AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 1 of 10
0
Each kit contains the parts necessary to service ONE burner.
Obtain one kit for each burner in the unit you are servicing.
AM Series Thermal Insulation Replacement Kit # 62632006 Contents
ITEM # QTY. PART NUMBER DESCRIPTION
1
1
60801149
SCREW
2
1
n/a
WASHER
3
1
60703047
O-RING
4
1
60909011
THERMAL INSULATION, BURNER
5
1
60701021
GASKET, WOOL
6
1
60909012
THERMAL INSULATION, HEAT EXCHANGER
Disclaimer
The information contained in these instructions are 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 this material.
Thermal Insulation Replacement Kit # 62632006
For AM Series Models 399, 500, 750 and 1000
ITEM 6:
P/N 60909012
THERMAL INSULATION,
HEAT EXCHANGER
(1 each)
ITEM 1:
P/N 60801149
Screw
(1 each)
TECHNICAL INSTRUCTIONS
ITEM 5:
P/N 60701021
GASKET, WOOL
(1 each)
ITEM 4:
P/N 60909011
THERMAL
INSULATION, BURNER
(1 each)
ITEM 3:
P/N 60703047
O-RING
(1 each)
ITEM 2:
P/N n/a
WASHER
(1 each)
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 2 of 10
1. Introduction
This Technical Instruction Document (TID) provides instructions for installing the AM Series
Thermal Insulation Replacement Kit # 62632006.
These instructions apply to the following AM Series models: 399, 500, 750 and 1000. Purchase
and install one kit for each burner in the unit you are servicing. For example, to service the AM
Series Model 1000 you must obtain four (4) Thermal Insulation Replacement Kits.
IMPORTANT!
The insulation refractory material is not hazardous.
However, if it breaks and creates dust, you should wear
standard, off the shelf breathing protection, such as a dust
mask, while handling and cleaning up.
2. Tools Required
• # 2 Phillips head screwdriver
• Flat blade screw driver
• Adjustable/ socket/open end Metric wrenches
3. Preparing the Unit for Thermal Insulation Replacement
Complete the following steps to prepare the unit for Thermal Insulation replacement.
WARNING! -
A VOLTAGE OF 120 VAC IS USED IN THIS SYSTEMS.
DISCONNECT POWER TO THE BOILER BEFORE PERFORMING
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.
IMPORTANT!
Observe local requirements and lockout procedures when
working on the boiler.
Preparing the Unit
1. Remove power from the unit by turning off electrical power upstream from the unit.
2. Turn off the supply gas upstream from the unit by closing the manual gas shut off valve.
3. Remove the top cover from the unit and then remove the two screws holding the front
cover in place.
4. Pull the upper portion of the front cover back about 2 inches and then pull it up one inch
and remove it from the unit.
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 3 of 10
4. Removing the Burner
Complete the following instructions on each burner in the unit.
Removing the Burner
1. Prepare a suitable cover for the burner so that no dirt, water, or other foreign objects fall
into the burner unit from above.
2. Referring to in Figure 1, loosen screws labeled “D” and then move the ignition
transformer, labeled “A,” up.
Figure 1: Removing the Spark Generator
3. Referring to in Figure 2, disconnect the two wires labeled “D” from the ignition electrodes,
disconnect the wire labeled “E” from the flame detection electrode (flame rod), and rotate
the air inlet silencer labeled “B” in the up direction.
4. Pull the air inlet silencer to the left (label “C”) and remove it from the fan.
Figure 2: Removing the Air Inlet Silencer
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 4 of 10
Removing the Burner – Continued
5. Referring to Figure 3, unscrew nut “H.” Take note of the gasket between nut “H” and the
gas valve.
Figure 3: Removing the Nut & Spring from the Gas Valve
6. Disconnect the electrical plug from the gas valve.
7. Use a screwdriver to remove the spring labeled “A.”
8. Referring to Figure 4, remove the gas valve from its position. Note the O-ring, labeled “L.”
Figure 4: Removing the Gas Valve
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 5 of 10
Removing the Burner – Continued
1. Referring to Figure 5, unscrew the four nuts labeled “B.”
2. Remove the entire fan and burner assembly, labeled “C.”
Figure 5: Removing the Fan and Burner Assembly
5. Replacing Heat Exchanger’s Thermal Insulation
Thermal insulations must be checked every year for any damage, including cracks, chips, or
other damage. If any damage is found they must be replaced.
These instructions will be repeated on each burner in the unit.
Replacing the Heat Exchanger’s Thermal Insulation
1. Unscrew nut from the thermal insulation (see Figure 6).
2. Use a screwdriver to remove the thermal insulation.
3. Prepare the screw and the washer to fix the new thermal insulation (see Figure 7).
Figure 6: Screw & Thermal Insulation
Figure 7: Screw & Washer
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 6 of 10
Replacing the Heat Exchanger’s Thermal Insulation – Continued
4. Align the bolt holes in the heat exchanger (detail B in Figure 8) with the corresponding
hole in the thermal insulation (detail A in Figure 8).
5. Install the thermal insulation in the heat exchanger, holding it in place with the screw and
washer included with the kit (see Figure 9). ). It is recommended that you use a high
temperature anti-seize compound when installing the screw to facilitate removal during
subsequent maintenance.
6. Replacing Burner’s Thermal Insulation
The burner’s thermal insulation must be checked every year and replaced if it is not intact.
Inspect for any damage including cracks, chips, or other damage, and replace if any damage is
found. These instructions will be repeated on each burner in the unit.
Replacing Burner’s Thermal Insulation
1. Unscrew the screws holding the electrodes in place (see Figure 10).
2. Remove both the ignition and flame detection electrodes (see Figure 11).
Figure 8: Replace the Thermal Insulation
Figure 9: Install the Thermal Insulation
Figure 10: Remove Electrode’s Screws
Figure 11: Remove the Electrodes
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 7 of 10
Replacing Burner’s Thermal Insulation – Continued
3. Remove the burner’s thermal insulation (see Figure 12).
4. Replace the O-Ring (see arrow in Figure 13) with the new one included in the kit.
5. Install the wool gasket in the back of the new burner thermal insulation (see Figure
14).
6. Install the new burner thermal insulation on the burner (see Figure 15).
Figure 12: Remove Thermal Insulation Figure 13: Replace the O-Ring
Figure 14: Combine Wool Gasket with
Thermal Insulation
Figure 15: Install Thermal Insulation in Burner
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 8 of 10
Replacing Burner’s Thermal Insulation – Continued
7. Assembly the ignition and detection electrodes, paying attention to the correct position
of the red gasket (shown with arrows in Figure 16).
8. Screw the electrodes in place (see Figure 17).
9. Before reinstalling the burner, clean the surface on which the gasket will sit (shown with
arrows in Figure 18) to ensure a good seal.
10. Install the reassembled fan burner assembly (see Figure 19) in the heat
exchanger by performing the steps in section 4 – Removing the Burner in reverse
order.
11. Complete the instructions above on the remaining burners in the unit.
Figure 16: Reassemble the Electrodes
Figure 17: Tighten the Electrodes
Figure 18: Clean Gasket Surfaces
Figure 19: Reassemble Burner Assembly
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 9 of 10
7. Check for Gas Leaks
Once the unit is reassembled and the electrical connection restored, open the manual gas shut
off valve and check the unit for gas leaks.
Checking for Gas Leaks
1. Use an approved leak detention method to check all junctions shown with arrows A
through E in Figure 20.
Figure 20: Gas Leak Check Locations
AM Series Thermal Insulation Replacement Instruction
Kit # 62632006 TID-0120_0A
07/28/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 10 of 10
© AERCO International, Inc., 2014
Date Description Changed By
07/28/2014 Rev A: Initial release (reference PIR 934-72) Chris Blair
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