Instruction No. GF-125U AERCO INTERNATIONAL, Inc. Northvale, New Jersey, 07647 USA User’s 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.
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 label on the backside of the control panel when calling about service or troubleshooting. Model #_________________________ Serial #__________________________ The information contained in this document is subject to change without notice from AERCO International, Inc. AERCO International, Inc.
Contents—GF-125U Contents Warnings and Cautions Emergency Shutdown Prolonged Shutdown Boiler & System Water 1 2 2 2 Chapter 1 Combustion Air Prevention of Contamination Potential Contaminating Products Areas likely to have these products 3 3 3 3 Chapter 2 Maintenance Schedule For the Service Technician For the End User 4 4 4 Chapter 3 Maintenance Procedures Daily Maintenance Monthly Maintenance Every 6 Months Maintenance 5 5 6 7 Chapter 4 Operating Instructions Safety 9 TO TURN OFF GAS TO APPLIANCE
Warnings and Cautions 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).
Emergency Shutdown CAUTION! DO NOT use this boiler if any part has been under water. Call a qualified service technician to inspect and replace any part that has been underwater. Boiler & System Water • • IMPORTANT The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel. • Emergency Shutdown If overheating occurs or the gas supply fails to shut off, DO NOT turn off or disconnect the electrical supply to the pump.
Prevention of Contamination Chapter 1 Combustion Air Prevention of Contamination Potential Contaminating Products • WARNING! IF THE ESTEEM COMBUSTION AIR INLET IS LOCATED IN ANY AREA LIKELY TO CAUSE OR CONTAIN CONTAMINATION, OR IF PRODUCTS, • • • WHICH WOULD CONTAMINATE THE AIR CANNOT BE REMOVED, THE COMBUSTION AIR MUST BE RE-PIPED AND TERMINATED TO ANOTHER LOCATION.
For the Service Technician Chapter 2 Maintenance Schedule For the Service Technician For the End User On an annual basis, or more frequently if conditions warrant, the following maintenance should be performed by a qualified service technician: • • • General • • • Monthly: • • • • • • • • • Attend to any reported problems. Inspect the interior of the boiler jacket area; clean and vacuum if necessary. Clean the condensate trap and fill with fresh water.
Daily Maintenance Chapter 3 Maintenance Procedures WARNING! THE ESTEEM MUST BE INSPECTED AND SERVICED ANNUALLY, PREFERABLY AT THE START OF THE HEATING SEASON, BY A QUALIFIED SERVICE TECHNICIAN. IN ADDITION, THE materials listed on page 2 of this manual. If any of these products are in the room from which the unit takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.
Monthly Maintenance Monthly Maintenance Check Pressure Relief Valve Check Vent Piping • • Visually inspect the flue gas vent piping for any signs of blockage, leakage or deterioration of the piping. Notify a qualified service technician immediately if any problems are found. • WARNING! FAILURE TO INSPECT THE VENTING SYSTEM Visually inspect the primary pressure relief valve and the relief valve discharge pipe for signs of weeping or leakage.
Every 6 Months Maintenance • • Ensure the condensate drain line is not blocked by pouring water through the plug port on the condensate drain assembly. The water should flow out of the end of the drain line. If water does not appear at the end of the drain line, contact a qualified service technician to inspect and clean the condensate line. To fill the condensate drain assembly, if necessary, remove the plug from the condensate assembly.
Every 6 Months Maintenance • WARNING! TO AVOID WATER DAMAGE OR SCALDING FROM VALVE OPERATION, A DISCHARGE LINE MUST BE CONNECTED TO THE RELIEF VALVE OUTLET AND DIRECTED TO A SAFE PLACE OF DISPOSAL. THIS DISCHARGE LINE MUST BE INSTALLED BY A QUALIFIED SERVICE TECHNICIAN OR HEATING / PLUMBING INSTALLER IN ACCORDANCE WITH THE TION MANUAL. ESTEEM INSTALLA- THE DISCHARGE LINE MUST BE TERMINATED SO AS TO ELIMINATE POSSIBILITY OF SEVERE BURNS OR PROPERTY DAMAGE SHOULD THE VALVE DISCHARGE.
Safety Chapter 4 Operating Instructions Safety FOR YOUR SAFETY READ COMPLETE INSTRUCTIONS BEFORE PROCEEDING WARNING! IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RE- SULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. IF YOU SMELL GAS • • • • • DO NOT try to light any appliance. DO NOT touch any electric switch; do not use any phone in your building DO NOT use a cell phone in your building Immediately call your gas supplier from a Different Location.
Operation Operation STOP! Read all the safety information on the preceding page. This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. 1. Set room thermostat(s) to lowest setting. 2. Turn the external manual gas valve handle clockwise “CLOSE” (valve handle shall be perpendicular to gas piping). 3. Turn the service switch on the Esteem 399 Low NOx control panel OFF. 4. Remove the front jacket panel on the unit. 5.
Standby Mode Chapter 5 BOILER CONTROL DISPLAY Boiler function Display Standby Mode StbY After the boiler is turned on, the control panel will display STANDBY mode as shown in the figure above. This is the standard mode for the Esteem. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display. The first character shows (on left side of display) the current status of the boiler depending on the condition of both the boiler and the burner.
Setting Boiler Parameters Key: Setting Boiler Parameters Parameter Mode P ARA To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once. MODE Key: STEP To scroll through the list of parameters, simply press the “STEP” button. To modify a parameter value, use the + or - keys. Then press “STORE” to save the value you just changed. The display flashes once to confirm the data has been saved.
Accessing Boiler Information NOTICE Accessing Boiler Information Information Mode The ignition counters and burner hours are split into three two digit numbers. I NFO To switch from STANDBY mode Information mode, press MODE twice. e M M is to Example: J 12 .34 .56 a P ARA I NFO ressin M on e ressin M t i e Press STEP until the system displays the information you need. The decimal point located behind the first position flashes to indicate that the boiler is in INFO mode.
Error (Hard Lockout) Mode Error (Hard Lockout) Mode If a system fault occurs while the boiler is running, the system goes into lockout and the display starts to flash with the first digit as an E and the next two digits represent the fault code. For a detailed description of the error codes, reference the Esteem Trouble Shooting Guide. WARNING! DURING A HARD LOCKOUT OR LOW WATER CONDITION THE BOILER WILL NOT RE-START WITHOUT SERVICE.
Jacket Components Appendix A: Replacement Parts Jacket Components Figure 3: Jacket Components Item 1 Description Display Control Panel 2 Part # 38027 38028 (Left) 38029 (Right) 34028 3 37051 Front Jacket Panel 5 37052 Side Jacket Panel (Left and Right) 6 37053 Top Jacket Panel 7 37054 Top Jacket Access Panel 8 37055 Control Cover Panel 9 33113 Wall Mounting Bracket with 1 Hardware 1A GF-125U Display Control Panel Extensions (Not Shown) Base Panel 15
Internal Components Internal Components Figure 4: Figure 4: Internal Components 16 Item Part # Description 1 2 3 4 5 6 7 8 9 10 28191 38030 38031 61022 61023 60013 22123 22124 22125 67003 Heat Exchanger Body Vent Outlet Adapter Combustion Air Inlet Adapter Supply & Return NTC Sensor (NTC1, NTC2) Flue NTC Sensor (NTC5) LWCO Pressure Device Condensate Drain Assembly Boiler Piping - Return Assembly Boiler Piping - Supply Assembly Pressure Gauge and Fitting GF-125U
Burner Components Burner Components 7 4 3 10 8 12 6 9 5 2 13 1 Figure 5: Figure 5: Burner Components Item Part # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 83025 24230 36059 58026 92078 -63086 58027 58028 --22126 22127 Combustion Chamber Insulation Burner Head with Gasket Burner Plate Blower with Gasket Gas Valve Venturi Ignition Cable Igniter with Gasket Sight Glass Assembly (Glass, Gasket and Bracket) Propane Orifice - Not Shown Burner Plate Gasket - Not Shown Gas Valve Piping Gas Supply P
Electronic Components Electronic Components Figure 6: Figure 6: Electronic Components 18 Item Part # Description 1 64061 Esteem Control Module 2 64062 Transformer with Surge Protection 3 64063 Esteem Control Module Display GF-125U
