Aerco 1B+ II Series User Manual Download Page 1

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AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, New York 10913

•

Phone: 800-526-0288

OMM-0063_0D

HE-110

USER MANUAL

Revised: 11/28/2018

Water Wizard

1B+ II

Water Heaters

SW1B+II Packaged Water Heater with

Pneumatically Controlled Valve (CXT-P)

Installation, Operation, and Maintenance

Covers all

1B+ II

models

including units with
pneumatically controlled valve
(Type CXT-P) or with an
Electronic Control System (ECS)
and electronically controlled
valve (CXT-E):

•

B+03

•

B+04

•

B+05

•

B+06

•

B+07

•

B+08

•

B+09

•

B+10

•

B+11

•

B+12

•

B+13

•

B+14

•

B+15

Note:

Number indicates number of

heating coils used (3 to 15).

Other applicable documentation includes:

SB-2006-02:

ECS Retrofit Instructions

AC-105:

Electronic Controls System (ECS) Manual

AC-103:

Pneumatic Temperature Controller Manual

Summary of Contents for 1B+ II Series

Page 1: ...tenance Covers all 1B II models including units with pneumatically controlled valve Type CXT P or with an Electronic Control System ECS and electronically controlled valve CXT E B 03 B 04 B 05 B 06 B 07 B 08 B 09 B 10 B 11 B 12 B 13 B 14 B 15 Note Number indicates number of heating coils used 3 to 15 Other applicable documentation includes SB 2006 02 ECS Retrofit Instructions AC 105 Electronic Con...

Page 2: ...thout 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...

Page 3: ...R 9 DE SCALING BY THERMAL SHOCK METHOD 26 CHAPTER 10 MAINTENANCE DISASSEMBLY 27 10 1 TOOLS AND EQUIPMENT 27 10 1 1 Common Tools and Equipment 27 10 1 2 SPECIAL TOOLS AND EQUIPMENT REQUIRED 27 10 2 ISOLATING THE HEATER 29 10 3 DISCONNECTING THE HEATER FROM THE FACILITY 30 10 4 ANTICIPATOR CHECK VALVE DISASSEMBLY 31 10 4 1 Special Tools Required 31 10 5 PREPARING TO REMOVE THE HEATER SHELL 32 10 6 R...

Page 4: ... Wizard Water Heaters OMM 0063_0D Installation Operation Maintenance Manual Page 4 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 CHAPTER 13 RECOMMENDED SPARE PARTS 44 ...

Page 5: ...n the same attention as specific precautions included in the instructions WARNING FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED SHUT OFF ALL INCOMING AND OUTGOING STEAM AND HOT WATER STOP VALVES AND CAREFULLY DECREASE ALL TRAPPED TRESSURES TO ZERO see SHUTDOWN IN OPERATERING PROCEDURES BEFORE PERFORMING ANY MAINTENANCE WARNING LIVE STEAM CAN CAUSE SEVERE ...

Page 6: ...ectronic Control System ECS with an electronically controlled valve CXT E and a bare heat exchanger without controls or valve See separate ECS Controls manual AC 105 for information about the Electronic controls System and electronically operated CXT E valve See Section 3 for available accessories 2 3 ACCESSORIES Accessories included in the AERCO B Heater Package Assembly See Figures 1a 1b 1c 21 2...

Page 7: ...heck Valve located in the Condensate Outlet Figure 12 Item 53 2 4 ALL OTHER ITEMS Stop valves check valves strainers unions or flanges and other piping and fittings as shown in Figures 3 through 6 are to be furnished by USER NOTE This instruction covers only the heat exchanger portion of the model B packaged heater assembly Separate instructions are included in this package covering steam control ...

Page 8: ...enance Manual Page 8 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 1a Dimensions for AERCO Helitherm Heat Exchanger Packaged Water Heater Model Water Wizard SW1B II with Pneumatic CXT P Valve Chapter 2 General Information ...

Page 9: ...ance Manual OMM 0063_0D 11 28 2018 Page 9 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 1b Dimensions for AERCO Helitherm Heat Exchanger Packaged Water Heater Model Water Wizard SW1B II with Bronze Heads ECS and CTX E Valve ...

Page 10: ...Maintenance Manual Page 10 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 1c Dimensions for AERCO Helitherm Heat Exchanger Packaged Water Heater Model Water Wizard SW1B II with Stainless Steel Heads ECS and CTX E Valve ...

Page 11: ...Maintenance Manual OMM 0063_0D 11 28 2018 Page 11 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 1d Dimensions for AERCO Bare Helitherm Replacement Heat Exchanger for Model Water Wizard SW1B II Chapter 3 Installation ...

Page 12: ...ude ample provision for expansion 5 Make all piping connections as instructed in Step 6 below and per the appropriate Figures shown a Single Heater Figure 3 b Parallel Heaters Figure 4 c Single Heater used with an Accumulator Figure 5 d Single Heater used with a Stratified Storage Tank Figure 6 or with any specific piping diagram which may have been furnished by AERCO for this installation 6 For t...

Page 13: ...e first two furnished have been assembled in the top head of the Heater by AERCO the third Valve is to be installed in the Heater hot water outlet piping by the user as illustrated in Figure 2 8 Before making final piping connections to and from the Heater and Control Valve blow out all piping thoroughly 9 If an air operated Control Valve is furnished in the Heater package make the necessary suppl...

Page 14: ...rd Water Heaters OMM 0063_0D Installation Operation Maintenance Manual Page 14 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 3 Piping Connections for a Single Heater ...

Page 15: ... Heaters HE 110 Installation Operation Maintenance Manual OMM 0063_0D 11 28 2018 Page 15 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 4 Piping Connections for Parallel Heaters ...

Page 16: ...Page 16 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 5 Piping Connections for a Single Heater used with an Accumulator Figure 6 Piping Connections for a Single Heater used with a Stratified Storage Tank Chapter 4 Principal of Operation ...

Page 17: ...than Cold Water migrates to the top of the Shell by convection These actions result in the hottest Water always being at the top of the Heater at the Heater outlet and at the How Water inlet to the Anticipator Temperature Sensing Tube See Figure 7 Hot Water from the top of the Heater Shell enters the open end of the Sensing Tube and Cold Water enters the Sensing Tube from the Shunt Tube at a rate ...

Page 18: ...ic of AERCO Model B II Water Heater showing Anticipator Temperature Control 4 2 HEAT EXCHANGER OPERATION WITH ELECTRONIC CONTROL SYSTEM ECS The Electronic Control System ECS available for the Water Wizard SW1B II offers features and functions not described in this manual Refer to the separate manual AC 105 for detailed descriptions of the function and operation of the ECS and electronically operat...

Page 19: ...st results in adjusting the temperature control a water flow of 10 to 25 of heater rating is desirable Slowly open all stop valves in the Steam inlet and condensate outlet lines 5 Slowly open all stop valves in the Steam inlet and Condensate outlet lines 6 Follow the instructions furnished with the air operated Temperature Controller and Control Valve or with self contained Temperature Regulator V...

Page 20: ... line if any and iii the cold water inlet line see Step 11c which follows c If the system includes an accumulator or stratified storage tank DO NOT SHUT OFF THE COLD WATER UNTIL THE HEATER HAS COOLED DOWN If the system is allowed to cool while the cold water is shut off the Heater liner may collapse because of formation a vacuum in the Heater 12 For DRAINING THE HEATER see the instruction included...

Page 21: ...lation Operation Maintenance Manual OMM 0063_0D 11 28 2018 Page 21 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 8 Model B II Heater Control Box Figure 9 Over Temperature Limit System Wiring Diagram ...

Page 22: ... held open to prevent creating a vacuum in the shell open the drain valve and drain the Heater completely 5 To refill the Heater and place it back into operation close the drain valve and proceed through Steps 1 12 and 13 under OPERATING PROCEDURES Chapter 5 6 2 CHECKING THE DRAINED WATER The constant flexure of the Heater coils under varying load conditions automatically provides a de scaling act...

Page 23: ...ted capacity 1 2 6 12 14 17 18 19 Heater overheats 1 5 6 8 11 13 14 Hot Water outlet temperature fluctuates widely 2 6 11 14 17 19 Insufficient Water through or from Heater 3 15 Excess or insufficient Condensate being returned from Heater 6 7 Steam being discharged into Condensate drain 18 19 Pressure Temperature Relief Valve pops 4 6 8 11 13 14 16 Heater shuts down below at or too near above requ...

Page 24: ... 5 Water to be heated is preheated too hot Reduce the preheating to a temperature at least 10 F under the desired Heater hot water outlet temperature 6 Condensate return piping has not been installed so that the Condensate drains freely by gravity and or the Condensate check valve leaks or has failed If necessary rearrange the Condensate return piping per Step 6e under INSTALLATIION Chapter 3 Insp...

Page 25: ...pair or replace each component as necessary 17 There is a leak in the Heater coil s steam riser or condensate return causing water from the shell to leak into the heating coil system or steam or condensate from the coil system to the shell To verify such a leak shut off the steam supply and break a connection in the Condensate Line CAREFULLY to avoid being burned Condensate will drain from the coi...

Page 26: ...rom a cold water faucet to the open relief valve connection 4 Open all shutoff valves in the Steam inlet line and the Condensate outlet line to allow Steam to the Heater After about 30 seconds or until Steam is blowing out of the Condensate drain line close the stop valve in the Condensate outlet line Leave the Steam inlet line open for about two minutes longer and then close all Steam inlet stop ...

Page 27: ...Tools and Equipment Combination Wrenches 7 16 5 8 13 16 1 1 16 1 1 8 Pipe Wrenches 12 and 24 Chain Hoist Voltmeter Brass Wire Brush Needle Nose Pliers Gasket Removal Tool Carpenter s Square Teflon Tape Orange Citric Cleaner Black Marker 10 1 2 SPECIAL TOOLS AND EQUIPMENT REQUIRED Hydrostatic Pressure Pump Range Up to 235 psig Torque Wrench 75 ft lbs With 1 1 4 1 5 16 1 1 2 Open End Spanners 1 1 4 ...

Page 28: ...0D Installation Operation Maintenance Manual Page 28 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 10 Tool Fabrication Details Coil Spacing and Retaining Tools Recommended Material 1018 steel ...

Page 29: ...ther 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 Steam Valve 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...

Page 30: ...Gauge 4 Disconnect the Steam line from the Valve and Bottom Head 5 Disconnect the water inlet from the Bottom Head 6 Disconnect the drain line from the Bottom Head 7 Disconnect the Condensate Drain piping from the Bottom Head 8 Disconnect all electrical wires to the Control Box Also disconnect all wiring between the Control Box and any external Solenoid Valve s 9 Using a 5 8 combination wrench rem...

Page 31: ...Check Valve Disassembly Instructions 1 Shut down the Heater in accordance with Step 10 under OPERATING PROCEDURES Manually and carefully open a relief valve to relieve any pressure in the Heater shell Figure 11 Model B II Heater Control Box 2 Disconnect the union in the Hot water outlet piping the one located beyond the outside diameter of the Heater top head Then remove the Nuts 51 and the Outlet...

Page 32: ...n accordance with Steps 1 through 4 in ROUTINE MAINTENANCE Chapter 6 2 If a self contained Control Valve is being used remove the Valve s Temperature Control Thermal Element from the Thermal Well Bushing 62 in the Heater Top Head Be careful not to damage the Element or its capillary 3 Disconnect ALL external piping from the Heater Top Head including that to the Relief Valve s 67 and the Water Sole...

Page 33: ...ith the mounting skid legs are to be removed with the stud left in place 3 Attach a chain hoist to the two lifting lugs on the Top Head Lift the Shell up to clear the internal coil bundle 4 Using a light source visually inspect the inside of the Heater Shell for evidence of damage to the Copper Shell Liner If any area of the Copper Liner is damaged replace the Shell down on the Bottom Head and con...

Page 34: ...ads should measure 1 1 8 for 2 NPT and 1 for 1 NPT 3 If the threads are less than the required depth use the appropriate 1 or 2 NPT tap to clean out the threads 4 Using the gasket removal tool remove the Shell Gasket from the Bottom Head Use care to avoid creating scratches or indents in the Bottom Head casting s gasket surface area Any linear scratches can potentially create a leak 5 Apply pipe d...

Page 35: ...eating surface of the Tail Piece and rotate the Union Nut several turns to check for any obstructions around the perimeter of the seating surface Figure 14 3 Contact your local AERCO Representative for replacement of the Coil if obstructions prohibit the rotation of the Union Nut 4 Using a brass wire brush clean the internal threads of the Union Nut 5 Using a citric orange cleaner spray the area b...

Page 36: ...ion Operation Maintenance Manual Page 36 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 SEE DETAIL A 0 DETAIL A TAILPIECE SEATING SURFACE UNION NUT SEALING SURFACE BOX HEADER Figure 14 Coil Assembly Preparation ...

Page 37: ... 1 8 MINIMUM Figure 15 Coil Assembly Spacing 11 4 PREPARATION OF COIL GASKETS Two 6 tab gaskets are provided with each replacement Coil Assembly Proceed as follows Figure 16 Coil Gasket Preparation 2 3 Preparation of Coil Gaskets 1 Form the Gasket into a round shape 2 Using Needle Nose Pliers form the 6 tabs on each Coil Gasket by bending each tab outward 2 to 3 degrees as shown in Figure 16 This ...

Page 38: ...until the center of the Spud is visually lined up to the cast notch on the Bottom Head 5 If this is a B II Water Wizard thread the Sub Cooling Coil onto the Condensate Riser hand tight ref paragraph 7 2 If this is not a B II Wizard Bundle assembly proceed to step 9 6 Measure the distance between the outside diameter of the Coil to the threaded stud protruding through the Bottom Head on both sides ...

Page 39: ... 0063_0D 11 28 2018 Page 39 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 17 Sub Cooling Coil Alignment Figure 18 Assembly of Coil to Steam Riser or Condensate Return STEAM RISER OR CONDENSATE RETURN UNION NUT COIL GASKET BOX HEADER SPUD ...

Page 40: ...use the appropriate Short Length wrench to tighten the Union Nuts to a seating condition 6 Insert the Coil Retaining tool through the first lower section of the Coil tubing Figure 8 7 Using a Torque Wrench set for 75 ft lbs insert the wrench in the proper torque direction on the Union Nut Figure 8 8 Apply pressure to the Coil Retaining tool in the opposite direction of the pressure being applied t...

Page 41: ...18 Page 41 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 19 Positioning of Coil Retaining Tool COIL RETAINING TOOL BOX HEADER RISER UNION NUT INSERT COIL RETAINING TOOL HERE BOX HEADER RISER TOP VIEW PARTIAL CUT AWAY SIDE VIEW COIL ASSEMBLY COIL ASSEMBLY ...

Page 42: ...nal pressure for 20 minutes 6 If leaks are detected remove the internal pressure 7 Remove the leaking Coil and inspect for causes for leak 8 If the leak is due to debris clean the Coil and reinstall 9 If there are damages to any surfaces contact your AERCO Representative for instruction for returning the failed Coil Anticipator Check Valve Reassembly 1 Insert the Valve Plug 36 the Washer 35 the Sp...

Page 43: ... If you are using electronic controls refer to document AC 105 OMM 0003 Electronic Control System ECS and Type CXT E Electronic Valve Reassembly of Shell Instructions 1 Install fittings into the inlet and outlet of the Bottom for the Risers that can supply a hydrostatic pressure source 2 One fitting should have a valve for the release of internal air pressure 3 The other fitting should be attached...

Page 44: ...h 5 15 1 Compound Pressure Gage 12 15 1 Green Indicator Light 24 15 1 Red Indicator Light 25 15 2 Outlet Flange Gasket 32 16 4 Head Gasket 54 16 Coil Assembly 56 16 Conical Coil Gasket 57 16 Minimum of 2 to a maximum of the number in your largest Heater 2 per Space Coil Assembly Item 56 plus 2 LIST B For Model B II Water Wizard with Pneumatic Operated Control Valve List A above plus Quantity Per H...

Page 45: ... HE 110 Installation Operation Maintenance Manual OMM 0063_0D 11 28 2018 Page 45 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 20 AERCO Model SW1B II Control Box Assembly and Parts List ...

Page 46: ...OMM 0063_0D Installation Operation Maintenance Manual Page 46 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 21 AERCO Model B II Water Heater w Pneumatic Valve Assembly and Parts List ...

Page 47: ...10 Installation Operation Maintenance Manual OMM 0063_0D 11 28 2018 Page 47 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 22 AERCO Model SW1B II Water Heater with ECS Assembly and Parts List ...

Page 48: ...0063_0D Installation Operation Maintenance Manual Page 48 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Figure 23 AERCO Bare Replacement Heat Exchanger for Model SW1B II Assembly and Parts List ...

Page 49: ... II Water Wizard Water Heaters HE 110 Installation Operation Maintenance Manual OMM 0063_0D 11 28 2018 Page 49 of 50 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 NOTES ...

Page 50: ...e Manual Page 50 of 50 11 28 2018 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Change Log Date Description Changed by 11 28 2018 Rev D Clarified reference to Startup procedure in Section 12 8 Startup Procedure Chris Blair AERCO International Inc 2018 ...

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