AER SWDW-24 Manual del propietario

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 1 of 58

TECHNICAL INSTRUCTIONS

DISCLAIMER

The information contained in this manual 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.

AERCO Technical Support:

(Mon–Fri, 8am-5pm EST)

1 (800) 526-0288

Creation Date: 12/30/2014

This document provides technical instructions for removing an

existing Control Valve Actuator and Control Box and replacing it with

a new CXT-E Electronic Control Valve Actuator and Electronic

Control System (ECS).

These instructions apply to the following Steam-to-Water (SW)

Double Wall (DW) Heater models:

•SWDW-24

•SWDW-45

•SWDW-68

This document replaces the following document (Dec. 6, 2010):

TSB-2010-06_0A_SWDW_Recirculator-CXT-E-ECS_Retrofit_Inst

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 2 of 58

1. INTRODUCTION ................................................................................................................... 3

1.1 Safety Precautions......................................................................................................... 3

1.2 Tools & Supplies Required............................................................................................. 4

1.3 Retrofit Kit Contents....................................................................................................... 4

2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES ................................................ 5

2.1 Isolating Water Heater.................................................................................................... 8

2.2 Draining Water Heater.................................................................................................... 8

2.3 Removal of Components on Top Head Assembly .......................................................... 9

2.4 Removal of Items Connected to Heater Shell................................................................10

2.5 Control Valve Actuator Removal....................................................................................10

2.5.1 Pneumatic Control Valve Actuator Removal .........................................................10

2.6 Electro-Hydraulic Control Valve Actuator Removal........................................................12

2.7 Control Box Removal ....................................................................................................16

3. RECOMMENDED REPLACEMENT OF VALVE ASSEMBLY PARTS .................................19

3.1 Valves Previously Equipped With Pneumatic or Electro-Hydraulic Actuators.................19

3.1.1 Valve Disassembly Procedure..............................................................................19

3.1.2 Valve Reassembly Procedure...............................................................................25

3.2 Valves Previously Equipped With Self-Contained Actuators..........................................26

4. INSTALLATION OF RETROFIT KIT ITEMS.........................................................................30

4.1 Installation of Control Valve Actuator and Linkage Assembly ........................................30

4.1.1 Linkage Assembly Installation...............................................................................31

4.1.2 Actuator Installation..............................................................................................34

4.2 Installation of ECS Components on Top Head Assembly..............................................35

4.2.1 Outlet Flange........................................................................................................35

4.2.2 Outlet Temperature Dual Sensor..........................................................................35

4.2.3 Water Solenoid.....................................................................................................35

4.2.4 NPT Plugs............................................................................................................36

4.2.5 Thermocouple and Circulator Installation For SWDW Heaters – Brazed Fittings..36

4.2.6 Thermocouple and Circulator Installation For SWDW – Compression Fittings......39

4.3 Compound Pressure Gauge..........................................................................................40

4.4 ECS Control Box Installation .........................................................................................41

5. POST INSTALLATION CONNECTIONS AND ADJUSTMENTS..........................................45

5.1 Input and Output Water Heater Connections.................................................................45

5.2 Adjustments ..................................................................................................................45

6. APPENDICES.......................................................................................................................48

APPENDIX A 8" SWDW ECS RECIRC. LOOP RETROFIT.................................................49

APPENDIX B 10" SWDW ECS RECIRC. LOOP RETROFIT...............................................51

APPENDIX C 12" SWDW ECS RECIRC. LOOP RETROFIT...............................................53

APPENDIX D VALVE KITS REQUIRED FOR UPGRADED PNEUMATIC OR ELECTRO-

HYDRAULIC ACTUATOR...................................................................................................55

APPENDIX E VALVE KITS REQUIRED FOR UPGRADED ................................................56

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 3 of 58

1. INTRODUCTION

This document provides the procedures necessary to remove an existing Control Valve Actuator

and Control Box and replace it with a new CXT-E Electronic Control Valve Actuator and Electronic

Control System (ECS). These procedures are applicable to all AERCO Indirect-Fired Steam-to-

Water Double-Wall Heaters with Control Valves ranging in size from 1 inch to 4 inches and

currently equipped with pneumatic, electro-hydraulic or self-contained valve actuators. This

document applies to Double Wall steam-to-water heaters.

These instructions must be performed by a skilled service technician capable of exercising the

necessary safety precautions when working with high temperature, pressurized steam and water

systems.

Instruction No. HE-111 is the required manual for SWDW models and is available from the O&M

Manuals section of the AERCO International website, www.aerco.com

1.1 Safety Precautions

Installation, maintenance and operating personnel must, at all times, observe all safety

regulations. The following warnings are general and must be given the same attention as specific

precautions included in these instructions.

WARNING!

FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO

PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED

Shut off all incoming and outgoing steam and water stop

valves and carefully decrease all trapped pressures to zero

before performing any maintenance.

WARNING!

LIVE STEAM CAN CAUSE SEVERE BURNS

Never search for leakage in a live steam line by sight alone or

by “feel”. Use a mirror or other suitable polished object.

Always provide yourself with personal protective equipment,

(PPE) such as gloves, eye protection, dust mask, hard hat, etc.

NOTICE:

Burn permits may be required for certain installations requiring

braising

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 4 of 58

1.2 TOOLS & SUPPLIES REQUIRED

The following tools are required to perform the retrofit procedures specified in this Service

Bulletin:

•Combination Wrenches: 7/16”, 9/16”, 5/8”, 13/16”, 1-1/16”, 1-1/8”, 8 mm

•Pipe Wrenches: 12”, 24”

•Vise-Grip Pliers

•Flat Tip Screwdriver, 1/2” Blade

•Phillips Head Screwdriver, No. 3

•Brass Wire Brush

•Needle Nose Pliers

•Tape Measure

•Black Marker

•Locktite 565 or equivalent

•Manufactures’ installation instructions referenced in text

1.3 RETROFIT KIT CONTENTS

The contents of the Retrofit Kits, Part No. 27004-6-TAB, 27004-6-TAB, and 27004-6-TAB are

included in Appendices A through C of this Bulletin. The contents included in these Appendices

are as follows:

•Appendix D: Lists Valve Kits required for previously installed Pneumatic and Electro -

Hydraulic Actuators

•Appendix E: Valve Kits for previously installed Self-Contained Actuator

WARNING!

HIGH VOLTAGE OF 120 VAC IS USED IN AERCO INDIRECT FIRED

WATER HEATERS. 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. FOLLOW OSHA

APPROVED LOCKOUT/TAGOUT PROCDURES.

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 5 of 58

2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES

The locations of the major items to be removed from an AERCO SWDW are shown in Figure 2-1.

These items include:

•Currently Installed Control Valve Actuator (Pneumatic, Self-Contained or Electro-

Hydraulic)

•Control Box

•Top Head Solenoid Valve

•Thermal Element

•Shunt Tube

•Temperature Gauges & Capillaries

•Existing Feedback Sensor

•Load Alert Components (Except for Units With Electro-Hydraulic Valves)

In addition to the items listed above, the Drain Ball Valve (if installed) and Cold Water Inlet piping

will be temporarily disconnected to permit installation of a Circulation Pump.

NOTE

Figure 2-1 shows component locations for a typical Double-Wall, Model

DW-24.

The actual size and location of affected components and assemblies may

vary, depending on Packaged Water Heater Model, size, and type of

Control Valve being retrofitted. Refer to the applicable AERCO Heat

Exchanger Manual provided with your installation for additional details.

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 6 of 58

CONDENSATE/BOILER

WATER OUTLET

HOT WATER

OUTLET

WATER HEATER

PT.NO.1

2869-1

°F

SHELL OUTLET

POWER ON TRIPPED

TUBE OUTLET

°F °F

TUBE INLET

S/W

-OR-

TEMP. GAGE

PRESS. GAGE

COMPOUND

W/W

TEMP. GAGE

SECONDARY OUT.

TEMP. GAGE

PRIMARY OUTLET

TEMP. GAGE

PRIMARY INLET

3/4" PLUGGED

DRAIN

STEAM/BOILER

WATER INLET

SOLENOID

VALVE

CONTROL

BOX

CONTROL

VALVE

MOUNTING

BRACKET

(SAVE)

Figure 2-1. Double-Wall Heater Component Locations (Sheet 1 of 2)

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 7 of 58

COLD WATER

INLET

RELIEF VALVE

BLOCKED)

PLUGGED OR

(NOT TO BE

DETECTION PORT

TUBE LEAK

DOUBLE WALL

WATER

SOLENOID

CONTROL BOX

STEAM/BOILER

WATER INLET

ORIFICE DISC

& SPRING RING

Figure 2-1. Double-Wall Heater Component Locations (Sheet 2 of 2)

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 8 of 58

2.1 ISOLATING WATER HEATER

To isolate the Water Heater from all facility energy sources (steam, water, electrical power),

proceed as follows:

1. Disconnect and Lock-Out/Tag-Out external AC power supplied to the Control Box and any

other devices connected to the Heater.

2. Using a voltmeter, check to ensure that all incoming voltage readings are zero Before

continuing.

3. If the Heater is equipped with a Pneumatic Control Valve Actuator, close the valve

supplying air inlet pressure to the Pneumatic Controller.

4. Close all stop valves in the Steam Inlet and Condensate Outlet lines.

5. On the water-side, close the stop valves in the following order:

(a) Hot water outlet line

(b) Recirculation line

6. Carefully open the Relief Valve located on the Top Head to relieve pressure in the Heater

Shell. Water should stop flowing from the valve within one minute. If water continues to

flow from the Relief Valve, one of the water stop valves is not securely closed.

2.2 DRAINING WATER HEATER

Allow the Water Heater to cool sufficiently prior to draining the unit. When sufficiently cooled, drain

as follows:

1. After ensuring there is no pressure build-up in the Heater Shell (para. 2.1, step 6), block

open the Relief Valve in the Top Head to avoid creating a vacuum in the Heater Shell

when it is drained.

2. Open the Drain Ball Valve in the Bottom Head and allow the potable water in the Heater

Shell to drain completely. The Drain is located on the Shell and may either be plugged with

a 3/4” NPT Plug or equipped with a Ball Valve and additional drain piping. Remove Plug or

open Drain Ball Valve as applicable.

CAUTION

DO NOT DISCARD ANY OF THE REMOVED PARTS OR ASSEMBLIES

UNLESS IT IS SPECIFICALLY INDICATED THAT THEY WILL NO

LONGER BE USED. IT IS RECOMMENDED THAT ALL REQUIRED

ITEMS BE REMOVED AS INDICATED IN THE FOLLOWING STEPS

PRIOR TO PERFORMING ANY OF THEREPLACEMENT

PROCEDURES IN SECTION 3.

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 9 of 58

2.3 REMOVAL OF COMPONENTS ON TOP HEAD ASSEMBLY

Virtually all components currently installed in the Water Heater Top Head must be removed prior

to installing the new Electronic Control System and Electronic Valve Actuator. Refer to Figure 2-

1, sheet 1 to locate the applicable Top Head components and proceed as follows:

1. Disconnect the pipe drain from the Water Solenoid Relief valve in the Top Head.

2. Disconnect the electrical leads between the Water Solenoid and the Control Box.

3. Remove the 120 VAC Water Solenoid from the nipple connecting it to the Heater Top Head.

This Solenoid will be replaced with a new 24 VDC Solenoid provided in the Retrofit Kit.

4. If a Self-Contained Control Valve is installed with the Heater, remove the Valve’s

Temperature Control Thermal Element from the Thermowell bushing in the Top Head.

5. If a Pneumatic Control Valve is installed with the Heater, remove the Thermal Element and

Bushing.

6. Remove the Dial Thermometer and Thermowell from the Top Head.

7. Remove the Aquastat Capillary and Thermowell from the Top Head.

8. Remove the Anticipator Check Valve (Load Alert) as follows:

(a) Disconnect the union or flange in the hot water outlet piping (located beyond the

outside diameter of the Top Head).

(b) Refer to Figure 2-2. Remove the four hex nuts securing the hot water Outlet Flange to

the Top Head. Remove the Flange, Flange Gasket and outlet piping connected to the

Flange. Retain the four hex nuts for reinstallation of a new Outlet Flange (Section 4).

Alert. These removed components will no longer be used. Also, the Outlet Flange and

Gasket will be replaced with new components provided in the Retrofit Kit.

FLANGE

GASKET

SPRING PLATE

ASSEMBLY

SPRING

VALVE PLUG

ASSEMBLY

HEX NUTS (4)

HOT WATER

OUTLET FLANGE

OUTLET

FLANGE

Figure 2-2. Anticipator Check Valve (Load Alert) Assembly

ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters

Technical Instruction Document TID-0140_0A

12/30/2014 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288 Page 10 of 58

2.4 REMOVAL OF ITEMS CONNECTED TO HEATER SHELL

In order to install several new ECS components, the Drain Ball Valve must be disconnected and

the Cold Water Inlet Orifice Disc removed. Proceed as follows:

1. Disconnect any external piping connected to the Cold Water Inlet and Drain Ball Valve

Outlet on the Heater Shell.

2. Locate the Orifice Disc in the Cold Water Inlet.

3. Using a pair of pliers, disconnect the snap ring securing the Disc in the Inlet Nozzle.

4. Remove the clip and the Orifice Disc from the Inlet Nozzle. Discard

2.5 CONTROL VALVE ACTUATOR REMOVAL

The Water Heater may currently be equipped with a Pneumatic, Self-Contained or Electro-

Hydraulic Control Valve Actuator. Therefore, refer to the appropriate paragraph for the type of

Control Valve Actuator currently installed.

NOTE

Following removal of the existing Control Valve Actuator, AERCO

recommends that the Valve Seat and Packing be replaced using the

appropriate items included with the Retrofit Kit. If the Valve is relatively

new (less than 1 year) and is currently equipped with a Pneumatic or

Electro-Hydraulic Actuator, replacement of these items may be omitted at

the discretion of the user. However, if the Valve is currently equipped with

a Self-Contained Actuator, replacement of these items is mandatory,

since the Valve must be virtually disassembled to remove the installed

Actuator. A new Valve Top (plus other items) must also be added to Self-

Contained Valves before an ECS Actuator and Linkage Assembly can be

installed.

2.5.1 Pneumatic Control Valve Actuator Removal

Refer to Figure 2-3 and remove the Pneumatic Control Valve Actuator as follows:

1. Disconnect the compression fitting connecting the control air line from the Actuator Top.

2. Loosen the hex nut under the indicator disk.

3. Insert a 1/8 inch steel rod in the hole provided in the upper shaft. Hold the rod to keep the

upper shaft from turning when performing the next step.

4. Using a pair of pliers, grasp the lower shaft and rotate it counterclockwise to separate it from

the upper shaft. Use care to avoid scratching the lower shaft.

5. Remove the two 3/8-16 cap screws securing the Pneumatic Actuator to the Valve Body.

Remove the entire Actuator from the Valve.

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