TID-0137_0A TECHNICAL INSTRUCTIONS AM Series Boiler Heat Exchanger Maintenance & Replacement For all models of AM Series Boilers, Including: Boilers: AM 399B AM 500B AM 750B AM 1000B Water Heaters: AM 399W AM 500W AM 750W AM 1000W AM Series Heat Exchanger Module Revised: 01/18/2015 TID-0137_0A AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 1 of 36 Ph.: 800-526-0288 01/18/2015
DISCLAIMER The information contained in this document 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. AERCO International is not liable for errors appearing in this manual, nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of these materials. TABLE OF CONTENTS 1: Material and Tool Requirements... 3 2: Preliminary Preparation of the Unit... 5 2.1: Initiating the Burners... 5 2.2: Closing Water and Gas Connections... 6 2.3: Draining Water from the Unit... 7 2.4: Removing the Covers... 8 2.5: Disconnecting Cables and Wiring Connections... 9 3: Removing the Heat Exchanger... 12 4: Installing the Heat Exchanger... 19 5: Final Reassembly... 29 5.1: Connecting Cables and Wiring Connections... 29 5.2: Installing the Smaller Wiring Harness... 29 5.3: Installing the Larger Wiring Harness... 31 5.4: Turning on Services and Leak Testing... 33 5.5: Turning On Water and Return to Service... 34 Page 2 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Material and Tool Requirements The following tools and materials are required to perform the heat exchanger replacement procedure. Piece of Wood (roughly 20 x 2-1/2 x 1/2 ) 10mm Nut Driver (19 Length) or 10mm Socket Wrench and Extension Phillips Screwdriver (TOR x 20 ) 46mm Pipe Wrench or Adjustable Wrench 30mm Pipe Wrench or Adjustable Wrench Scotch Tape (or equivalent) Silicone Grease Wrench (10mm) Gasket x2 (1-1/4 Dia.) (P/N 60701007) Gasket (3/4 Dia.) (P/N 607001006) Gasket (P/N 60702096) Gasket (P/N 60702097) Air Compressor Page 3 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
GAS SUPPLY INLET WATER SUPPLY OUTLET WATER SUPPLY HEADER WATER RETURN INLET WATER RETURN HEADER WATER RETURN DRAIN VALVE WATER SUPPLY DRAIN VALVE Figure 1-1: AM Series Rear Panel Features NOTE These instructions can be used for maintenance of an existing functional heat exchanger module or can be used to replace a defective heat exchanger module with a new one. Refer to the notes in the instructions for specific instructions. Page 4 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Preliminary Preparation of the Unit 2.1: Initiating the Burners To prepare the boiler or water heater for the maintenance procedure perform the following: Initiating the Units Burners 1. Ensure power is supplied to the unit, then turn on the unit by placing the power switch to the ON position (Figure 2-1). POWER SWITCH 2. Wait for the unit to finish initializing. Figure 2-1: Turning the Power Switch to ON 3. Increase the unit setpoint to the maximum by pressing and holding down the Setpoint + Button on the front panel controls until maximum is reached. 4. Press the Reset Button. 5. The Setpoint Icon will blink while setpoint temperature is rising and the burners are initializing. As burners finish initializing, each one will be indicated by the circled number in the upper left of the display (Figure 2-2). BURNER INDICATOR ICONS SETPOINT ICON SETPOINT + BUTTON RESET BUTTON Figure 2-2: AM Series Controls and Display 6. Once all the burner indicator icons are showing in the display, turn the boiler power switch to OFF, as this means all automatic valves are now locked in the open position. Page 5 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
2.2: Closing Water and Gas Connections Closing Water and Gas Connections 1. Turn OFF the water supply and return pipe valves. See Figure 2-3. WATER SUPPLY VALVE: OFF WATER RETURN VALVE: OFF Figure 2-3: Turn OFF Water Supply and Return Pipe Valves 2. Turn OFF the gas supply valve. See Figure 2-4. GAS SUPPLY VALVE: OFF Figure 2-4: Turn OFF Gas Supply Valve 3. Completely remove power from the unit by shutting off electrical power upstream from the boiler. WARNING! High voltages are used in AM Series systems. It is required that all power applied to these boilers is removed first before performing any of the procedures described in this document. Use extreme care when accessing circuits and electrical connections within the equipment. Serious personal injury or death may occur if this warning is not observed. Page 6 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
2.3: Draining Water from the Unit Follow the procedure below to drain the unit of water. Draining Water from the Unit 1. Connect the air compressor hose to the drain valve of the water return header. See Figure 2-5. 2. Connect a drain hose to the drain valve of the water supply header. See figure 2-5. CONNECT AIR COMPRESSOR HOSE TO WATER RETURN DRAIN VALVE CONNECT DRAIN HOSE TO WATER SUPPLY DRAIN VALVE AIR COMPRESSOR HOSE WATER RETURN DRAIN VALVE WATER SUPPLY DRAIN VALVE DRAINING WATER DRAIN HOSE Figure 2-5: Connections for Draining Water from the Unit 3. While positioning the drain hose outlet in an appropriate receptacle or drain, slowly open the water return drain valve to allow compressed air into the unit. CAUTION! Monitor the AM Series relief valve so as not to release too much pressure from the air compressor into the unit or the pressure relief valve might be tripped. WARNING! Water drained from the boiler may be very hot. Use caution to avoid scalding. Page 7 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
2.4: Removing the Covers and Intitial Diassembly In order to remove the unit covers, refer to Figure 2-6 and follow the steps below: Removing the Covers and Initial Disassembly 1. Lift up, by hand, the Top Cover A. 2. Remove two Front Cover screws B. 3. Pull back the upper part of Front Cover C for 2 inches, then pull it up for one inch and remove it from the unit. 4. Pull back upper part of Bottom Cover D for 2 inches, then pull it up for one inch and remove it from the unit. A Top Cover (E) B Front Cover Screws (2 each) C Front Cover D Bottom Cover Figure 2-6: Removing the Top and Front Covers Page 8 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Covers and Initial Disassembly - Continued 5. Remove the plastic blower cover by pulling it from the blower. See Figure 2-7. 6. Pull out the air inlet piece and attached hose from the blower inlet. See Figure 2-7. 6 6 5 Figure 2-7: Removing the Blower Cover & Air Inlet Connector/Hose 2.5: Disconnecting Cables and Wiring Connections Disconnecting Cables and Wiring Connections 1 2 Figure 2-8: Unscrewing Gas Valve Connector & Cutting Harness Cable Tie 1. Unscrew the Phillips head screw from the gas valve connector but leave it plugged in for now. See Figure 2-8. 2. To the right of the blower, cut the cable tie that ties the cables together. See Figure 2-8. Page 9 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Disconnecting Cables and Wiring Connections - Continued 3. Unplug the two blower power harnesses from the blower. 4. Perform the following to remove the igniter assembly from the heat exchanger: a) Detach igniter cables from the two igniter terminals. b) Detach the igniter power harness from the connector on the igniter. c) Detach the igniter ground wire lug from the screw on the burner flange. d) Remove the two igniter mounting screws. e) Remove the igniter assembly from the heat exchanger. 5. Disconnect the two harness connectors from the high limit thermostat. 6. Disconnect the harness from the pressure sensor (Module 1 only). 7. Disconnect the wires from the flow meter. 8. Disconnect the motorized valve power harness (see Figure 2-10). 9. Disconnect the cable from the flue gas flow sensor (red). 10. Disconnect the cable from the flue gas high limit sensor (blue). 11. Disconnect cable from the flame detector terminal on left side of blower flange. 6 1 e d 3 b c a BURNER FLANGE 7 9 10 5 BLOWER Figure 2-9: Cable Harness Disassembly 11 Page 10 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Disconnecting Cables and Wiring Connections - Continued MOTORIZED VALVE 8 MOTORIZED VALVE CABLE Figure 2-10: Disconnecting Power Cable of Motorized Valve 12. Gather all wire harnesses from under and around the heat exchanger and drape onto the open panel door so that they are kept away from the heat exchanger (Figure 2-11). STEP 12: CABLES & HARNESSES OPEN PANEL DOOR Figure 2-11: Draping Cables and Harnesses onto Panel Door 13. This ends the wire harness preparation. Proceed to the next section for disassembly of the heat exchanger from the unit. Page 11 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger Removing the Heat Exchanger NOTE Refer to Figure 3-1 for Steps 1-3. 1. Remove nut on left side of the gas valve with the 46mm wrench. Ensure that the gasket located between pipe and gas well is retained for later reassembly. 2. Remove nut at lower right position on burner flange with short 10mm wrench, as shown in Figure 3-1. 3. Remove the other three nuts, as indicated in Figure 3-1, with the 19 long 10mm socket wrench. STEP 1: REMOVE GAS VALVE NUT w/30mm PIPE WRENCH & RETAIN THE GASKET! STEP 3: REMOVE THE OTHER THREE BURNER NUTS w/19 LONG 10mm WRENCH STEP 2: REMOVE THIS BURNER NUT with SHORT 10mm WRENCH Figure 3-1: Disconnections to Remove Burner/Blower Assembly 4. Carefully remove the entire blower/burner assembly from the heat exchanger, as shown in Figure 3-2. HEAT EXCHANGER BURNER/BLOWER ASSEMBLY Figure 3-2: Removing the Blower/Burner Assembly from the Heat Exchanger Page 12 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued 5. Perform the following to remove the igniter assembly from the heat exchanger below the one being removed: NOTE Refer to Figure 2-10 for image of igniter removal details. a) Detach igniter cables from the two igniter terminals. b) Detach the igniter power harness from the connector on the igniter. c) Detach the igniter ground wire lug from the screw on the burner flange. d) Remove the two igniter mounting screws. e) Remove the igniter assembly from the heat exchanger. 6. Remove the two (or four) screws holding the lower bracket between heat exchangers. 7. Remove the two (or four) screws holding the upper bracket between heat exchangers. This bracket is not present on the uppermost heat exchanger. STEP 7: REMOVE THE TWO TO FOUR SCREWS TO REMOVE UPPER BRAKET (NOT PRESENT ON TOP HEAT EXCHANGER). STEP 6: REMOVE THE TWO TO FOUR SCREWS TO REMOVE LOWER BRAKET (NOT PRESENT ON LOWEST HEAT EXCHANGER) STEP 5: REMOVE LOWER IGNITER ASSEMBLY Figure 3-3: Removing Lower Igniter, Flow Sensor, and Brackets Page 13 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued 8. If the pressure sensor is installed on the heat exchanger being maintenance or on the heat exchanger below it, unscrew it and set aside for later reassembly. Figure 3-4 shows the location of the pressure sensor as being on the heat exchanger below the one being serviced. STEP 8: PRESSURE SENSOR Figure 3-4: removal of the Pressure Sensor 9. Use a large plastic bag to cover the all the other heat exchanger assemblies below the one being removed, as shown in Figure 3-5. This is to prevent unit components from contamination by possible residual leakage when disconnecting the water connections to the heat exchanger. Ensure that if the pressure sensor opening is below, it is covered TAPE BAG HIGH AGAINST INSIDE OF THE UNIT HERE IF THE PRESSURE SENSOR WAS REMOVED FROM HERE, BE SURE TO COVER OPENING. TAPE BAG AGAINST SIDE OF HEAT EXCHANGER HERE TUCK BAG UNDER THE HEAT EXCHANGER LOWER EDGE ENSURE ALL LOWER COMPONETS ARE COMPLETELY COVERED Figure 3-5: Placing Protective Plastic over Lower Components Page 14 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued 10. Completely loosen the water supply nut, as shown in Figure 3-6, using the 46mm wrench. 11. Completely loosen the water return nut on the outlet side of the flow meter, as shown in Figure 3-6, using the 46mm wrench. STEP 10: LOOSEN THE WATER SUPPLY NUT COMPLETELY WITH 46mm WRENCH STEP 11: LOOSEN THE WATER RETURN NUT COMPLETELY WITH 46mm WRENCH AND RETAIN THE O-RING GASKET! Figure 3-6: Loosening the Return and Supply Connection Nuts 12. At the rear of the unit, completely loosen the nut for the water supply of the heat exchanger being replaced using the 46mm wrench, as shown in Figure 3-7. STEP 12: COMPLETELY LOOSEN THE WATER SUPPLY NUT AT THE REAR OF THE UNIT WITH 46mm WRENCH. Figure 3-7: Loosening the Water Supply Nut at Rear of Unit Page 15 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued 13. Place the piece of wood under the left side of the heat exchanger as shown in Figure 3-8. It should be placed precisely as shown in the right side image to prevent damage to the module below when removing the heat exchanger. STEP 13: PIECE OF WOOD Figure 3-8: Placing Piece of Wood under Left-Side of Heat Exchanger 14. There are four 10mm bolts affixing the heat exchanger module to the inside rear panel of the unit. Completely remove the two bolts on the left side, as indicated in Figure 3-9, using the 19 long 10mm nut driver. 15. Loosen (but do not remove) the two bolts on the right side, as indicated in Figure 3-9, using the 19 long 10mm nut driver. STEP 14: COMPLETELY REMOVE THE TWO BOLTS ON LEFT WITH 19 LONG 10mm NUT DRIVER. STEP 15: LOOSEN (DO NOT REMOVE) THE TWO BOLTS ON RIGHT WITH 19 LONG 10mm NUT DRIVER. Figure 3-9: Removing and Loosening Bolts Affixing Heat Exchanger to Rear Panel Page 16 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued 16. Remove the four 10mm bolts affixing gas inlet to the gas piping, as shown in the left image of Figure 3-10. 17. After removing the bolts, pull the entire gas inlet piping to the right (as you are facing the rear of the unit), as indicated in right image of Figure 3-10. STEP 16: REMOVE FOUR 10mm BOLTS STEP 17: PULL GAS TRAIN TOWARD YOU. Figure 3-10: Disconnecting 10mm Bolts from Gas Connection at Rear Panel 18. The heat exchanger may now be removed by first pushing to the left to disengage from the two loosened bolts and flue connections on the right, and then pulling it straight out from the unit. See Figure 3-11. PUSH LEFT RETAIN O-RING Figure 3-11: Removing Heat Exchanger from the Unit NOTE Retain the O-Ring (Figure 3-12) from the flow meter connection, for later reassembly, during removal of the heat exchanger. Page 17 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
Removing the Heat Exchanger - Continued RETAIN O-RING FLOW METER Figure 3-12: Retain Flow Meter O-Ring 19. If the heat exchanger is being replaced with a new one, use the 46mm wrench to loosen the nut attaching the water return piping to the old heat exchanger, as indicated in Figure 3-13 and install it onto the new heat exchanger. STEP 19: USE 46mm WRENCH TO REMOVE, THEN RECONNECT TO NEW HEAT EXCHANGER. NOTE! This instruction only applies if the heat exchanger is being replaced with a new one. Figure 3-13: Removing Water Return Pipe & Flow Meter from Old Heat Exchanger 20. Remove the flue gasket, as shown in Figure 3-14, and replace if necessary. 21. Remove the lower smaller flue gasket, as shown in Figure 3-14, and replace if necessary. STEP 20: REMOVE FLUE GASKET STEP 21: REMOVE CONDENSATE DRAIN GASKET Figure 3-14: Removing the Two Gaskets from the Flue Page 18 of 36 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 TID-0137_0A 02/02/2015 Ph.: 800-526-0288
AM Series Heat Exchanger Replacement Installing the Heat Exchanger Installing of the Heat Exchanger 1. If the flue and/or condensate gaskets are being replaced, use a brush to liberally apply a silicone lubricant to the flanges of the affected inlet(s), as shown in Figure 4-1. Figure 4-1: Applying Silicone Lubricant to Upper and Lower Flue Openings 2. Retrieve the two replacement flue gaskets (P/N 60702097 & 60702096) from the heat exchanger maintenance kit. 3. Install the upper larger gasket (P/N 60702097), ensuring that seals inside and outside the opening are correctly mated to the flue inlet flange. Orient with the notch in the gasket facing toward you, and match the arrow on the gasket to the square mark on the flue inlet flange (Figure 4-2). 4. Install the lower smaller gasket (P/N 60702096), ensuring that seals inside and outside the opening are correctly mated to the flue inlet flange. STEP 3: INSTALL FLUE GASKET STEP 4: INSTALL CONDENSATE DRAIN GASKET Figure 4-2: Fitting the Gaskets Securely Inside and Outside the Flange TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 19 of 36 Ph.: 800-526-0288 12/09/2014
Installing of the Heat Exchanger - Continued NOTE Ensure that the upper flue gasket is oriented so that the arrow mark on the rim of the gasket is lined up with the square mark on the flue inlet flange. See Figure 4-3). FLUE INLET GASKET ARROW MARK SQUARE MARK Figure 4-3: Upper Flue Inlet Gasket Orientation Marks 5. If the heat exchanger is NOT being replaced, but just receiving maintenance, then carefully tip over the heat exchanger letting the excess water drain from the water supply outlet, as shown in Figure 4-4. NOTE! Step 5 only applies if the heat exchanger is being serviced but NOT replaced. Figure 4-4: Draining Excess Water from the Heat Exchanger TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 20 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 6. Liberally apply silicone lubricant to both the Flue outlet and condensate outlet of the heat exchanger being installed. See Figure 4-5. Figure 4-5: Applying Silicone Lube to Flue Outlet (L) and Condensate Outlet (R) 7. Retrieve the piece of wood used when removing the heat exchanger. Position the piece of wood on the heat exchanger below at an angle as shown in Figure 4-6. The rear end of the wood is over the left rear of the heat exchanger, with the front end positioned at the front center. STEP 7: PIECE OF WOOD Figure 4-6: Wood Position for Installing Heat Exchanger TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 21 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 8. Ensure the upper and lower 10mm bolts on the right side at the rear of the unit (Figure 4-7) are installed but loose so that the slots on the heat exchanger right-side mounts can easily slip under. TWO 10mm BOLTS ON RIGHT SIDE AT REAR SHOULD BE INSTALLED BUT NOT TIGHTENED. Figure 4-7: Heat Exchanger Bolts at Rear of Unit 9. Insert the new heat exchanger into the unit, as shown in Figure 4-8, ensuring that the piece of wood underneath retains its position. Figure 4-8: Installing the Heat Exchanger into the Unit TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 22 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 10. Push the heat exchanger to the left to allow aligning and seating at the right side with the appropriate inlet openings in the flue chimney for the flue outlet and condensate drain outlet. See Figure 4-9. Figure 4-9: Seating the Flue and Condensate Connections 11. After seating the flue and condensate connections to the flue chimney, slip the right rear mounting tabs at the rear of the heat exchanger under the upper and lower loosened rightside 10mm bolts on the rear panel of the unit, as shown in Figure 4-10. Figure 4-10: Slipping the Heat Exchanger Mounting Slots Under the Loose Bolts TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 23 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 12. Install and tighten the upper and lower bolts on the left side, as indicated in Figure 4-11, using the 19 long 10mm nut driver. 13. Tighten the upper and lower bolts on the right side, as indicated in Figure 4-11, using the 19 long 10mm nut driver. STEP 12: INSTALL & TIGHTEN THE TWO BOLTS ON LEFT WITH 19 LONG 10mm NUT DRIVER. STEP 13: TIGHTEN THE TWO BOLTS ON RIGHT WITH 19 LONG 10mm NUT DRIVER. Figure 4-11: Affixing the Heat Exchanger to the Unit Rear 14. If the heat exchanger is NOT being replaced, use a knife to cut off the old return inlet gasket from the water supply inlet connection, and completely scrape clean of all old gasket residue. See Figure 4-12. STEP 14: REMOVE OLD WATER SUPPLY INLET GASKET NOTE! This instruction only applies if the heat exchanger is being serviced but NOT replaced. Figure 4-12: Removing the Old Water Supply Inlet Gasket TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 24 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 15. Retrieve a new water supply gasket (P/N 60701007), and install it when reconnecting the water return piping to the water supply inlet on the heat exchanger. Hand tighten ONLY at this point. See Figure 4-13. NEW GASKET CONNECT WATER SUPPLY PIPING HAND TIGHTEN ONLY Figure 4-13: Reconnecting Water Supply Piping using New Gasket 16. Connect the water return piping to the flow meter connection, ensuring it is seated properly and that the O-ring is still installed in the flow meter connection. Hand tighten ONLY at this point. See Figure 4-14. CHECK CONNECTION SEATING AND ENSURE O-RING IS PRESENT BEFORE APPLYING NUT. WATER RETURN PIPING CONNECT WATER RETURN PIPING NUT TO FLOW METER CONNECTION HAND TIGHTEN ONLY! Figure 4-14: Reconnecting Water Return Piping TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 25 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 17. Remove the nylon material protecting the lower unit components. 18. At the rear of the unit, tighten the nut for the water supply using the 46mm wrench. See Figure 4-15. STEP 18: TIGHTEN THE WATER SUPPLY NUT AT THE REAR OF THE UNIT WITH 46mm WRENCH. Figure 4-15: Tightening the Water Supply Nut at Rear of Unit 19. Use the 46mm wrench to tighten the water supply connection to the heat exchanger. See Figure 4-16. 20. Use the 46mm wrench to tighten the water return connection to the flow meter (Figure 4-16). STEP 19: TIGHTEN WATER SUPPY CONNECTION STEP 20: TIGHTEN WATER RETURN CONNECTION Figure 4-16: Wrench Tightening the Water Supply and Water Return Nuts TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 26 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger - Continued 21. Install and tighten the four 10mm bolts connecting the gas supply piping to the rear of the unit per Figure 4-17. 22. Reinstall the bracket(s) below and/or above (depending on which heat exchanger is being reinstalled). See Figure 4-17. STEP 21: INSTALL FOUR 10MM BOLTS OF GAS CONNECTION STEP 22: INSTALL SPACER BRACKET(S) Figure 4-17: Tighten 10mm Bolts for Gas Connection and Install Spacer Bracket(s) NOTE If servicing the bottom heat exchanger, ignore steps 23-26. 23. Install the igniter belonging to the heat exchanger below with the two screws removed at disassembly. See Figure 4-18. 24. Connect the two igniter cables to the two igniter terminals. See Figure 4-18. 25. Connect the igniter power cable to the igniter. See Figure 4-18. 26. Attach the igniter ground wire to the screw on the lower heat exchanger. See Figure 4-18. 27. If the pressure sensor is located on the heat exchanger below, attach the lead from the lower harness. See Figure 4-18. If located on the heat exchanger being serviced, do not attach anything to it at this point. STEP 23: INSTALL LOWER IGNITER STEP 27: PESSURE SENSOR STEP 25: POWER CONN. STEP 26: GRND WIRE STEP 24: IGNITER CABLES Figure 4-18: Install Lower Igniter and Make Connections TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 27 of 36 Ph.: 800-526-0288 01/18/2015
Installing of the Heat Exchanger Continued 28. Install the burner/fan assembly into the heat exchanger cavity. See Figure 4-19. 29. Affix the three bolts with the 19 long 10mm socket driver. See Figure 4-19. 30. Affix the one 10mm bolt (lower right side) with the small 10mm wrench. See Figure 4-19. 31. Connect the gas pipe to the gas valve, ensuring to include the gasket removed during disassembly, and tighten the nut using the 46mm wrench. See Figure 4-19. STEP 31: CONNECT AND TIGHTEN NUT w/30mm PIPE WRENCH AFTER INSTALLING THE GASKET. STEP 29: INSTALL AND TIGHTEN THREE BURNER NUTS w/19 LONG 10mm WRENCH STEP 30: INSTALL AND TIGHTEN THIS BURNER NUT with SHORT 10mm WRENCH Figure 4-19: Reassembly of Burner/Blower to Heat Exchanger 32. Install the upper igniter with the two screws removed at disassembly. See Figure 4-20. 33. Attach the two igniter cables to the igniter terminals on the burner flange. See Figure 4-20. STEP 32: INSTALL UPPER IGNITER STEP 33: CONNECT IGNITER CABLES TO IGNITER TERMINALS Figure 4-20: Install Upper Igniter and Connect Igniter Cables to Terminals TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 28 of 36 Ph.: 800-526-0288 01/18/2015
Final Reassembly 5.1: Connecting Cables and Wiring Connections Refer to Figure 5-1 to distinguish between the smaller and larger wiring harnesses that were draped over the unit door during disassembly. SMALLER HARNESS BLUE WIRE LARGER HARNESS YELLOW WIRE GAS VALVE CONNECTOR Figure 5-1: Smaller and Larger Harnesses 5.2: Installing the Smaller Wiring Harness Installing the Smaller Wiring Harness 1. Take the part of the harness with the yellow wire and pass it around the rear between the two heat exchangers until yellow wire part is coming from the left of the blower assembly, leaving the harness with blue wire part on the right side of the blower assembly. See Figure 5-2.. IT COMES OUT HERE. HARNESS WITH BLUE WIRE REMAINS ON RIGHT SIDE OF HEAT EXCHANGER STEP 1: PASS YELLOW CABLE OF SMALLER CABLE THROUGH HERE AND AROUND THE BACK BETWEEN THE HEAT EXCHANGERS UNTIL. Figure 5-2: Initial Arrangement and Routing of Smaller Harness TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 29 of 36 Ph.: 800-526-0288 01/18/2015
Connecting Cables and Wiring Connections 2. Route the Yellow wire up behind the gas valve and connect to the return sensor. 3. On the right side of the blower assembly, the cable with the red wire is connected to the flow meter. 4. Insert the connector on the black flapper valve wire (coming from the blower assembly) into the connector on the harness, as shown in Figure-5-3. This connector is tied with the other cables on the right side (per routing in Step 1) but can be identified by its shorter lead out from the cable tie. 5. Connect harness with blue wire to the flue sensor (blue connector) on the right side of the heat exchanger. See Figure 5-3. STEP 2: RETURN SENSOR (YELLOW) RETURN PIPING STEP 3: FLOW METER (RED) STEP 5: FLUE SENSOR (BLUE) STEP 4: FLAPPER VALVE WIRE (BLACK) INTERT HERE Figure 5-3: Return Sensor, Flow Meter, Flapper Valve Connections 6. On the left side of the blower assembly, the purple wire is connected the supply sensor, which is located below the gas valve and on the supply piping. See Figure 5-4. SUPPLY PIPING STEP 7: SUPPLY SENSOR (PURPLE) Figure 5-4: Supply Sensor Connection TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 30 of 36 Ph.: 800-526-0288 01/18/2015
5.3: Installing the Larger Wiring Harness Installing the Larger Wiring Harness 1. Take the part of the large harness with the gas valve connector, flame detector, and high limit thermostat connectors (Figure 5-5) and pass it around the rear between the two heat exchangers until gas valve part of cable emerges from the left of the blower assembly (leaving the other harness section on the right side of the blower assembly). FLAME DETECTOR LEAD GAS VALVE CONNECTOR HIGH LIMIT THERMOSTAT CONNECTORS Figure 5-5: Larger Harness Gas Valve Connector Cable Section NOTE Refer to Figure 5-6 for steps 2 through 4. 2. Install the gas valve connector to the gas valve, and affix the two screws to secure it. 3. Connect the flame detector lead to the terminal of the flame detector on the burner flange. 4. Connect the two appropriate connectors to the high limit thermostat. STEP 2: GAS VALVE CONNECTOR STEP 3: FLAME DETECTOR STEP 4: HIGH LIMIT THERMOSTAT Figure 5-6: Larger Harness Left Side Cable Connections TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 31 of 36 Ph.: 800-526-0288 01/18/2015
Installing the Larger Wiring Harness NOTE Refer to Figure 5-7 for steps 5 through 10. 5. Connect the fan connector (with red and orange wires) to the upper fan connector. 6. Connect the fan connector (with blue and green wires) to the lower fan connector. 7. Connect the two pin connector (with red wires) to the flue sensor fuse connector (red). 8. Connect the igniter power cable to the upper igniter. 9. Connect the igniter power cable ground wire tab to the screw on the burner flange, just above the igniter cables. 10. Plug in the motorized valve. STEP 8: IGNITER POWER CONN. IGNITER GROUND WIRE STEP 9: IGNITER GROUND SCREW STEP 5: UPPER FAN CONN. (RED/ORG) STEP 7: FLUE SENSOR FUSE (RED) STEP 10: MOTORIZED VALVE STEP 6: LOW ER FAN CONN. (BLU/GRN) Figure 5-7: Larger Harness Right Side Cable Connections TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 32 of 36 Ph.: 800-526-0288 01/18/2015
5.4: Turning on Services and Leak Testing Testing for Gas Leaks and Final Assembly 1. Turn ON the gas supply valve. See Figure 5-8. TURN GAS SUPPLY VALVE: ON Figure 5-8: Turn Gas Supply Valve to ON 2. Perform a soap test for leaks on the gas inlet section of the gas valve. Use an appropriate soap solution, and monitor for the presence of bubbles, which indicate leaks. If leaks are found, shut off gas, reinstall inlet hardware, and retest. Gas pressures for testing are according to local or national codes and regulations. See Figure 5-9. Figure 5-9: Testing with Soap Solution for Leaks (Bubbles) 3. Reinstall the air inlet (and hose) into the left side inlet on the blower. See Figure 5-10. 4. Reinstall plastic blower cover onto the blower by pushing it into place. See Figure 5-10. STEP 3: AIR INLET CONN. & HOSE STEP 3: AIR INLET CONN. & HOSE STEP 4: BLOWER COVER Figure 5-10: Installing the Air Inlet Connector/Hose and Blower Cover TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 33 of 36 Ph.: 800-526-0288 01/18/2015
5.5: Turning On Water and Return to Service Turning On Water and Return to Service 1. Turn OFF the drain valves of the water supply and return headers by turning both knobs clock-wise. See Figure 5-11. TURN WATER DRAIN VALVES: OFF Figure 5-11: Turn OFF the Drain Valves of Supply and Return Headers 2. Turn ON the water supply and return pipe valves. See Figure 5-12. WATER SUPPLY VALVE: ON WATER RETURN VALVE: ON Figure 5-12: Turn ON the Water Supply and Return Pipe Valves 3. Visually inspect the supply and return connections at the front of the boiler for water leaks. 4. If there are no water leaks, close the front panel door and affix with screw on left side. 5. Refer to Section 2.4, and by reversing the instructions, reinstall front, bottom, and top covers to the unit. 6. The AM unit may now be returned to service. TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 34 of 36 Ph.: 800-526-0288 01/18/2015
NOTES: TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 35 of 36 Ph.: 800-526-0288 01/18/2015
Change Log: Date Description Changed By 02/02/2015 Rev-0A: Release Curtis Harvey AERCO International, Inc., 2011 TID-0132_99 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 36 of 36 Ph.: 800-526-0288 01/18/2015