AMEREC STEAMBATH GENERATORS 230V~N and 400V~N3

Transcription

1 Page 1 Possible Controls K60 OR K30 AK/3K AG/3G WARNING Electrical grounding is required on all Steambath Generats. All electrical supplies should be disconnected when servicing generat. All wiring must be installed by a licensed electrical contract in accdance with local and national codes. AMEREC STEAMBATH GENERATORS 230V~N and 400V~N3 (AK/3K "MASTER" GENERATOR TO BE GANGED WITH ONE OR TWO AG/3G "SLAVE" GENERATORS) AK17 = AK10 + AG7 + Appropriate Control Kit AK20 = AK10 + AG10 + Appropriate Control Kit AK30 = AK10 + (2) AG10 + Appropriate Control Kit 3K20 = 3K12 + 3G8 + Appropriate Control Kit 3K24 = 3K12 + 3G12 + Appropriate Control Kit 3K28 = 3K14 + 3G14 + Appropriate Control Kit 3K36 = 3K12 + (2) 3G12 + Appropriate Control Kit SAVE THESE INSTRUCTIONS. READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION. POST "WARNING" LABEL OUTSIDE STEAMBATH FOR SAFETY WARNINGS. REQUIRED POSTING ON DOOR OF STEAM ROOM OR ADJACENT TO DOOR FOR ALL COMMERCIAL INSTALLATIONS. SECTION 1: GENERAL INFORMATION AG/3G The steam generats come CE marked, assembled and ready f installation. Check that the size and rating of the generat is suitable f your application; refer to Steam Room Construction and Generat Sizing Guide (document ). All plumbing must be installed by a licensed plumber in accdance with all applicable local and national codes. Generats are f indo use only. Generats are not f space heating purposes. Be certain that steambath enclosures are properly sealed to avoid water damage from escaping steam. It is recommended that 100% silicone caulk be used to seal all pipes and fi ttings. Steam must be prevented from escaping into the wall cavity. Never shut off the water to a steam generat while it is in use. Electric Shock Hazard - High voltage exists within this equipment. There are no user serviceable parts in this equipment. REDUCE THE RISK OF OVERHEATING AND SCALDING 1. Exit immediately if uncomftable, dizzy sleepy. Staying too long in a heated area is capable of causing overheating. 2. Supervise children at all times. 3. Check with a doct befe use if pregnant, diabetic, in po health under medical care. 4. Breathing heated air in conjunction with consumption of alcohol, drugs medication is capable of causing unconsciousness. Do not contact steam head. Stay at least 12" away from hot steam escaping from the steam outlet. CAUTION! WARNING REDUCE THE RISK OF SLIPPING AND FALL INJURY Use care when entering exiting the steam room, flo may be slippery. NOTE: F additional safety instructions, see owner s manual. The AG and 3G line of AMEREC Steambath Generats are "Slave" Generats which can not operate as stand alone generats. These generats can only be controlled by an AK 3K generat which will function as a "Master" generat. Up to two generats can be "ganged" with, controlled by, a single AK 3K generat. The sole purpose of ganging is to increase the volume of steam generated without using multiple controls. Control signals are passed from the AK/3K generat to the "Slave" generat(s) via the cable(s) provided with the "Slave" generat(s). IMPORTANT An exhaust fan installed outside the steam room is strongly recommended to remove excess steam from the bathroom shower area.

2 Page 2 Table of Contents Section Description Page - Imptant Safety Instructions 3 2 Select Mounting Location 4 3 Mounting the Steam Generat 4 4 Plumbing Instructions Water Quality Requirements 7 6 Wiring Instructions Electrical Infmation Chart 9 8 Wiring Instructions (Slave Generats) Operational Test Service Troubleshooting Exploded Parts Diagram - AK Exploded Parts Diagram - AG Wiring Diagrams 19-21

3 Page 3 IMPORTANT SAFETY INSTRUCTIONS 1. READ AND FOLLOW ALL INSTRUCTIONS. 2. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times. 3. WARNING - To reduce the risk of injury: a. The wet surfaces of steam enclosures may be slippery. Use care when entering leaving. b. The steam head is hot. Do not touch the steam head and avoid the steam near the steam head. c. Prolonged use of the steam system can raise excessively the internal human body temperature and impair the body s ability to regulate its internal temperature (hyperthermia). Limit your use of steam to minutes until you are certain of your body s reaction. d. Excessive temperatures have a high potential f causing fetal damage during the early months of pregnancy. Pregnant possibly pregnant women should consult a physician regarding crect exposure. e. Obese persons and persons with a histy of heart disease, low high blood pressure, circulaty system problems, diabetes should consult a physician befe using a steambath. f. Persons using medication should consult a physician befe using a steambath since some medication may induce drowsiness while other medications may affect heart rate, blood pressure and circulation. 4. WARNING - Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above the nmal body temperature of 98.6 degrees F. The symptoms of hyperthermia include an increase in the internal temperature of the body, dizziness, lethargy, drowsiness and fainting. The effect of hyperthermia include: a. Failure to perceive heat: b. Failure to recognize the need to exit the steambath: c. Unawareness of impending risk: d. Fetal damage in pregnant women: e. Physical inability to exit the steambath: and f. Unconsciousness. WARNING - The use of alcohol, drugs medication can greatly increase the risk of hyperthermia. SAVE THESE INSTRUCTIONS

4 Page 4 K60 Temp Sens Cable, 25 Control Cable, 25 MASTER DIAGRAM 1 Slave Control Cable, 25 SLAVE SLAVE SECTION 2: SELECT MOUNTING LOCATION Slave Control Cable, 25 The Amerec Steam Generat can be hung on a wall set on it s base. The best mounting location will satisfy all most of the following conditions: 1. The steam line should slope to allow condensation to drain into the steam room. 2. The steam line should be less than 6 m long, 3 m is preferred. Steam lines over 6 m long should be insulated. 3. The mounting location should minimize the number of bends and elbows in the steam line. 4. The steam line should enter the room 380 to 460 mm above the nearest surface, at least 300 mm from the nearest wall and as far from the bathers as possible. 5. The steam outlet should be located to avoid potential user contact. 6. The generats should be installed in a dry, well ventilated area. The space provided should be at least: 7 cu ft f one generat 17 cu ft f two generats 27 cu ft f three generats Suggested locations are under a vanity, in a closet, attic, crawl space basement. Preferably in the same room. Note: The generat must be in an area protected from freezing. 8. The slave generats should be installed within a 7,6 m cable length of the master generat and the master generat should be within a 6 m cable length of the control installation. See diagram 1. Note: Longer control and slave cables are available. Contact Technical Suppt at suppt@amerec.com f assistance. 9. The installation should provide clearance f service and element removal. See diagram The mounting location should allow f a drain hookup. There should be no me than three 90 bends and 3 m of pipe between any generat s drain outlet and its drain valve inlet. See dia. 15. WARNING Do not mount outdos. Protect from freezing. Unit must be located so as to allow access f service. The steam generat will not operate properly unless it is mounted level with the arrows pointed up. IMPORTANT Befe deciding on a mounting location, please read through these installation instructions completely and take a careful look at al of the diagrams. An exhaust fan installed outside the steam room is strongly recommended in der to remove excess steam from the steambath shower area It is strongly recommended that no exhaust fan be installed inside the steam room. Doing so will result in a loss of heat and steam through the exhaust fan and pt. Insulate all steam lines and drain lines within the enclosed space. Each generat must be provided with at least 150 mm f wiring access at the control wiring end. Each generat must be provided with at least 380 mm clearance at the pipe end. There should be at least 900 mm in front of the louvered cover at each generat f service access. DIAGRAM 2 SECTION 3: MOUNTING THE GENERATORS IMPORTANT: The generat must be level side to side and end to end after installation. Wall Mounting: Note the location of the mounting holes on the back of the steam generat. The screws must set directly into studs equivalent suppts, Drill pilot holes on 254 mm and 305 mm centers and on level (see diag. 2 at right) then install two #10 1-1/2 screws provided into the 305mm holes. Do not tighten. Carefully hang the generat on the two screws. Tighten the screws. Install two #10 1-1/2 screws provided into the 254 mm holes and tighten. Replace the front cover. Secure the front cover with its four sheet metal screws. Flo Mounting: In general, the width of the generat allows it to sit on a shelf, across ceiling joists on a fl o. The generat must be on a fl at surface and restrained from moving. Nmally, the piping will provide adequate suppt but if not, additional suppt must be provided. All fl o mounted generats must have provision f routine draining of the steam tank.

5 Page 5 DIAGRAM 3: SERVICE CLEARANCE 0,9 m min Service Clearance 150 mm min Service Clearance 150 mm min Service Clearance 380 mm min Service Clearance 380 mm min Service Clearance DIAGRAM 4 DIAGRAM 5: WATER LINES SHOWN WITH OPTIONAL FILTER (NOT PROVIDED) SHOWN WITH OPTIONAL WATER FILTER (NOT PROVIDED) SECTION PREFERRED INSTALLATION 4: PLUMBING THE GENERATORS All plumbing shall be installed by a licensed plumber and confm with local and national codes. Materials (locally available): - 3/8 O.D. copper tube, shut off valves and compression to 3/8 male NPT adapter f the water supplies to the generats. - 1/2 copper pipe and unions f the steam lines to the steam rooms and the tank drains. - 3/4 copper pipe, fi ttings, and a union f the Pressure Relief Valve drain. - Tube 100% silicone caulk. - Pipe compound. Note: other materials may be required. PREFERRED IMPORTANT Maximum recommended input water pressure not to exceed 100 PSI. If the generats are mounted in a place diffi cult f the home owner to access, the water supply shut-off valve should be located where it can be quickly accessed in an emergency. Do not use a saddle valve saddle fi tting f the water shut-off valve. Flush water supply line befe fi nal hookup. 1. INSTALL WATER LINE See diagrams 4 and 5. Run 3/8 copper tube between the nearest cold water line and the WATER INLET fi tting on the generat. Locate a shut-off valve near the generat. Connect this line to the generat with a 3/8 compression adapter. When tightening this fi tting always use two wrenches so there will be no strain on the water inlet valve. F better servicability, use a separate shut-off valve f each generat. See diagrams 3 and INSTALL STEAM LINE See diagrams 4 and 6. a: At the Generat: Install a 1/2 male NPT sweat adapt into the generat s steam outlet. Install a 1/2 union in the steam line near the generat. Run the 1/2 steam line from the generat to the steam room. Refer to SECTION 2: SELECT MOUNTING LOCATION. b: F best perfmance, 12 and 14kW steamers should have two steam heads f each steam generat. F smaller generats, go directly to step C below. When installing two heads on one steam line: bring the steam line into a tee centered between the two heads then elbow both outlets through the wall. Each head should have the same lengths of pipe and the same number of bends from the main steam line. See diagram

6 Page 6 Location dimensions f two steam heads SECTION 300mm min 150mm min 380 to 460mm from nearest surface DIAGRAM 6 AK12, 3K12, 3K14 One steam line into two outlets: Tee at center, equal pipe lengths and same number of turns to each outlet. 4: PLUMBING THE GENERATORS (continued) C: At the steam room: The steam line should enter the room 380 to 460 mm above the nearest surface, at least 300 mm from a surface to the side and as far as possible from bathers. - Drill/prepare a 35 mm hole f the each steam line entry. - Center the 1/2" copper steam pipe in the 35 mm hole. See diagram 7. - Terminate the steam line with a 1/2" NPT male adapter. Stub the line out into the room 9,5 mm from the fi nished surface. - Secure the steam line to a structural member. IMPORTANT If the steam line is in an area where the temperature will be below 4 C, if the steam line is me than 6 m long, best results can be obtained by insulating the steam pipe. WARNING Do not put a shut off valve in the steam line. Avoid traps and valleys where water could collect and cause a steam blockage. The hot steam line must be insulated against user contact. Centering the steam pipe is critical in rooms made of plastic, acrylic, resin, fiberglass similar materials. Allowing the steam pipes to touch materials not rated f 100 C higher will result in damage to these materials. Do not install the steam head near bench(es) where steam may spray where condensation will drip on the user as this will present a scald hazard. The steam pipe entry and any other entry into the steam room must be caulked to avoid damage caused by steam leakage into the wall. C: At the steam room: Locate each steamer's outlet(s) 380 to 460 mm above the nearest surface, at least 300 mm away from surfaces to the sides and at least 150 mm between each outlet fi tting. Keep all steam outlets as far from bathers as possible. DIAGRAM 7 DIAGRAM 8 DIAGRAM 9 35 mm DIAMETER HOLE CENTER IN OPENING 0.6 mm 1/2" NPT SWEAT ADAPTER 35 mm DIAMETER HOLE 0.6 mm S P A C E R S T U D 300 mm min FROM WALL 1/2" NPT FITTING 380 to 460 mm FROM NEAREST SURFACE EXTEND FITTING 9,5 mm FROM WALL 300 mm FROM WALL 150 mm min BETWEEN HEADS 380 to 460 mm FROM NEAREST SURFACE 3. INSTALL STEAM HEAD INSULATOR(S): Fill in gaps (using 100% Silicone caulk between steam pipe and fi nished wall surface at point of entry (see diagram 5).Apply silicone caulk to the fi nished wall side of the steam head insulat and screw on hand tight until fl ush with the wall with the opening pointing down. If a hand tight fi t does not align with the opening pointing down, use tefl on tape on the steam line threads to adjust the fi t. (Note: 12 kw and 14 kw Generats use 2 steam heads each. See diagram 6)

7 Page 7 SECTION 1/2" NPT FITTING DIAGRAM mm DIAMETER HOLE FILL GAP USING 100% SILICONE CAULK 9,5 mm FROM WALL STEAMHEAD INSULATOR FRAGRANCE RESERVOIR STEAMHEAD FACE SEAL BACK OF STEAMHEAD INSULATOR 100% SILICONE CAULK 4: PLUMBING THE GENERATORS (continued) IMPORTANT Check all of the standard fi xtures in the steam room. All fi xture penetrations and steam head insulats must be sealed with 100% silicone caulk to avoid moisture damage within walls. 5. INSTALL PRESSURE RELIEF VALVE Install the pressure relief valve into its pt on the generat. The pressure relief valve outlet must drain in accdance with local and national codes. 6. INSTALL DRAIN VALVE Install a 76 mm long 1/2" pipe nipple (provided) directly into the tank as shown in diagram 8. Install the drain valve (Refer to Amerec's ADK Installation Instructions, document , f me detailed instructions). Install a 1/2" union on the outlet side of the drain valve. Run a 1/2" copper drain line to a gravity fl ow drain. Do not run the drain uphill. HEATING ELEMENT ACCESS WARNING Do not connect the pressure relief valve output into the steam line. The pressure relief valve must be installed in such a fashion that the risk of scalding is reduced to a minimum. Draining the pressure relief valve into the steam room may present a scald hazard. Boiling water may be discharged from the drain. Proper precautions should be taken too insure safety. Do not connect the drain valve into the steam line. Draining the tank into the steam room may present a scald hazard and/ damage materials used to construct the steam room. DIAGRAM 11 The drain must be connected in accdance with local and national codes. SECTION 5: WATER REQUIREMENTS The nature of a steambath generat requires testing of the feedwater to avoid potential high concentrations of impurities which can cause a deposit scale to fm on the internal surfaces. This deposit scale can interfere with the equipment's proper operation and even cause premature generat failure. CONDUIT VALVE 76 mm NIPPLE Concentration of impurities is generally controlled by treating the feedwater and "blowing down" the generat when it is not heating. The "blow down" process involves removing a ption of the tank water with high solid concentration and replacing it with makeup water. To insure proper operation, the water supply should be tested pri to operating the equipment. There are several treatment processes which can be used if you have a problem with hard water. A local reliable water treatment company can recommend the appropriate treatment if required. The recommended feed water quality is listed below. Feedwater Quality Hardness, ppm ( gpg) T-Alkalinity, ppm ( gpg) Silica Range, ppm ( gpg) IMPORTANT! Regular maintenance will help your steamer wk properly f a long time. Check f leaks, loose damaged wires, signs of crosion and calcium build up in the tank on the level probe. This is particularly imptant in areas with high calcium levels and other water quality problems. Calcium build can cause po steamer perfmance and damage the heating elements!

8 Page 8 SECTION 6: WIRING INSTRUCTIONS 1.CONTROL CABLE ROUGH-IN The low voltage controls can be mounted directly to a fi nished wall up to 7.6 meters from the generat and either inside outside the steam room. A 7,6 m 8 conduct cable (provided) is required f connecting the control to the steam generat. String the 6,8 m cable from the control location through 13 mm holes in the wall studs ceiling joists to the generat. Run one control cable f each control being installed. Note: Do not staple through damage cable. Use facty supplied cables only. Note: The master steam generat requires at least one control and may have up to three. Controls may include one (1) K30 control and/ one (1) two (2) K60 controls. A wall mounted temperature sens is required when using K30 K60 controls. One (1) KT60 control may be used in place of a K60. The KT60 has a built in temperature sens and must be installed inside the steam room. When a KT60 is installed, the wall mounted sens is not installed. WARNING Electrical Shock Hazard. Disconnect all electrical power befe servicing the generat. All wiring should be installed by a licensed electrical contract in accdance with local and national codes. The generat is designed f hookup with copper wire only. DIAGRAM TEMPERATURE SENSOR CABLE ROUGH-IN do not install with a KT60 It is recommended that the sens be mounted in the steam room 150 mm from the ceiling, but not directly over the steam dispersion head me than 2,1 m above the fl o. Using a 22 mm hole saw, drill a hole in the fi nished wall where the sens is to be mounted. String the sens cable from the sens location through 13 mm holes in the wall studs ceiling joists to the generat location. Leave 305 mm of slack at the sens location. Note: Do not staple through damage cable. Use facty supplied cables only. 3. ELECTRICAL ROUGH-IN Size wire f the generat as indicated by the Electrical Infmation Chart on page 9. Use crect size and type to meet electrical codes. Leave 1,2 m of slack wire at generat location to fi nish hookup. Connect the generat to a dedicated circuit breaker. A GFI device is generally not required. One may be installed if required by local codes the owner. A GFI device will tend to nuisance trip due to heater element aging. 4. ELECTRICAL FINISH Route the copper mains wire with appropriate strain relief through the hole marked POWER ENTRY. Connect the mains wires to terminals marked 230V and N (single phase) L1, L2, L3 and N (three phase). Connect the earth wire to the earth ground lug ( ). 5. INSTALL GENERATOR CONTROL (K30,K60) See diagram 12 The low voltage K30 and K60 controls can be mounted directly to a fi nished wall either inside outside the steam room. Using a 50mm hole saw, drill a hole in the fi nished wall where the control is to be mounted (the control cable should already be roughed-in to this location). With the decative cover removed from the control switch assembly, insert the two control mounting screws through the control housing (may need to punch through skinned holes) and screw 6 to 7 mm into the mounting bracket. Locate the control cable and plug it into the back of the control housing. Run a bead of 100% silicone caulk in-between the 2 ridges around the perimeter on the back of the control housing and place a small amount under each screw head. Insert the mounting bracket into the wall cavity by fi rst pushing with the control housing and then with a hard fl at surface on the control housing mounting screws which extend out through the control face. Once the mounting bracket has been inserted into the fi nished wall, center the control and tighten the mounting screws to draw the control housing securely against the fi nished wall. Do not over tighten the mounting screws. Install the decative cover plate by sliding the top of the cover plate over the tab on the top of the control housing then push on the bottom of the cover plate to complete the snap fi t. Route the generat end of the control cable through the generat hole marked CONTROL WIRING ENTRY using the strain relief provided. Plug the control cable into the connect on the printed circuit board assembly. Insert cable into connect S30 if a K30 control is used connect S60A if a K60 control is used. See diagram 12. SEALANT (MUST FILL GROUT LINE FOR TILE WALLS MOUNTING BRACKET 50 mm DIAMETER MOUNTING HOLE IN FINISHED WALL CONTROL HOUSING CONTROL HOUSING MOUNTING SCREWS --DO NOT OVER TIGHTEN! --SEAL SCREW HEADS WITH SILICONE 22 mm MOUNTING HOLE SENSOR CABLE DIAGRAM 13 DECORATIVE CONTROL COVER PLATE SILICONE CAULK TEMPERATURE SENSOR (PROBE MUST BE POINTED DOWN) FINISHED WALL

9 Page 9 SECTION 6: WIRING INSTRUCTIONS (continued) 6. OPTIONAL SECONDARY GENERATOR CONTROL As an option, a second K60 control can be installed with an AK generat to provide ON/OFF control both inside and outside the steam room. The second control should be installed as described in paragraphs 1 & 5, with the second control cable plugged into connect S60B f the K60 Control on the printed circuit board assembly. See diagram INSTALL TEMPERATURE SENSOR (REQUIRED FOR K60 OR K30 ONLY) The temperature sens should be mounted 150 mm below the ceiling, inside the steam room, but not directly over the steam dispersion head me than 2,1 m above the fl o. OPTIONAL AUTOMATIC DRAIN CONNECTION, TB2 DIAGRAM 14 (K30 & K60 Controls) K30 (S30) TEMPERATURE SENSOR (K60 K30 only) KT60/K60 PRIMARY (S60A) Using a 2,1 m hole saw, drill a hole in the fi nished wall where the sens is to be mounted (the sens cable should already be roughed-in to this location). Locate the sens cable, pull it out through the hole and plug it into the temperature sens. It is best to tape the sens and cable connection together to avoid disconnection inside the wall. TEMPERATURE SENSOR PLUG (ROOM) KT60/K60 SECONDARY (S60B) STEAM CONTROL Apply silicone caulk to the back of the control (see diagram 13) and insert the sens in the hole. Make sure that the sens probe is pointing down once installed. Tape the sens in place while the silicone hardens. Route the generat end of the sens cable through the generat hole marked CONTROL WIRING ENTRY using the control cable strain relief. Plug the sens cable into the connect marked ROOM on the printed circuit board assembly. See diagram 14 SECTION 7 ELECTRICAL INFORMATION CHART ELECTRICAL INFORMATION CHART MODEL AC VOLTAGE PHASE NOMINAL WATTS NOMINAL AMPS RECOMMENDED SAFETY DEVICE AG7 230V~ N ,9 40A AG10 & AK10 230V~ N ,9 50A AG12 & AK12 230V~ N ,0 31,9 3G8 400V~ N ,3 15A 3G10 & 3K10 400V~ N ,6 20A 3G12 & 3K12 400V~ N ,2 25A 3G14 & 3K14 400V~ N ,9 25A Notes: Use only copper wire rated 600V~ and 75 C better All models require Earth connection All models require Mains plus Neutral connections All Mains must supply minimum 195V~ while steamer is heating Steamer must be connected to a means of disconnecting all Mains supply connections after installation AT12 steamers require two (2) Mains supplies 25A 40A SECTION 8: WIRING INSTRUCTIONS (SLAVE GENERATORS) 1. ELECTRICAL ROUGH-IN Size wire f the Generat as indicated by the Electrical Infmation Chart on page 9. Use crect size and type to meet electrical codes. Leave 1,2 m of slack wire at Generat location f fi nish hookup. Connect the Generat to a dedicated circuit breaker. A GFCI device is generally not required. One may be installed if required by local codes the owner. A GFCI may nuisance trip due to heater element aging. a. Route the copper supply wire with appropriate strain relief through the hole marked POWER ENTRY. b. Connect the supply wires to the terminal block marked 230V and N (single phase) L1, L2, L3 and N (three phase). c. Connect the earth wire to the earth lug ( ).

10 Page 10 SECTION 8: WIRING INSTRUCTIONS (SLAVE GENERATORS) (continued) 2. INSTALL SLAVE CONTROL CABLE a. Route one end of the slave control cable through the Generat hole marked "Control Wiring Entry". Use the strain relief provided. Plug the slave control cable into the connect J1 on the slave PCA. See Diagrams 14 and 15. b. Connect the other end of the slave control cable to the Master Generat. SECTION 9: OPERATIONAL TEST 1. Assure power and water are on. 2. Press the ON/OFF. The control should light-up. 3. Allow 10 minutes f the steam to start. 4. Once the steam starts, press the ON/OFF. The steam should stop; there shouldn't be any water fl ow. The control should not be lit-up. 5. Press the ON/OFF. The control should light up. 6. Within one minute the unit should again produce steam. It should call f water once every two minutes me depending on its power rating. It s nmal f the fl ow of steam out the steam head to slow f up to 10 seconds each time the unit calls f water. WARNING Electrical shock hazard! Disconnect all electrical power befe servicing. All wiring should be installed by a licensed electrical contract in accdance with local and national codes. The Generat is designed f hookup with copper wire only! User Shock Hazard! Installer must maintain control wiring segregation. All control wiring must be restrained in the "Control Area" designated in Diagram 15. Protect the AG cable per local codes if it is in: areas exposed to weather; chemical hazardous atmospheres; areas which may exceed their temperature ratings if routed adjacent to wires with voltage above 230V. DIAGRAM The unit will shut down automatically in 30 minutes if the R30K K30 Control is used, up to 60 minutes if the K60 Control is used. When the time runs out the steam will stop and there should not be any water fl ow. The control should not be lit. 8. If the unit does not operate as described above, refer to SECTION 11: TROUBLESHOOTING GUIDE. SECTION 10: SERVICE THE UNIT IS NOW READY FOR OPERATION. 1. DESCRIPTION OF AMEREC (SLAVE) SERIES GENERATOR The AG Slave is controlled by an "AK 3K" Master Generat. Control signals are transmitted to the Slave from the Master via the 8 wire slave control cable provided. The AK 3K Printed Circuit Assembly provides the interface circuitry between the AK Master and the Slave Printed Circuit Assembly. The Slave PCA provides the basic functions necessary to pro duce steam. It controls makeup water, provides a water level permissive f powering the elements and provides raw DC power f the system. 2.MAINTENANCE OF GENERATOR VISUAL INSPECTION - Whenever the Generat is opened inspect f any evidence of water leaks. Inspect the wiring f any evidence of overheating. Check all electrical connections f tightness. FLUSH TANK - Flush monthly, me often, depending on local water conditions. DIAGRAM 15 a. The Generat should be cool. b. Press the ON/OFF button. The control should light. c. Open the manual drain valve (manually open the automatic drain valve, if installed). d. The unit will drain without heating the water. e. Allow the water to run f a full 10 minutes, then press ON/OFF. The control light should turn off. CONTROL AREA f. Allow the unit to drain completely. When the water stops, close the drain valve(s).

11 Page 11 SECTION 10: SERVICE (continued) 3. REPAIR OF GENERATOR a. ELEMENT REPLACEMENT Disconnect power from the unit. Drain the tank. Open the front and HEATING ELEMENT ACCESS covers. Note the wire connections. See Diagram 28. Remove the element wires. Using a hot water element socket, remove the element. To install a new element, mount a new element gasket on the element. Clean the element pt and add a light coat of Rectseal No. 5 pipe thread compound to the threads. Insert and hand tighten the element gasket combination. Notice the element end ientation as shown in Diagram 17. Tighten the element until the ientation is the same as Diagram 17, ± 15. The gasket should be set and tight but not defmed to a rounded bulbous appearance. If the drain valve was removed reinstall it. Reconnect the wiring. Test the unit per SECTION 9: OPERATIONAL TEST. Check f leaks at the element. Replace the front cover and the HEATING ELEMENT ACCESS cover. b. PRINTED CIRCUIT REPLACEMENT Printed circuit assembly (PCA) removal and replacement must be perfmed in the sequence described below. Any other method can damage the PCA s. IMPORTANT The PCA s contain static sensitive devices. Static electricity may damage PCA s. Handle accdingly. WARNING All electrical supplies should be disconnected befe servicing Generat. F continued safe operation use facty authized replacement elements only. Electrical Shock Hazard. PCA s have exposed 230V on them. Disconnect 230V power to the generat befe servicing. The relays may be damaged if the crect ientation of the connects is not observed. See Diagram 31. To remove the PCA: Disconnect power from the unit. Note and tag the positions of all wires that plug into the printed circuit assembly mounted relays. Remove all the wires from the relays. When removing these wires, pull on the connect, not the wire. Disconnect all three (3) wires from the water level probe. Next slide these wires out by slightly bending the wire clamp retaining these wires. Disconnect the two (2) blue wires from the water solenoid valve. Five (5) seven (7) stand-offs hold the board in place. Remove all the stand-offs by pinching the tops removing the screws. When it is completely disconnected, it may be lifted out of the enclosure. See Diagram 21. To install the board, reverse this procedure. Test the unit per SECTION 9: IMPORTANT The blue wire connected to L on the PCA must be connected to the shtest of the three level probes. c. WATER SOLENOID REPLACEMENT: Disconnect power from the unit. Turn the water supply OFF. Disconnect the water supply from the water solenoid valve. Remove the front cover. Remove the two blue wires from the water solenoid valve. Rotate the self-tightening hose clamp so it can be loosened with a pair of pliers. Squeeze the clamp and move it down towards the shelf and off the valve outlet tube. Remove the two 1/4" - 20 hex head bolts and lock washers that attach the valve to the chassis. Pull the valve off the rubber fi ll hose. To install the valve, reverse these instructions. Test the unit per SECTION 9: OPERATIONAL TEST. d. LEVEL PROBE REPLACEMENT: Disconnect power from the unit. Remove the front cover. Disconnect all three (3) wires from the water level probe. Using a 32 mm box wrench, remove the level probe. Install a new level probe. Tighten until the bottom of the plastic nut is 6,4 mm to 9,5 mm above the top of the pt. See Diagram 18. Reattach the three (3) wires. Test the unit per SECTION 9: OPERATIONAL TEST. IMPORTANT The blue wire connected to L on the PCA must be connected to the shtest of the three level probes. IMPORTANT The level probe may be extremely tight. Damage to the insulation chassis may result unless the tank is properly blocked suppted during probe removal installation. It may be necessary to completely disconnect and disassemble the Genera t. DIAGRAM 16 DIAGRAM 17 DIAGRAM 18 VERTICAL ± 15 ELEMENT END ORIENTATION White Wires Blue Wire GASKET HEAT ELEMENT

12 Page 12 DIAGRAM 14 DIAGRAM 20 PCA Power Relays Connections 3 versions available Heating Element Connections Line Power Connections Ref: Fast-On Lug Note Tab offset in opening on relay DIAGRAM 21 To remove control PCA: Remove screw from metal standoff the carefully lift up on the PCA near each nylon mounting post. Use needlenose pliers to squeeze and release locking tabs on mounts as needed.

13 Page 13 SECTION 11: TROUBLESHOOTING GUIDE There are no user serviceable parts in the Generat. All repairs should be perfmed by a qualifi ed service person. F additional assistance the facty authized service person nearest you call, Amerec Technical Suppt at suppt@amerec.com. The Troubleshooting Guide below is meant as a general aid only. Follow ACTION TO BE TAKEN in der until the problem is resolved. Where replacements repairs are indicated, see the appropriate paragraph of SECTION: 10 SERVICE. Table 1 SYMPTOMS PROBABLE CAUSES ACTION TO BE TAKEN Control won t turn ON Improper power supplied 1. a. Make sure circuit breaker is ON 230/400V supplied. (Control light off) (no power) b. Using Voltmeter, check the voltage across the two fuses on the PCA printed circuit assembly. Voltage should be 230V. Note: Control Cables must Control improperly connected c. Check fuses on the PCA. If fuse(s) are blown, replace with be crectly plugged in equivalent fuse. If the fuse blows again- contact Amerec befe power is turned on. Ak 3K PCA printed circuit Technical Suppt. assembly is faulty. 2. Turn off power to the generat 3. Check the control(s) installed per section 5. Re-apply power and test Control cable is faulty operation. 4. Replace master PCA printed circuit assembly- contact Amerec Control is faulty Technical Suppt. 5. Replace control cable- contact Amerec Technical Suppt 6. Replace the control- contact Amerec Technical Suppt Master unit is inoperable. AK 3K Master PCA Slave unit(s) are OK. unit is faulty. Contact Amerec Technical Suppt. Master unit is OK. AK 3K Master PCA unit faulty 1. Make sure the Slave control cable is connected. The only Slave unit is 2. In the Master unit move the Slave control cable to the unused connect inoperable. Slave control cable is faulty on the Master PCA. Slave unit is faulty 3.a. If symptoms disappear replace the Master PCA. If problem remains contact Amerec Technical Suppt. b. If symptoms remain the same, go to Table II Master unit is OK. AK 3K Master PCA unit faulty 1. In the Master unit swap the Slave control cables on the Master PCA. One of 2 Slave units is 2. If the symptoms move to the other Slave unit replace the Master PCA. inoperable Slave control cable is faulty 3. If the symptoms move to the other Slave unit, swap the Slave generat Slave unit is faulty ends of the Slave control cable between the Slave units. 4. If the symptoms move to the other Slave unit, the slave control cable connected to be the inoperable Slave unit is faulty- replace it. 5. If the symptoms remain the same, go to Table II Master unit is OK. Slave control cables are faulty 1. Make sure the Slave control cable is connected. Both Slave units are 2. Replace the Master PCA unit. inoperable. AK 3K Master PCA unit faulty Technical Suppt PO Box 2258 Woodinville, WA USA Phone: Fax: suppt@amerec.com

14 Page 14 Table II SYMPTOMS PROBABLE CAUSES ACTION TO BE TAKEN Master control OFF Water solenoid valve 1. Turn off power to the Slave Generat. If the water stops, go to step 3. Water won t shut off and is stuck open. 2.a. Remove the water solenoid valve, disassemble, clean, re-assemble, runs out of the Slave unit s and check f proper operation. steam head. AG PCA is faulty b. Replace valve. If problem remains, contact Amerec Technical Suppt. 3.a. Unplug the Slave control cable connected to the Slave unit. Slave control cable is faulty b. Turn ON power to the Slave unit. c. If water stops running, replace the PCA in the Master unit. AK 3K Master PCA unit d. If the water doesn t stop running, contact Amerec Technical Suppt. is faulty Master control ON Connection betwee the blue wire 1. Check the green ground wires to the slave tank and the PCA. Note: Water won t shut off and and the water level probe Not used on later models. runs out of the Slave unit s is faulty 2. Check that the blue and white wires are properly attached to the water steam head. probe. AG 3G PCA is faulty 3.a. Unplug the Slave control cable connected to the Slave unit. b. If water stops running, replace the PCA in the Master unit. Slave control cable is faulty c. If the water doesn t stop running, contact Amerec Technical Suppt. AK 3K Master PCA unit is faulty Master Unit Steams. Improper no power supplied 1.a. Make sure the circuit breaker to the Slave unit is ON. Slave unit won t steam. b. Using a voltmeter, check the voltage across the two fuses on the No water Supplied Slave PAL. Voltage should be 230V. c. Check fuses on the Slave PAL. If fuse(s) are blown, replace with Plugged water solenoid valve equivalent fuse. If the fuse blows again- Call AMEREC Service Dep. 2. Check f proper water supply (supply valve ON ) to Slave unit. Water level probe is faulty 3. Check f Slave ( common) drain valve closed. 4.a. Push the Master unit s control OFF. Burnt out heating elements b. Open the Slave ( common) drain valve allowing tank to drain completely. AG 3G PCA is faulty c. Close the drain valve. d. Push the Master unit s control ON. Slave control cable is faulty e. Unit will begin fi lling. Listen f a click noise on the slave unit. Within AK 3K in the Master unit is faulty. 20 seconds after click noise is heard, the water fi ll will shut off. This will indicated the Slave tank is full. Go to step 7. If the tank does not fi ll, see Symptoms: Slave won t fi ll up 5. If the Slave tank has fi lled but the relay click was not heard, temparily ground the two long probes of the water level probe. If the click is heard as both the probes are grounded, check probe wiring, if ok replace the level probe. If the click is not heard go to step Contact Amerec Technical Suppt. Master unit ON Improper no power supplied 1.a. Make sure the circuit breaker to the Slave unit is ON. Slave tank drained. b. Using a voltmeter, check the voltage across the two fuses on the Slave unit won t fi ll up. No water Supplied Slave PAL. Voltage should be 230V. c. Check fuses on the Slave PAL. If fuse(s) are blown, replace with Plugged water solenoid valve equivalent fuse. If the fuse blows again- contact Amerec Tech Suppt. 2. Check f proper water supply (water valve ON ). Check f drain Water level probe is faulty valve closed. 3. Remove the blue wire from the level probe. If the unit fi lls, clean Burnt out heating elements replace the level probe. 4. Reconnect the blue wire to the shtest level probe. At the water valve AG 3G PCA is faulty solenoid, slide back the red connect enough to get the voltmeter probes on the solenoid terminals. Measure the voltage across the solenoid Slave control cable is faulty terminals. If it is not 230V, replace the PCA. If 230V is found, proceed with AK 3K in the Master steps 5 & 6. unit is faulty. 5. Remove water solenoid valve: disassemble, clean, reassemble and check f proper operation. 6. Replace the water solenoid valve. 7. Contact Amerec Technical Suppt. Water continually sputters Foaming contaminants in 1. Flush tank 3 times. See Section 8: FLUSHING PROCEDURE. out of any steam head the water supply. 2. contact Amerec Technical Suppt.

15 Page 15 DIAGRAM 22 (AK/3K GENERATOR)

16 Page 16 PARTS LIST (AK GENERATOR) NUMBER PART NAME DESCRIPTION 1 FRAME CHASSIS 2 TERMINAL POWER INPUT TERMINAL BLOCK 3 COVER FRONT WITH WD LABEL 4 COVER ELEMENT ACCESS 5 TANK TWO ELEMENTS 6 INSULATION BLANKET 7 BRACKET L BRACKET 8 NIPPLE DRAIN NIPPLE 11 CAP CAP, THREAD PROTECTOR 12 LABEL MODEL AND RATINGS 13 PROBE TRIPLE LEVEL 14 ELEMENT REPLACEMENT ELEMENT 15 VALVE WATER INLET 16 CLAMP SELF-TIGHTENING 17 HOSE WATER INLET PARTS AND/OR RETURNS F assistance parts dering, please contact your local Amerec Dealer, phone Amerec at suppt@amerec.com. Please help us to serve you better by: 1. Identifying the problem by using the troubleshooting guide in this manual. 2. Read Number 12, the Model and Ratings Label, to obtain your unit's model and code number. 3. When dering parts, please provide the number, description and quantity needed. When dering wires wire assemblies, please describe the wires by col, location and / their con nection points. 4. Do not return any material to Amerec without fi rst contacting Amerec f a Return Authization Number. Freight must be prepaid to Amerec. 18 CLAMP AUGER 19 VALVE MANUAL DRAIN 20 GASKET ELEMENT ACCESS 21 BRACKET MOUNTING BRACKET 22 VALVE PRESSURE RELIEF 23 PCA PRINTED CIRCUIT ASSEMBLY, AK 24 LUG GROUND 28 BOLT 1/4-20 x 1/2" 29 WASHER 1/4" LOCK 33 CONTROL CONTROL, K30, K6 KT60 HOUSING 34 CABLE CONTROL CABLE 35 SENSOR TEMPERATURE SENSOR (K30 & K60 ONLY) 36 CABLE TEMPERATURE SENSOR CABLE (K30 & K60 ONLY) 37 STEAM HEAD DISPERSION HEAD (NOT SHOWN) 38 PLACARD SAFETY (NOT SHOWN) 39 LABEL WIRE DIAGRAM 40 FUSES 100 MA & 1A (NOT SHOWN) 41 FUSES 1A NON TIME DELAY 43 STANDOFF STAND OFF 44 COVERPLATE DECORATIVE CONTROL COVER PLATE

17 Page 17 DIAGRAM 23 (AG/3G GENERATOR)

18 Page 18 PARTS LIST (AG GENERATOR) NUMBER PART NAME DESCRIPTION 1 FRAME CHASSIS 2 TERMINAL POWER INPUT TERMINAL BLOCK 3 COVER FRONT WITH WD LABEL 4 COVER ELEMENT ACCESS 5 TANK TWO ELEMENTS 6 INSULATION BLANKET 7 BRACKET L BRACKET 8 NIPPLE DRAIN NIPPLE 11 CAP CAP, THREAD PROTECTOR 12 LABEL MODEL & RATINGS 13 PROBE TRIPLE LEVEL 14 ELEMENT REPLACEMENT ELEMENT 15 VALVE WATER INLET 16 CLAMP SELF-TIGHTENING 17 HOSE WATER INLET PARTS AND/OR RETURNS F assistance parts dering, please contact your local Amerec Dealer, phone Amerec at suppt@amerec.com. Please help us to serve you better by: 1. Identifying the problem by using the troubleshooting guide in this manual. 2. Read Number 12, the Model and Ratings Label, to obtain your unit's model and code number. 3. When dering parts, please provide the number, description and quantity needed. When dering wires wire assemblies, please describe the wires by col, location and / their con nection points. 4. Do not return any material to Amerec without fi rst contacting Amerec f a Return Authization Number. Freight must be prepaid to Amerec. 18 CLAMP AUGER 19 VALVE MANUAL DRAIN 20 GASKET ELEMENT ACCESS 22 VALVE PRESSURE RELIEF 23 PCA PRINTED CIRCUIT ASSEMBLY, AG 24 LUG GROUND 28 BOLT 1/4-20 x 1/2" 29 WASHER 1/4" LOCK 34 CABLE CONTROL CABLE 37 STEAM HEAD DISPERSION HEAD (NOT SHOWN) 38 PLACARD SAFETY (NOT SHOWN) 39 LABEL WIRE DIAGRAM 40 FUSES 100 MA TIME DELAY 41 FUSES 1A NON TIME DELAY 43 STANDOFF STAND OFF

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