizes and locations of piping and other connections to the boiler, see appropriate dimensional drawing. 2) Drain valve and condensate drain hose should be arranged to permit the fluids to drain freely by gravity to a convenient floor drain. The relief valve should be piped vertically to a height 18" above the floor. 3) All piping and electric connections (service switches, conduit boxes, etc.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 11: AM 399/500 Single Unit Installation Page 22 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Figure 12: AM Series 399/500 Single Unit Installation with DHW Installed Page 23 of 30 AERCO International, Inc. • 100 Oritani Dr.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 13: AM Series 399/500 Multiple Unit Installation Page 24 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Figure 14: AM Series 399/500 Multiple unit Installation With DHW Installed Page 25 of 30 AERCO International, Inc. • 100 Oritani Dr.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 15: AM 750/1000 Single Unit Installation Page 26 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Figure 16: AM Series 750/1000 Single Unit Installation with DHW Installed Page 27 of 30 AERCO International, Inc. • 100 Oritani Dr.
GF-146-P TAG-0074 0B AM Series Piping Application Guide Figure 17: AM Series 750/1000 Multiple Unit Installation Page 28 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping Application Guide GF-146-P TAG-0074 0B Figure 18: AM Series 750/1000 Multiple unit Installation With DHW Installed Page 29 of 30 AERCO International, Inc. • 100 Oritani Dr.
AM Series Piping GF-146-P Application Guide TAG-0074 0B Change Log Date Description Changed By 04/08/2014 Rev 0A: Release Curtis Harvey © AERCO International, Inc., 2014 www.aerco.com Page 30 of 30 AERCO International, Inc. • 100 Oritani Dr.
