AER AM Series Owner's manual

TID-0137_0A
TECHNICAL INSTRUCTIONS
Revised: 01/18/2015
AM Series Boiler
Heat Exchanger Maintenance & Replacement
AM Series Heat Exchanger Module
For all models of AM Series
Boilers, Including:
Water Heaters:
•AM 399W
•AM 500W
•AM 750W
•AM 1000W
Boilers:
•AM 399B
•AM 500B
•AM 750B
•AM 1000B
TID-0137_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 36
Ph.: 800-526-0288 01/18/2015

AM Series Boiler Heat Exchanger Maintenance & Replacement
Technical Instruction Document
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
Material and Tool Requirements.................................................................................31: Preliminary Preparation of the Unit............................................................................52:2.1: 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
Removing the Heat Exchanger..................................................................................123: Installing the Heat Exchanger...................................................................................194: Final Reassembly........................................................................................................295:5.1: 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 2of 36 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TID-0137_0A
02/02/2015 Ph.: 800-526-0288

AM Series Boiler Heat Exchanger Maintenance & Replacement
Technical Instruction Document
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
Wrench (10mm)
Gasket
(P/N 60702096)
Gasket
(P/N 60702097)
Gasket x2 (1-1/4” Dia.)
(P/N 60701007)
Gasket (3/4” Dia.)
(P/N 607001006)
Silicone Grease
Scotch Tape
(or equivalent)
Air Compressor
Page 3of 36 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TID-0137_0A
02/02/2015 Ph.: 800-526-0288

AM Series Boiler Heat Exchanger Maintenance & Replacement
Technical Instruction Document
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.
WATER
SUPPLY
HEADER
WATER RETURN
HEADER
WATER RETURN
INLET
WATER SUPPLY
OUTLET
WATER RETURN
DRAIN VALVE
WATER SUPPLY
DRAIN VALVE
GAS SUPPLY
INLET
Page 4of 36 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TID-0137_0A
02/02/2015 Ph.: 800-526-0288

AM Series Boiler Heat Exchanger Maintenance & Replacement
Technical Instruction Document
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).
Figure 2-1: Turning the Power Switch to ON
2. Wait for the unit to finish initializing.
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).
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.
POWER SWITCH
SETPOINT +
BUTTON
BURNER
INDICATOR
ICONS
SETPOINT
ICON
RESET
BUTTON
Page 5of 36 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TID-0137_0A
02/02/2015 Ph.: 800-526-0288