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ECS Upgrade for SW Double Wall Heaters, Kits 27035, 27036, 27037

Technical Instruction Document

TID-0142_0A

12/30/2014

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, New York 10913

•

Phone: 800-526-0288

Page 5 of 24

Figure 2-1: Before Upgrade

-

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

Hot Water Outlet

Remove existing

temperature controller

and replace with P/N

64028-12

ECS Control Box

Remove Flow Sensor

assembly and discard.

Install 61009-1 (Type J

Thermocouple) and 93029

(1/4” NPT x 3/16” Tube

Compression Fitting)

Plug vacated hole

(Drain Hole) with 9-

22 (1/4” NPT Hex

Head Plug)

Condensate Outlet

Steam Inlet

Leak Detection Port

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Содержание 27035

Страница 1: ...ness 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 instructions for upgrading the Electronic Control System ECS fo...

Страница 2: ... To Heater Shell 8 2 5 Installation Of ECS Components On Top Head Assembly 8 2 5 1 Thermocouple Circulator Installation For SWDW Heaters Brazed Fittings 8 2 5 2 Thermocouple Circulator Installation For SWDW Heaters Compression Fittings 12 2 5 3 Temperature Controller Replacement 13 2 5 4 Setpoint Temperature Adjustment 13 2 5 5 Wiring the ECS Control Box for the Circulator and Temperature Control ...

Страница 3: ...ent and the contents of the Upgrade Kits for all Heater Models 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 R...

Страница 4: ...river No 3 Brass Wire Brush Needle Nose Pliers Tape Measure Black Marker Loctite 565 or equivalent Manufactures installation instructions referenced in text Brazing equipment for assembling P N 97049 if burn permit available 1 3 Upgrade Kit Contents The contents of the Upgrade Kits P N 27035 27036 and 27037 are included in Appendices A through C at the end of this document 2 EQUIPMENT ISOLATION AN...

Страница 5: ...gure 2 1 Before Upgrade Double Wall Heater Component Locations Sheet 1 of 2 Hot Water Outlet Remove existing temperature controller and replace with P N 64028 12 ECS Control Box Remove Flow Sensor assembly and discard Install 61009 1 Type J Thermocouple and 93029 1 4 NPT x 3 16 Tube Compression Fitting Plug vacated hole Drain Hole with 9 22 1 4 NPT Hex Head Plug Condensate Outlet Steam Inlet Leak ...

Страница 6: ...gure 2 1 Before Upgrade Double Wall Heater Component Locations Sheet 2 of 2 ECS Control Box Plug vacated hole with P N 9 22 1 4 NPT Hex Head Plug Condensate Outlet Leak Detection Port Orifice Disc and Snap Ring Within Cold Water Inlet Opening Cold Water Inlet Remove Flow Sensor assembly and discard Replace with P N 61009 1 Type J Thermocouple and P N 93029 1 4 NPT x 3 16 Tube Compression Fitting H...

Страница 7: ...top 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 unit 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 section 2 1 step 6 block open the Relief Valve in the To...

Страница 8: ...Remove the clip and the Orifice Disc from the Inlet Nozzle and discard 2 5 Installation of ECS Components on Top Head Assembly The ECS components to be installed on the Top Head Assembly include Cold Water Inlet Thermocouple and Circulator Installation Note that brazing is preferred method of assembling P N 970049 However if a burn permit or brazing equipment is not available then compression fitt...

Страница 9: ...e Wall Heaters Kits 27035 27036 27037 Technical Instruction Document TID 0142_0A 12 30 2014 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 9 of 24 Figure 2 2 Location of Cold Water Inlet ...

Страница 10: ...lt New York 10913 Phone 800 526 0288 Page 10 of 24 Figure 2 3 Circulator Sub assembly 3 Assemble remaining items as shown in Figure 2 3 22102 12614 8 Brazed 97049 Compression 97052 59095 90075 for SVVDVV24 90076 for SVVDW45 90077 for SVVDW68 93265 91045 45 00 CUT AT ASSEMBLY TO SUITE Brazed 97049 Compression 97052 69101 59095 90074 93326 90058 93325 22102 93325 ...

Страница 11: ...Attach 3 Tee to the unit s hot water outlet flange 7 Attach nipple to the 3 Tee 8 Attach union to nipple 9 Obtain the following from kit 1 5 Street elbow 12614 8 1 5 Tube x 1 5 Male NPT adapter 97049 x2 1 5 Copper tube 91045 45 00 1 5 Flange w 2 3 8 x 16 bolts and nuts 59095 set hardware aside for use in Step 17 1 5 Taco Circulator Cartridge 69101 for measurement purposes 10 Braise one 1 1 5 tube ...

Страница 12: ...kit Thermocouple 61009 1 27 Screw thermocouple into threaded coupling on Cold Water Inlet 28 Connect the outlet piping to new Hot Water Outlet Tee 29 Conduct checks laid out in section 3 1 2 5 2 Thermocouple Circulator Installation For SWDW Heaters Compression Fittings NOTE This is an acceptable alternative to brazing see Section 2 5 1 Use Loctite 565 or equivalent on all threaded potable water fi...

Страница 13: ... follows 1 Open the Control Box door to access the Temperature Controller 2 The Temperature Controller is installed in a sleeve as shown in Figure 2 5 To unplug and remove the 3 Controller from its sleeve simply pry the latching ears outward and pull the Controller out of the panel 4 To install a replacement Temperature Controller simply slide it into the front panel sleeve until the latching ears...

Страница 14: ... of the Heater and the lower display will show the current setpoint temperature stored in memory default 140 F 2 Ensure that the Temperature Controller is set to the AUTO automatic mode and the AUTO indicator is lit If the MAN indicator is lit press the AUTO MAN button to toggle the mode setting Indicator OP1 should also be lit 3 If the lower display does not show the desired setpoint temperature ...

Страница 15: ... lower display Up Button Press to increase the value shown in the lower display NOTE External power at 120 to 240 VAC 50 60 Hz is required to operate the circuitry contained in the ECS Control Box Power connections are made internally by routing the power wiring through the cutout provided on the right side of the Control Box 2 5 5 Wiring the ECS Control Box for the Circulator and Temperature Cont...

Страница 16: ...ng components a Label Connect To MIXED INLET TEMP THERMOCOUPLE 2 Pin Connector on Thermocouple 8 Fill system with domestic tap water The system must be filled before operating the circulator The bearings are water lubricated and should not be allowed to operate dry Filling the system will result in immediate lubrication of the bearings It is always good practice to flush a new system of foreign ma...

Страница 17: ...Technical Instruction Document TID 0142_0A 12 30 2014 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 17 of 24 Figure 2 8 Typical Recessed Panel Behind Control Box Door Figure 2 9 Typical ECS Control Box AC Power Connections ...

Страница 18: ...ng items must be checked to ensure the proper connections have been made 1 Drain Connection Ensure that the side of the plugged Drain Ball Valve has been replaced and that all external drain piping is reconnected 2 Cold Water Inlet Ensure that the Cold Water Inlet Flange is connected to the cold water inlet piping 3 Steam Line Ensure that the Steam supply line is connected to the inlet of the CXT ...

Страница 19: ...6 27037 Technical Instruction Document TID 0142_0A 12 30 2014 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 19 of 24 Figure 3 1 DW 68 Double Wall Water Heater With ECS Control System CXT E Control Valve Sheet 1 of 2 ...

Страница 20: ...37 Technical Instruction Document TID 0142_0A 12 30 2014 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 20 of 24 Figure 3 1 DW 68 Double Wall Water Heater With ECS Control System CXT E Control Valve Sheet 2 of 2 SIDE VIEW ...

Страница 21: ... 2 SCH 40 X 2 1 2 LG 1 90075 NIPPLE 1 1 2 NPT SCH 40 X 11 1 2 1 91045 45 00 COPPER TUBE 1 5 45 LG 1 93265 UNION 1 1 2 NPT THREADED 2 93325 REDUCING COUPLING 3 NPT X 2 NP 1 93326 UNION 2 NPT THREADED 2 97049 ADAPTER MALE PIPE 1 1 2 TUBE X Table A 2 Compression Fittings Construction Assembly 27035 2 Qty Component Description 1 61009 1 TYPE J THERMOCOUPLE SINGLE ELEMENT 1 93029 COMPRESSION FITTING NP...

Страница 22: ... 40 X 2 1 2 LG 1 90076 NIPPLE 1 1 2 NPT SCH 40 X 12 1 2 1 91045 45 00 COPPER TUBE 1 5 45 LG 1 93265 UNION 1 1 2 NPT THREADED 2 93325 REDUCING COUPLING 3 NPT X 2 NP 1 93326 UNION 2 NPT THREADED 2 97049 ADAPTER MALE PIPE 1 1 2 TUBE X Table B 2 Compression Fittings Construction Assembly 27036 2 Qty Component Description 1 61009 1 TYPE J THERMOCOUPLE SINGLE ELEMENT 1 93029 COMPRESSION FITTING NPT X 3 ...

Страница 23: ...0 X 2 1 2 LG 1 90077 NIPPLE 1 1 2 NPT SCH 40 X 13 1 2 1 91045 45 00 COPPER TUBE 1 5 45 LG 1 93265 UNION 1 1 2 NPT THREADED 2 93325 REDUCING COUPLING 3 NPT X 2 NP 1 93326 UNION 2 NPT THREADED 2 97049 ADAPTER MALE PIPE 1 1 2 TUBE X Table C 2 Compression Fittings Construction Assembly 27037 2 Qty Component Description 1 61009 1 TYPE J THERMOCOUPLE SINGLE ELEMENT 1 93029 COMPRESSION FITTING NPT X 3 16...

Страница 24: ...Document TID 0142_0A 12 30 2014 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Phone 800 526 0288 Page 24 of 24 International Inc AERCO International Inc 2014 Change Log Date Description Changed By 12 30 2014 Rev A Initial release replacement for TSB 11 007 Chris Blair ...

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