AERCO CXT-E Retrofit Kit User Manual

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

TECHNICAL INSTRUCTIONS

Technical Instruction Document TID-0141_0A

This document provides 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).

This document applies to kit number 27004-TAB.
These instructions apply to the following types and models:

• HELITHERM HEATER MODELS:

This document replaces the following document, origi nal ly released 04/11/2007:

• A-Plus

• B-Plus

• B-Plus II (Water Wizard)

• E-Plus

• WATER-TO-WATER (WW) DOUBLE-WALL (DW) HE ATER MODELS:

• WWDW-24

• WWDW-45

• WWDW-68

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 t he furnishing, performance, or use of these
materials.

AERCO Technical Support:

(Mon–Fri, 8am -5pm EST)

1 [phone]

Creation Date: 12/30/2014

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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

1.1 SAFETY PRECAUTIONS ............................................................................................... 3

1.2 Tools & Supplies Required ............................................................................................. 3

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

2. EQUIPMENT ISOLATIO N AND REMOVAL PROCEDURES ................................................ 5

2.1 Isolating Water Heater ...................................................................................................11

2.2 Draining Water Heater ...................................................................................................11

2.3 Removal of Components on Top Head Assembly .........................................................12

2.4 Removal of Items Connected to Bottom Head ...............................................................13

2.5 Control Valve Actuator Removal ....................................................................................14

2.5.1 Pneumatic Control Valve Actuator Removal .........................................................14

2.5.2 Electro-Hydraulic Control Valve Actuator Removal ...............................................16

2.5.3 Self-Contained Control Valve Actuator Removal ...................................................18

2.6 Control Box Removal ....................................................................................................21

3. RECOMMENDED REPLACEMENT OF VALVE ASSEMBLY PARTS .................................24

3.1 Valves Previously Equipped With Pneumatic or Electro-Hydraulic Actuators .................24

3.1.1 Valve Disassembly Procedure ..............................................................................24

3.1.2 Valve Reassembly Procedure ...............................................................................30

3.2 Valves Previously Equipped With Self-Contained Actuators ..........................................31

4. INSTALLATION OF RETROFIT KIT ITEMS .........................................................................35

4.1 Installation of Control Valve Actuator and Linkage Assembly ........................................35

4.1.1 Linkage Assembly Installation ...............................................................................36

4.1.2 Actuator Installation ..............................................................................................38

4.2 Installation of ECS Components on Top Head Assembly ..............................................40

4.2.1 Outlet Flange ........................................................................................................40

4.2.2 Outlet Temperature Dual Sensor ..........................................................................40

4.2.3 Water Solenoid .....................................................................................................40

4.2.4 NPT Plugs ............................................................................................................41

4.3 Flow Meter Installation...................................................................................................41

4.3.1 Flow Meter Installation For Helitherm Heaters ......................................................

4.3.2 Flow Meter Installation For Water-to-Water Double-Wall Heaters .........................44

4.4 Boiler Water Inlet and Outlet Temperature Sensors – (Water-to-Water Heaters) ...........45

4.4.1 E-Plus Water Heaters ...........................................................................................45

4.4.2 Water-to-Water Double-Wall Water Heaters .........................................................46

4.5 Compound Pressure Gauge ..........................................................................................48

4.5.1 Helitherm Steam-to-Water Units ...........................................................................49

4.6 Installation of New Orifice Disc ......................................................................................49

4.7 ECS Control Box Installation .........................................................................................51

5. POST INSTALLATION CONNECTIONS AND ADJUSTMENTS ..........................................54

5.1 Input and Output Water Heater Connections .................................................................54

5.2 Adjustments ..................................................................................................................54

43

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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 Water
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. In addition, this document applies
to both steam-to-water (SW) and water-to-water (WW) 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.

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.

1.2 TOOLS & SUPPLIES REQUIRED

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

• 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

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

1.3 RETROFIT KIT CONTENTS

The contents of the Retrofit Kits, Part No. 27004-[ ] are included in Appendices A through D of
this document. The contents included in these Appendices are as follows:

• Appendix A: Lists the Basic ECS Retrofit Kit contents for each Water Heater Model

• Appendix B: Lists Optional Items based on: valve size, flow rate, type of actuator

currently installed

• Appendix C: Lists Valve Kits required for previously installed Pneumatic and Electro -
Hydraulic Actuators

• Appendix D: Lists Valve Kits required for previously installed Self-Contained Actuators

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.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES

The locations of the major items to be removed from an AERCO Indirect Fired Water Heater are
shown in Figures 2-1 (Helitherm Models) and 2-2 (Double-Wall Models). 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 Flow Meter and Orifice Disk.

NOTE

Figure 2-1 shows the locations of the affected components and
assemblies for a typical Helitherm, Model SW1B-Plus II Water Wizard
installation. Figure 2-2 shows component locations for a typical Water-to­Water Double-Wall, Model WWDW-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.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

P&T RELIEF VALVE

CONTROL BOX

HOT WATER OUTLET

TEMPERATURE GAUGE

COMPOUND

PRESSURE

GAUGE

WATER HEATER

PT.NO.12869­1

SHELL OUTLET

°F PSIG

STEAM PRESS.

POWER ON TRIPPED

WIRING CONDUIT TO
WATER SOLENOID VALVE

CONTROL VALVE*

HEATER SHOWN WITH
PNEUMATIC CONTROL
VALVE. AN ELECTRO­HYDRAULIC OR SELF­CONTAINED VALVE MAY
ALSO BE USED WITH THE
PACKAGED HEATER.

*NOTE:

SECOND OPTIONAL
P&T RELIEF VALVE

SHUNT TUBE

SHUNT TUBE

FRONT VIEW

COLD WATER IN

DRAIN

DRAIN BALL

VALVE

STEAM
IN

Technical Instruction Document TID-0141_0A

Figure 2-1. Typical Helitherm Water Heater Component Locations (Sheet 1 of 3)

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

STEAM INLET

CONTROL VALVE*
(PNEUMATIC SHOWN)

AIR PRESSURE IN
(PNEUMATIC VALVE ONLY)

SOLENOID
VALVE

CONDUIT

CHECK VALVE

SIDE VIEW

CONTROL

BOX

Technical Instruction Document TID-0141_0A

Figure 2-1. Typical Helitherm Water Heater Component Locations (Sheet 2 of 3)

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

BOTTOM

TOP

SOLENOID

VALVE

LOAD ALERT**

P&T RELIEF

VALVE(S)

SHUNT TUBE

THERMAL
ELEMENT

CONTROL

BOX

VALVE

FEEDBACK
SENSOR

SHUNT TUBE

COLD WATER IN

ORIFICE DISC

DRAIN VALVE

CONDENSATE OUT

STEAM IN

CONTROL
VALVE

LOAD ALERT NOT
USED WITH ELECTRO­HYDRAULIC CONTROL
VALVE.

**NOTE:

SPRING RING

OUTLET
FLANGE

MOUNTING

BRACKET

(SAVE)

Technical Instruction Document TID-0141_0A

Figure 2-1. Helitherm Water Heater Component Locations (Sheet 3 of 3)

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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

NOTE

The majority of illustrations contained in these instructions show a typical
Water Wizard, Model SW1B Plus II Packaged Water Heater. Additional
supporting illustrations are provided only where significant differences
exist between the Water Wizard and the AERCO Heater being retrofitted.
For example: E-Plus Water-to-Water Heaters or Water-to-Water Double­Wall (WWDW) Models.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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. On water-to-water
systems, do not rely on the Boiler Water Out Check Valve to stop the flow of water.

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

(a) Hot water outlet line
(b) Recirculation lin e
(c) Cold water inlet line

6. Carefully open the Relief Valve located on the Top Head to relieve pressure in the Heater
Shell. W ater 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. If the unit is a Water-to-Water Double-Wall Heater (WWDW-24,
WWDW-45 or WWDW-68), 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. Rem ove Plug or
open Drain Ball Valve as applicable.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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.

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 2­1, sheet 3 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 2-3. 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).

(c) Remove the Spring Plate Assembly, Spring and Valve Plug Assembly from the Load

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.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

FLANGE
GASKET

SPRING PLATE

ASSEMBLY

SPRING

VALVE PLUG

ASSEMBLY

HEX NUTS (4)

HOT WATER
OUTLET FLANGE

OUTLET
FLANGE

Technical Instruction Document TID-0141_0A

Figure 2-3. Anticipator Check Valve (Load Alert) Assembly

NOTE

For Water-to-Water Double-Wall Heater Models (WWDW-24, WWDW-45,
WWDW-68), the items removed in section 2.4 are located on the Shell of
the Heater instead of the Bottom Head. Therefore, refer to Figure 2-2 for
Water-to-Water Double-W all Models.

2.4 REMOVAL OF ITEMS CONNECTED TO BOTTOM HEAD

In order to install several new ECS components, the Drain Ball Valve must be disconnected and
the Cold Water Inlet Orifice Disc replaced. The locations of these items are shown in Figure 2-1,
sheet 3. Proceed as follows:

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

2. Locate the Orifice Disc in the Cold Water Inlet (Figure 2-1, sheet 3).

3. Using a pair of pliers, disconnect the snap ring securing the Disc in the Bottom Head.

4. Remove the clip and the Orifice Disc from the Bottom Head. This Orifice Disc will be
replaced in Section 4 with a new Disc provided in the Retrofit Kit.

5. Next, temporarily remove the Drain Ball Valve from the Bottom Head (Figure 2-1, sheet 3).
Retain this Ball Valve for reinstallation in Section 4.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

2.5 CONTROL VALVE ACTUATO R REMOVAL

The Water Heater may currently be equipped with a Pneumatic, Self-Contained or Electro­Hydraulic Control Valve Actuator. Therefore, refer to the appropriate section 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 Self­Contained 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 2-4 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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ACTUATOR

INDICATOR DISK

LOWER SHAFT

CAP SCREWS (2)

UPPER SHAFT

HOLE

HEX NUT

VALVE BODY

VALVE TOP

DETAIL “A”

PNEUMATIC

ACTUATOR

VALVE

BODY

SEE

DETAIL “A”

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

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Figure 2-4. Pneumatic Control Valve Actuator Removal

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

2.5.2 Electro-Hydraulic Control Valve Actuator Removal

Refer to Figure 2-5 and remove the Control Valve Actuator as follows:

1. Disconnect the electrical connectors from the Actuator.

2. Loosen the Upper Hex Nut above the Lower Crossbar shown in Figure 2-5.

3. While holding the Lower Shaft with a pair of pliers, completely remove the Upper Hex Nut.

4. Remove the four hex head bolts securing the Electro-Hydraulic Actuator to the Valve Top.

5. Lift the entire Actuator off the Valve Top. Also, remove the Actuator Gasket.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

PNEUMATIC

ACTUATOR

VALVE

BODY

SEE

DETAIL “A”

VALVE

BODY

UPPER
HEX NUT

LOWER
HEX NUT

VALVE TOP

ACTUATOR

GASKET

HEX HEAD

BOLTS (4)

LOWER

CROSSBAR

DETAIL “A”

Technical Instruction Document TID-0141_0A

Figure 2-5. Electro-Hydraulic Control Valve Actuator Removal

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

2.5.3 Self-Contained Control Valve Actuator Removal

Refer to Figure 2-6 and remove the Self-Contained Valve Actuator as follows:

1. Loosen the locknut on the thermal element adjustment sleeve. Unscrew the adjustment
sleeve to remove the sleeve and thermal element from the Actuator.

2. Carefully loosen the compression fittings on the upstream and downstream tubing to relieve
any trapped pressure buildup. Completely remove both the upstream and downstream
tubing assemblies and compression fittings. The tapped NPT ports in the Valve Body will be
plugged during the replacement procedures in Section 3.

3. Remove the hex head cap screws securing the Actuator to the Valve Body. Valve sizes
from 1” to 2” have 6 cap screws, while sizes 2 ½” to 4” Valves have 8 cap screws.

CAUTION

Use care when performing step 4 to avoid damaging or scratching internal
Valve Body parts. It is imperative that the Actuator be lifted straight up to
avoid sticking or binding.

4. Lift the Actuator Housing straight up and off the Valve Body. Doing so will also remove the
entire inner valve assembly (Figure 2-7), including the Valve Stem, Seat, Valve Plug Shaft
and Top/Bottom Pistons. Depending on the age and condition of the valve, considerable
force may be required to pull the Pistons through the Valve Body. If it cannot be removed,
the Valve Stem may be used as an impact hammer to remove scale build-up on the internal
valve surfaces and allow Piston removal.

Replacement parts for these removed items are provided in the applicable Retrofit Kit for
the Valve size being retrofitted. These items will be replaced in Section 3. The Retrofit Kit
also contains a new Lower Shaft, Valve Top/Gasket, plus additional replacement items for
the Valve being retrofitted.

5. Proceed as follows, depending on the size of the Valve being retrofitted:

(a) For 2 ½ to 4 inch Valves, separate the Valve Seat Retaining Disc from the Valve Seat

by removing the four (4) cap screws (Figure 2-7).

(b) For 1 to 2 inch Valves, hold the Valve Plug Shaft with a pair of pliers and remove the

Valve Stem Retaining Nut from the Shaft (Figure 2-8).

6. Insert a 1/8 inch steel rod through the hole near the top of the Valve Stem (Figure 2-7 or 2-

8).

NOTE

If “flats” are provided on the Actuator Connecting Shaft and Valve Stem,
open-end wrenches may be used in step 7 to disconnect the Valve Stem
and Actuator Shaft.

7. Grasp the Actuator Connecting Shaft (Figure 2-7 or 2-8) with a pair of pliers. Carefully turn
the Valve Stem counterclockwise and separate it from the Actuator Connecting Shaft.

8. Replacement of all required Valve parts will be accomplished using the appropriate
instructions and illustrations in Section 3.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

THERMAL ELEMENT
ADJUSTMENT SLEEVE

LOCKNUT

1/8" NPT
COMPRESSION
ELBOWS

UPSTREAM
TUBE

DOWNSTREAM

TUBE

HEX HEAD
CAP SCREWS

1/4" NPT
COMPRESSION
ELBOW

VALVE

BODY

Technical Instruction Document TID-0141_0A

Figure 2-6. Self-Contai ned Control Valve Actuator Removal

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ACTUATOR
CONNECTING
SHAFT

ACTUATOR

HOUSING

VALVE

BODY

VALVE STEM

TOP PISTON

BOTTOM

PISTON

HOLE

VALVE SEAT

RETAINING

DISC

CAP SCREWS
(4)

VALVE SEAT

ACTUATOR
CONNECTING
SHAFT

HOLE

VALVE STEM

RETAINING

NUT

VALVE PLUG
SHAFT

VALVE

BODY

Technical Instruction Document TID-0141_0A

Figure 2-7. Self-Cont ained Control Valve Actuator Removal – 2 ½” to 4”

Figure 2-8. Self-Cont ained Control Valve Actuator Removal – 1” to 2”

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

2.6 CONTROL BOX REMOVAL

The existing Control Box (Figure 2-1) is secured to the Heat Exchanger using a special mounting
bracket. The top end of this mounting bracket contains a slotted cutout which is inserted around
one of the studs securing the top head to the shell flange. A hex nut secures the bracket in place.
The currently installed Control Box will no longer be used. However, the mounting bracket will be
reused to mount the new ECS Control Box. Remove the Control Box and mounting bracket
assemblies as follows:

1. Check to ensure that the external power source has been turned off.

2. Disconnect all power supply wiring to the Control Box. Also, disconnect all wiring between
the Control Box and any external Solenoid Valves.

3. If a Pneumatic Control Valve Actuator is currently installed on the Heater, disconnect the air
supply and control air tubing from the Control Box.

4. Disconnect the Pressure Gauge compression fittings.

5. Cut all wire ties leading to the Control Box. Do not cut the thermal element.

6. Loosen, but do not r emove, the hex nut securing the Control Box Mounting Bracket to the
Top Head stud (Figure 2-9).

7. Completely remove the Control Box and Mounting Bracket from the Water Heater.

8. Open the Control Box door. From the rear of the Control Box, remove the six 8-32 screws
securing the Rear Mounting Panel to the enclosure (Figure 2-10).

9. Remove the Rear Mounting Panel from the Control Box to access the two screws securing
the Mounting Bracket to the Box

IMPORTANT

Save the Control Box Mounting Bracket when it is removed from the
Control Box. This Mounting Bracket will be used to install the new ECS
Control Box.

10. Remove the two screws securing the Mounting Bracket to the Control Box. Separate the
Control Box and Mounting Bracket. This Control Box will no longer be used and can be
discarded. However, the Mounting Bracket will be reused to attach the new ECS Control
Box to the Heater in Section 4.

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 21 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

HEX NUT

TOP HEAD

SHELL FLANGE

MOUNTING

BRACKET

(SAVE)

HEX NUT

CONTROL

BOX

DETAIL “A”

CONTROL

BOX

SEE

DETAIL “A”

TOP HEAD

SHELL FLANGE

MOUNTING

BRACKET

STUD

Technical Instruction Document TID-0141_0A

Figure 2-9. Control Box Mounting Details

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

SHELL OUTLET

°F PSIG

STEAM PRESS.

CALIBRATED CONTROLLER

ADJUST SETPOINT DIAL

TO DESIRED TEMPERATURE

ONLY

REFER TO MANUAL AC-103

FOR MAINTENANCE INSTRUCTIONS

PT.NO.123151

MOUNTING
BRACKET
(SAVE)

8-32 x 3/8" LG.

SCREWS (QTY=6)

MOUNTING
BRACKET
SCREW

CONTROL BOX USED WITH PNEUMATIC CONTROL VALVE

REAR

MOUNTING

PANEL

TOP

MOUNTING
BRACKET
SCREW

REAR

MOUNTING

PANEL

Technical Instruction Document TID-0141_0A

Figure 2-10. Control Box With Door Open

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

3. RECOMMENDED REPLACEMENT OF VALVE ASSEMBLY PARTS

As mentioned in section 2.5, AERCO recommends that the Valve Seat and Packing be replaced
on the Valve Body, prior to installing the ECS Retrofit Kit items described in Section 4. Valve
Bodies which previously utilized Self-Contained Actuators must be modified to include new
additional items such as: a Valve Top, Valve Stem and a Packing Nut.

Refer to the applicable sections which follow for the Valve size and Actuator type used on your
system.

NOTE

The procedures in sections 3.1 and 3.2 which follow, assume that the
previously installed Pneumatic, Electro-Hydraulic or Self-Contained
Actuator has already been removed.

3.1 VALVES PREVIOUSLY EQUIPPED WITH PNEUM ATIC OR ELECTRO-HYDRAULIC

ACTUATORS

The parts replacement items required for Valve Bodies which previously used Pneumatic or
Electro-Hydraulic Actuators are basically identical. Only minor variations exist for the various
Valve Body sizes. The Valve Body components for 1.00” to 2.00” and 2.50” to 4.00” are shown in
Figures 3-1 and 3-2, respectively.

3.1.1 Valve Disassembly Procedure

Proceed as follows:

NOTE

Steps 1 through 5 which follow apply to all valve sizes shown in Figure 3-1
and 3-2.

1. Remove the Hex Nut (17) from the Valve Body Shaft.

2. Remove the Packing Nut (18) and Packing Assembly (20).

3. Remove the Bolts or Cap Screws (14) securing the Valve Top (21).

4. Remove the Valve Top (21) and Valve Top Gasket (13).

5. Carefully lift out the entire Shaft /Seat / Piston Assembly.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

6. For 1 inch to 2 inch Valve sizes, refer to Figure 3-1 and remove the following items in the
order specified:

(a) Lock Washer (23)
(b) Retaining Ring (11)
(c) Pilot Spring (10)
(d) Valve Stem Retaining Nut (35)
(e) Lower Shaft (16) and Valve Stem (12)
(f) Retaining Disc (8)
(g) Disc Seat (7)
(h) Seat Retainer (34)
(i) Valve Plug Shaft (5)

7. For 2 ½, 3 and 4 inch Valve sizes, refer to Figure 3-2 and remove the following items in the
order specified:

(a) Lock Washer (23)
(b) Pilot Spring Retainer (11)
(c) Pilot Spring Backup Washer (31), - 4 inch Valve Only
(d) Pilot Spring (10)
(e) Socket Head Cap Screws (9)
(f) Valve Seat Retaining Disc (8)
(g) Lower Shaft (16) and Valve Stem (12)
(h) Valve Seat (7)
(i) Top Piston (6) and Bottom Piston (3) Assemblies

8. Clean all parts thoroughly and remove all dirt and/or scale.

9. Next, proceed to the Valve Reassembly procedures in section 3.1. 2 and replace the items
indicated with the new parts provided in the Retrofit Kit.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

3

2

6

24

13

14

1

5

7

8

12

20

18

16

35

10

32

31

23

33

34

11

21

17

Technical Instruction Document TID-0141_0A

Figure 3-1. Valve Assembly Sizes 1.00” to 2.00”

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 26 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PA RT NAME

1.00 INCH

1.25 INCH

1.50 INCH

2.00 INCH

1 1 VALVE BODY

20762

20759

20758

20761 2 1

SEAT CAGE

16844

16845

16837

16843 3 1

BOTTOM PISTON

121540

121525

121502

121529 4

NOT USED

5 1 VALVE PLUG SHAFT

16849

16839

16838

16848 6 1

TOP PISTON

121539

12154

121501

121530

7 1 DISC SEAT

121541

121527

121510

121531

8 1 RETAINING DISC

121542

121513

121504

121532 9

NOT USED

10 PILOT SPRING

121528

121528

121528

121528

11 1 RETAINING RING

121545

121545

121545

121545

12 1 VALVE STEM

122655

122654

122651

122650

13 1 VALVE TOP GASKET

122136

122136

122136

122136

14 6 BOLT, HEX, 3/8-16

122405

122405

122405

122405

16 1 LOWER SHAFT

121979

121980

121980

121982

17 2 HEX NUT, 1/4-20

6-226

6-226

6-226

6-226

18 1 PACKING NUT

122664

122664

122664

122664

19 2 BOLT, HEX 3/8-16 x 5/8 LG

54014

54014

54014

54014

20 1 PACKING ASSY

121567

121567

121567

121567

21 1 VALVE TOP

16943

16943

16943

16943

22 NOT USED

23 1 LOCKWASHER

122666

122666

122666

122666

24 1 SEAT CAGE GASKET

123080

123081

123082

123083

ITEMS

30

31 1 BOTTOM PISTON RETAINING NUT

122982

122982

122982

122982

32 1 TOP PISTON RETAINING NUT

121543

121543

121543

121543

33 1 LOWER PILOT SEAT ASSY

121505

121505

121505

121505

34 1 SEAT RETAINER

N/A

121559

121506

121506

35 1 VALVE STEM RETAINING NUT

121503

121503

121503

121503

Technical Instruction Document TID-0141_0A

PARTS LIST TABLE FOR VALVE ASSEMBLY SIZES 1.00” TO 2.00”

25

THRU

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NOT SHOWN

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

16

18

20

21

23

22

24

2

1

3

5

4

6

7

8

9

10

14

11

12

13

31

17

Technical Instruction Document TID-0141_0A

Figure 3-2. Valve Assembly Sizes 2.50” to 4.00”

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 28 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PA RT NAME

2.50 INCH

3.00 INCH

4.00 INCH

1 1 VALVE BODY

20765-1

20766-1

20775 2 1

SEAT CAGE

16961

161004

161046 3 1

BOTTOM PISTON

16962

161007

161048 4 1

PISTON RETAINING RING

122173

122173

122234 5 1

VALVE PLUG SHAFT

16972

161006

161047 6 1

TOP PISTON

16970

161005

161050 7 1

VALVE SEAT

121935

122032

122178 8 1

VALVE SEAT RETAINING DISC

121934

122031

122177 9 4

10-32 x 3/4” LG. SOCKET HD. CAP

122174

122174

122238

10

1

PILOT SPRING

122081

122232

121823

11

1

PILOT SPRING RETAINER

122082

122082

122173

12

1

VALVE STEM

122648

122658

122659

13

1

VALVE TOP GASKET

122083

122204

122203

14

4

CAP SCREW 5/8-11 x 1-1/2” LG.

N/A

6-310

6-310

15

2

3/8-16 NUT (4” VALVE ONLY)

N/A

N/A

6-264

16

1

LOWER SHAFT

122223

122230

122224

17

2

1/4-20 NUT

6-226

6-226

N/A

18

1

PACKING NUT

122664

122665

122665

19

2

3/8-16 x 5/8” LG. CAP SREWS

54014

54014

54014

20

1

PACKING ASSY

121567

121568

121568

21

1

VALVE TOP

18781

18823

18824

22

1

SEAT BACK-UP RING

122326

122327

122328

23

1

LOCKWASHER

122666

122667

122667

24

1

SEAT CAGE GASKET

123084

123085

123086

ITEMS

30

31

1

PILOT SPRING BACKUP WASHER

N/A

N/A

122246

Technical Instruction Document TID-0141_0A

PARTS LIST TABLE FOR VALVE ASSEMBLY SIZES 2.50” TO 4.00”

25

THRU

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NOT SHOWN

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

3.1.2 Valve Reassembly Procedure

Reassembly is accomplished by basically reversing the previous Disassembly steps. Refer to
Figure 3-1 or 3-2 for the applicable Valve size. Perform the following steps in the order specified
and REPLACE the items shown in BOLD type with the new parts provided in the Retrofit Kit.

1. For 1 inch to 2 inch Valve sizes, refer to Figure 3-1 and reassemble or replace the following
items in the order specified:

(a) Valve Plug Shaft (5)
(b) Seat Retainer (34)
(c) Replace Disc Seat (7)
(d) Retaining Disc (8)
(e) Lower Shaft (16) and Valve Stem (12)
(f) Valve Stem Retaining Nut (35)
(g) Pilot Spring (10)
(h) Retaining Ring (3)
(i) Lock Washer (23)
(j) Proceed to step 3 and continue the Valve Reassembly process. Steps 3 through 6

apply to ALL valve sizes.

2. For 2 ½, 3 and 4 inch Valve sizes, refer to Figure 3-2 and reassemble or replace the
following items in the order specified:

(a) Top Piston (6) and Bottom Piston (3) Assemblies
(b) Replace Valve Seat (7)
(c) Lower Shaft (16) and Valve Stem (12)
(d) Valve Seat Retaining Disc (8)
(e) Socket Head Cap Screws (9)
(f) Pilot Spring (10)
(g) Pilot Spring Backup Washer (31), - 4 inch Valve Only
(h) Pilot Spring Retainer (11)
(i) Lock Washer (23)
(j) Proceed to step 3 and continue the Valve Reassembly process. Steps 3 through 6

apply to ALL valve sizes.

3. Replace Valve Top Gasket (13) and reassemble Valve Top (21) on Valve Body (1).

4. Secure Valve Top (21) to Valve Body (1) with the Bolts or Cap Screws (14).

5. Replace Packing Assembly (20) and reassemble Packing Nut (18) in Valve Top (21).

6. The last step of the Valve Reassembly procedure is to replace two Hex Nuts on the Valve
Shaft. Valve sizes from 1 to 3 inches contain two 1/4-20 Hex Nuts in the Retrofit Kit.
However, 4 inch Valves contain two 3/8-16 Hex Nuts in the Kit. Replace the appropriate Hex
nuts on the Valve Shaft.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

3.2 VALVES PREVIOUSLY EQUIPPED WITH SELF-CONTAINED ACTUATORS

The internal parts and assemblies contained in Valves which were previously equipped with Self­Contained Actuators must basically be rebuilt with the items provided in the Retrofit Kit. The
Retrofit Kit for Valve sizes from 1.00” to 2.00” include an Inner Pilot Assembly Kit (29021-[ ]) and
a Valve Piston Assembly Kit (12168-[ ]). The items in these kits are shown in Figures 3-3 and 3-4.
Kits for Valve sizes from 2.50” to 4.00” include a Main Valve Assembly Kit (27006-[ ]) containing
the items shown in the exploded view in Figure 3-5.

In addition to replacement the parts contained in these Kits, new items must be added to ALL
Valve Bodies which previously used Self-Contained Actuators. These items include:

• Lower Shaft

• Valve Top

• Valve Top Gasket

• Hex Bolts (1” to 2” Valves) or Cap Screws (2.5” to 4.0” Valves) to secure Valve Top

• Packing Assembly

• Packi ng Nut

• 1/4” NPT Plugs which get inserted into tapped holes in Valve Body

Refer to Figure 3-1 (1” to 2” Valves) or Figure 3-2 (2.5” to 4” Valves) for the locations of these
items.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

1

2

3

4

5

PRE-LOAD SPRING RETAINING RING

VALVE STEM RETAINING NUT

1.00"-2.00" CXT-P (PNEUMATIC)

VALVE STEM

LOWER PILOT PRE-LOAD SPRING

1

3
4

1

ITEM

2

1

REQ

1

1

121545

121503

122655

121528

1.00"

DESCRIPTION

121528

121528

121528

121545

121545

121545

121503

122651

121503

122654

1.25"

121503

122650

1.50" 2.00"

5

1 LOCKWASHER

122666 122666 122666 122666

Technical Instruction Document TID-0141_0A

Figure 3-3. Inner Pilot Assembly Kit (29021-[ ]) for 1.00” to 2.00” Valves

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

3

18

39

38

37

33

42

40

43

BOTTOM PISTON RETAINING NUT

LOWER PILOT SEAT ASSEMBLY

TOP PISTON RETAINING NUT

1

3

122982

121618-1.50 (1.50 PARTS LIST)

PART NO.ITEM REQ DESCRIPTION

DISC SEAT

DISC RETAINER

121543

121505

18

33

1

1

121510

121504

37

38

1

1

SEAT RETAINER (SEE NOTE 2)

43

TOP PISTON

BOTTOM PISTON

VALVE PLUG SHAFT

121501

121506

39

40

1

1

16838

121502421

1

SEAT RETAINER (SEE NOTE 2)

TOP PISTON RETAINING NUT

LOWER PILOT SEAT ASSEMBLY

BOTTOM PISTON RETAINING NUT

42

DESCRIPTIONREQITEM PART NO.

121618-2.00 (2.00 PARTS LIST)

DISC RETAINER

121505

122982

3

18

1

1

121532

121543

33

37

1

1

BOTTOM PISTON

TOP PISTON

DISC SEAT

121530 1

40

121506

121531

38

39

1

1

121529 1

VALVE PLUG SHAFT16848431

REQUIRED FOR 1.00 VALVE

NOTES:

121618-1.00 (1.00 PARTS LIST)

1122982

3

PART NO.ITEM REQ

33

121543

121505181

1

-

37

38

-

1

BOTTOM PISTON RETAINING NUT

DESCRIPTION

LOWER PILOT SEAT ASSEMBLY

TOP PISTON RETAINING NUT

SEAT RETAINER (SEE NOTE 1)

DISC SEAT

121539

39

40

1 TOP PISTON

42

43

121542 1 DISC RETAINER

121541

121540 BOTTOM PISTON1

16849 1 VALVE PLUG SHAFT

SEAT RETAINER (SEE NOTE 2)

TOP PISTON RETAINING NUT

LOWER PILOT SEAT ASSEMBLY

BOTTOM PISTON RETAINING NUT

1

18

121505

121618-1.25 (1.25 PARTS LIST)

PART NO.

122982

3

ITEM

1

REQ DESCRIPTION

DISC RETAINER

DISC SEAT

121513

121543

33

37

1

1

121527

38

39

1

VALVE PLUG SHAFT

BOTTOM PISTON

TOP PISTON

1121525

42

121514401

16839431

121559 1

Technical Instruction Document TID-0141_0A

Figure 3-4. Valve Piston Assembly Kit (121618-[ ]) for 1.00” to 2.00” Valves

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 33 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE PLUG SHAFT

BOTTOM PISTON

SEAT CAGE

SOCKET HEAD CAP SCREW

SEAT

RETAINING DISC

TOP PISTON

VALVE STEM

LOWER PILOT SPRING

PILOT SPRING BACK-UP WASHER

LOWER PILOT SPRING RETAINER

PISTON RETAINING RING

LOCKWASHER

SEAT BACK-UP RING

SEAT CAGE GASKET

1

1

1

3

2

1

5

4

1

6

1

1

4

8

7

1

9

1

1

13

11

10

1

1

12

1

14

1

15

1

16961

16972

16962

161004

161006

161007

161046

161047

161048

121935

16970

122648

122032

161005

122658

122174

121934

122081

122174

122031

122232

122178

161050

122659

122238

122177

122233

N/A N/A

122173

122082

122666

122173

122082

122667

122326

123084

122327

123085

122246

122234

122173

122667

122328

123086

PARTS LIST

ITEM

2 1/2"

QTY.

DESCRIPTION

3" 4"

15

1

11

2

3

4

14

5

6

7

8

9

13

12

10

Technical Instruction Document TID-0141_0A

Figure 3-5. Main Valve Assembly Kit (27006-[ ]) for 2.50” to 4.00” Valves

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 34 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ADAPTER

PART NO. 24038-1

(FOR 1 TO 3 IN. VALVES)

USE THIS PIN

LOCATION FOR

4 IN. VALVES

USE THIS PIN

LOCATION FOR

1 - 2 IN. VALVES

ADAPTER

PART NO. 24038-2

(FOR 4 IN. VALVE ONLY)

13 - 3/8 IN.

4–1/2 IN. x

1-15/16 IN. WIDE

USE THIS PIN

LOCATION FOR

2 -1/2 & 3 IN.

VALVES

INDICATOR

PLATE

INDICATOR

PLATE

Technical Instruction Document TID-0141_0A

4. INSTALLATION OF RETROFIT KIT ITEMS

When installing the new Electronic Control Valve Actuator and Electronic Control System (ECS)
Control Box, a number of ancillary items must also be installed or replaced. These include a new
Flow Meter, a replacement Water Solenoid Valve and several Temperature Sensors.

To install the Retrofit Kit items, proceed as follows:

4.1 INSTALLATION OF CONTROL VALV E ACTUATOR AN D LINKAGE ASSEMBLY

Identical Actuator Assemblies, part no. 69170 are used on all AERCO Control Valve sizes from 1
inch to 4 inches. However, there are two types of Linkage Assemblies designated part no. 24038­1 and -2 used with different sizes of AERCO Control Valves. Linkage Assembly, part no. 24038-1
is used on AERCO Valve sizes ranging from 1 inch to 3 inches. The 24038-2 Linkage Assembly is
used only on 4 inch Valves. The primary difference between these two assemblies is the Linkage
Assembly Adapter shown in Figure 4-1. In addition, the linkage pin location for 24038-1
assemblies will vary for 1 to 2 inch Valves and for 2 ½ to 3 inch Valves, as shown in the upper
portion of Figure 4-1.

Figure 4-1. Linkage Assemblies Part No. 24038-1 & 240 38-2

The installation procedures for the Linkage Assembly and Actuator Assembly are provided in
sections 4.1.1 and 4.1.2, below.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

4.1.1 Linkage Assembly Installation

Remove the Linkage Assembly from the Retrofit Kit and install as follows:

1. Check to ensure that the correct Linkage Assembly and Adapter are provided for the valve
size being retrofitted (Figure 4-1). Also, ensure that the Linkage pin is inserted in the correct
location for this valve size.

CAUTION

It is imperative that the Gasket provided with the Linkage Assembly
be installed between the Valve Top and Linkage Assembly. Failure
to do so will void the equipment warranty.

2. Refer to Figure 4-2 and position the Gasket and Linkage Assembly on the Valve Top as
shown.

3. Secure the Linkage Assembly to the Valve Top using the two 3/8-16 Hex Head Bolts
provided.

4. Install two 1/4-20 Hex Nuts (1 to 3 inch Valves), or two 3/8-16 Hex Nuts (4 inch Valve) on
the Valve Shaft (Figure 4-2).

5. Rotate the two Hex Nuts clockwise towards the lower end of the Valve Shaft.

6. Install the Indicator Plate on the Valve Shaft with the curved end facing upward as shown in
Figure 4-3.

7. Attach the Valve Shaft to the Linkage Adapter by rotating the Shaft counterclockwise (as
viewed from above). If the Valve Shaft cannot be turned by hand, use an open-end wrench
to turn the “double-nuts” on the Shaft until it engages the Linkage Adapter threads.

8. Press down on the Valve Shaft to compress the Pilot Spring in the Valve Body.

9. Raise the Indicator Plate so it is contacting the bottom of the Adapter and observe the
position on the Linkage Scale. Rotate the Valve Shaft as necessary until the raised Indicator
Plate is aligned with the “0” (zero) marking on the Linkage Scale.

10. When properly aligned, raise the Hex Nuts on the Valve Shaft by rotating them
counterclockwise. Position the Hex Nuts so they are snug against the Indicator Plate.

11. Proceed to section 4.1.2 to install the Actuator Assembly.

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GASKET

INDICATOR
PLATE

ACTUATOR

LINKAGE

ADAPTER

VALVE TOP

HEX HEAD

BOLTS (2)

U-BOLT &

HEX NUTS

VALVE SHAFT

HORIZONTAL
SHAFT

8 mm HEX NUTS (2)
(ON BOTTOM SIDE
OF BRACKET)

HEX NUTS (2)

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

Figure 4-2. Actuator and Linkage Installation Details

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

SHAFT PIN
LOCATION

LINKAGE ADAPTER

INDICATOR
PLATE

0

1

LINKAGE
ASSEMBLY

SCALE

PACKING NUT

VALVE TOP

LINKAGE

GASKET

HEX NUTS (2)

VALVE SHAFT

VALVE BODY

5

CAP SCREW

8-32 HEX NUT
(FAR SIDE)

4

INDICATOR PLATE

(CURVED END)

3

2

1

59028-1 (1” VALVE)

Technical Instruction Document TID-0141_0A

4.1.2 Actuator Installation

Remove the Actuator Assembly (69170) from the Retrofit Kit and install as follows:

ITEM QTY PART DESCRIPTION PART NUMBER

1 1 LINKAGE ASSEMBLY 24038-1 (1” TO 3” VALVES)
2 1 SCALE

59028-1.25 (1.25” VALVE)
59028-1.5 (1.5” VALVE)
59028-2 (2” VALVE)
59028-2.5 (2.5” VALVE)
59028-3 ( 3” VALVE)

59028-4 (4” VALVE)
3 2 8-32 HEX NUT 123322
4 2 3/8-16 X 5/8 LONG CAP SCREW 54014
5 1 GASKET 81046

Figure 4-3. Linkage Installation Details

1. Depress and hold the Clutch Button (Figure 4-4) and rotate the pointer to approximately 80°
on the dial. Release the Clutch Button when properly positioned.

CAUTION

DO NOT DEPRESS THE CLUTCH BUTTON WITH POWER APPLIED
TO THE ACTUATOR

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

0

90

neptronic

1 2 3

COVER
SET SCREW

CLUTCH

DIAL &

POINTER

CENTER

SLOT

COVER

CABLE

CONNECTOR

LINKAGE

SHAFT

Technical Instruction Document TID-0141_0A

2. Slide the Actuator onto the Linkage Assembly Shaft (Figures 4-2 & 4-4). Ensure that the pin
on the Linkage Assembly is inserted in the center slot on the bottom of t he Actuator (Figure
4-4).

3. Press down on the Linkage Adapter and verify that the Indicator Plate is aligned with the “0”
Scale marking.

4. With the Indicator Plate properly aligned, tighten the U-bolt hex nuts using an 8 mm wrench.
Torque the nuts to 60 in-lbs.

5. This completes the mechanical installation of the Actuator Assembly. The electrical
connections will be made during installation of the Control Box in section 4.7.

Figure 4-4. Actuator Assembly, Part No. 69170

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

4.2 INSTALLATION OF ECS COMPONENTS ON TOP HEAD ASSE MBL Y

The ECS to be installed on the Top Head Assembly include:

• Outlet Flange & Gasket

• Outlet Temperature Dual Sensor

• Water Solenoid Valve and piping

• Plugs for previously installed: Shunt Tube, Thermal Element, Feedback Sensor, etc.,

etc.

4.2.1 Outlet Flange

New Outlet Flange (95015) and Gasket (122152) are provided in the Retrofit Kit. This new Flange
contains a tapped hole which permits easy installation of the new Outlet Temperature Dual
Sensor described in para. 4.2.2. To install the new Outlet Flange and Gasket:

1. Ensure that the Outlet opening in the Top Head (see Figure 2-1, sht. 3) has been thoroughly
cleaned of any gasket residue from the previously installed gasket.

2. Position the new Outlet Flange and Gasket on the four studs protruding from the Top Head
on the Heater.

3. Secure the Outlet Flange to the Top Head using the four hex nuts previously removed in
para. 2.3, step 8. Tighten the hex nuts using an alternating pattern to obtain a uniform seal.
Reconnect the outlet piping to new Outlet Flange.

4.2.2 Outlet Temperature Dual Sensor

The Outlet Temperature Dual Sensor (61008-1) provided in the Retrofit Kit includes two Type J
Thermocouples which are housed in a thermowell. The Thermocouple leads are terminated with a
4-pin connector.

1. Install the Outlet Temperature Dual Sensor in the tapped hole provided on the new Outlet
Flange installed in the previous section.

2. Connection of the Dual Sensor electrical connector will be accomplished following
installation of the ECS Control Box (para. 4.4).

4.2.3 Water Solenoid

The 120 VAC Water Solenoid removed in Section 2 will be replaced with the 24 VDC Solenoid
Valve provided in the Retrofit Kit. Proceed as follows:

1. Attach the new Solenoid Valve (92110) to the nipple in the Top Head (ref. Figure 2-1, sht. 3)

2. Reconnect the previously installed drain piping to the Solenoid Valve outlet.

3. Electrical connection of the Solenoid Valve will be accomplished following installation of the
ECS Control Box.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

4.2.4 NPT Plugs

Each Retrofit Kit contains f o ur NPT Plug s in the following sizes:

• 1/4 inch

• 1/2 inch

• 3/4 inch

• 1 inch

These plugs are installed in the remaining tapped holes in the Top Head where components used
with the previous Control System were installed. The location and size of the required Plugs may
vary depending on the specific AERCO Heater Model being retrofitted. Refer to Figure 2-1 for
reference.

Ensure that all tapped holes in the Top Head have been plugged before proceeding with the
installation.

4.3 FLOW METER INSTALLATION

As part of the Electronic Control System (ECS) Retrofit, a new Flow Meter must be added to the
Packaged Heater. The purpose of this meter is to provide a feed-forward signal to the
Temperature Controller contained in the ECS Control Box. The installation location will vary
depending on whether the AERCO Water Heater Model being retrofitted is a Helitherm Heat
Exchanger (A-Plus, B-Plu s, B-Plus II and E-Plus), or a Water-to-Water Double-Wall Heat
Exchanger (WWDW-24, WWDW-45, WWDW-68). For Helitherm Model Heaters, the Flow Meter
is installed between the Cold Water Inlet and the Drain Outlet on the Bottom Head of the Heater
(Figures 4-5 and 4-6). How ever, for Water-to-Water Double Wall Heater Models, the Flow Meter is
installed between the Cold Water Inlet and Drain Outlet on the Heater Shell. See Figure 4-7. All
required installation components are included in the Retrofit Kit. Proceed to section 4.3.1
(Helitherm) or 4.3.2 (Water-to-Water Double-Wall), as applicable.

IMPORTANT

Prior to installing the inlet or outlet tubes to the Flow Meter (step 2 of
sections 4.3.1 and 4.3.2), it will be necessary to first temporarily remove
the strain relief assembly shown in Figure 4-8. After removal, perf orm the
following steps:

1. First, hand-tighten the inlet and outlet tube compression fittings to the
Flow Meter. Position the “flats” on the fitting to avoid interfering with
reinstallation of the strain relief in the next step.

2. Next, attach the strain relief to the Flow Meter cable (Figure 4-8).

3. After the strain relief is installed, fully tighten the inlet and outlet tube
compression fittings to the Flowmeter.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

INLET TUBE

COLD WATER

INLET

FLOW

METER

FRONT

HEATER

SHELL

DRAIN

BOSS

FLEXIBLE

OUTLET

TUBE

DRAIN WITH

MODIFIED

NIPPLE

FRONT

COMPRESSION FITTING

(1/4" NPT x 1/2" TUBE)

INLET TUBE

FLEXIBLE OUTLET TUBE

COMPRESSION FITTINGS

(1/2" NPT x 1/2" TUBE)

COLD WATER

INLET

DRAIN WITH

MODIFIED

NIPPLE

COMPRESSION FITTINGS

(1/2" NPT x 1/2" TUBE)

FLOW METER

REAR

COMPRESSION FITTING

(1/4" NPT x 1/2" TUBE)

TO ECS

CONTROL

BOX

Technical Instruction Document TID-0141_0A

Figure 4-6. Typical (B+) Helitherm Heater Flow Meter Location – Bottom View

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Figure 4-5. Typical (B+) Helitherm Heater Flow Meter Location – Front View

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

COLD

WATER

INLET

DRAIN

PORT

TEE

3/4" CLOSE

NIPPLE

DO NOT

LEAK DETECTION PORT

PLUG OR OBSTRUCT !

EXCHANGER CONSTRUCTED WITH

THIS IS A VENTED U - TUBE HEAT

AN INNER OR OUTER TUBE

FAILURE IS INDICATED BY

DOUBLE WALL TUBE.

FRONT

SIDE

Technical Instruction Document TID-0141_0A

Figure 4-7. Water-to-Water Double-Wall Heater Flow Meter Location

4.3.1 Flow Meter Installation For Helitherm Heaters

For A-Plus, B-P l us, B-Plus II and E-Plus Heaters, the Flow Meter connections are made at the
Bottom Head of the Heater. The Flow Meter Inlet side connects to the Cold Water Inlet using
Rigid Tubing. However, the Outlet side of the Flow Meter connects to the Drain Outlet using
Flexible Tubing. A typical B-Plus or B -Plus II installation is shown in Figures 4-5 and 4-6. Refer to
these Figures when performing the following steps:

1. Obtain the Flow Meter, Rigid Inlet Tube, Flexible Outlet Tube and Compression Fittings
from the Retrofit Kit. Refer to Appendix A for the applicable part numbers for the tubing and
fittings required for the unit being retrofitted.

2. Attach the Rigid Inlet Tube and Flexible Outlet Tube to the Flow Meter using the fittings
provided in the kit.

3. Next, obtain the Modified 2” NPT Nipple (9006) from the Retrofit Kit.

4. Remove the existing 2’ NPT Nipple from the Drain Outlet on the Bottom Head.

5. Install the new Modified 2” NPT Nipple in the Bottom Head. Attach the ¼ NPT coupling to
the tapped hole in the Modified Nipple.

6. Connect the Flow Meter Outlet Flexible Hose to the Modified Nipple on the Drain Outlet
using the compression fitting. Connect the Rigid Flow Meter Inlet Tube to the Cold Water
Inlet using the compression fitting provided in the kit.

7. Position the Flow Meter so that the Paddle Wheel is in the “Vertical” plane as shown in
Figure 4-8. Tighten all Flow Meter connection fittings.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

FRONT

VERTICAL

SIDE

STRAIN
RELIEF

PADDLE

WHEEL

SHAFT

Technical Instruction Document TID-0141_0A

Figure 4-8. Flow Meter Orientation

4.3.2 Flow Meter Installation For Water-to-Water Double-Wall Heaters

Flow Meter connections for Double-Wall Heater Models WWDW-24, WWDW-45 and WWDW-68
are made on the Shell as shown in Figure 4-7. As with Helitherm Models, Rigid Tubing is used for
the Flow Meter Inlet connection to the Cold Water Inlet and Flexible Tubing is used for the Outlet
connection at the Drain. Flow Meter installation is accomplished as follows:

1. Obtain the Flow Meter, Rigid Inlet Tube, Flexible Outlet Tube and Compression Fittings
from the Retrofit Kit.

2. Attach the Rigid Inlet Tube and Flexible Outlet Tube to the Flow Meter using the fittings
provided in the kit.

3. Next, obtain the 3/4” Close Nipple (9-234) and 3/4 x 1/4 x 3/4” Tee (59032) from the Retrofit
Kit.

4. If installed, remove the 3/4” NPT Plug from the Drain Port on the Heater Shell (Ref. Figure
2-2, sht 1).

5. Install the Close Nipple and Tee in the Drain Port (Figure 4-7)

6. Connect the Flow Meter Outlet Flexible Tubing to the Drain Outlet Tee as shown in Figure
4-7. Connect the Rigid Inlet Tube from the Flow Meter to the Cold Water Inlet using the
compression fitting provided.

7. Position the Flow Meter so that the Paddle Wheel is in the “Vertical” plane as shown in
Figure 4-8.

NOTE

Section 4.4 applies ONLY to Water-to-Water He at er Models which include
E-Plus and Water-to-Water Double-Wall Models. Disregard the
procedures in section 4.4 for ALL Steam-to-Water Heater Models and
proceed directly to section 4.5.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

4.4 BOILER WATER INLET AND OUTLET TEMPER ATURE SENSORS – (WATER-TO-

WATER HEATERS)

If the Water Heater being retrofitted is an E-Plus or a Water-to-Water Double-Wall, two additional
Temperature Sensors (Type J Thermocouples) must be added. These are the Boiler Water Inlet
Temperature Sensor and Boiler Water Outlet Temperature Sensor. For E-Plus (Helitherm)
Heaters, the Inlet and Outlet Sensors are mounted in the Bottom Head and Top Head,
respectively as shown in Figure 4-9. For Water-to-Water Double-Wall Heaters, the Boiler Water
Inlet and Outlet Temperature Sensors are mounted at the locations shown in Figure 4-10.

These two additional Temperature Sensors are identical (part no. 61009-1) and therefore can be
installed in either location.

4.4.1 E-Plus Water Heaters

Refer to Figure 4-9 and install the Boiler Water Inlet and Outlet Sensors as follows:

1. Check to ensure that the capillary tubes and compression fittings have been removed from
the Boiler Inlet and Outlet Valve Spool Piece Assemblies shown in Figure 4-9. If they have
not been previously remove, disconnect and remove these items at this time.

2. Install the Boiler Water Inlet Temperature Sensor in the tapped opening in the Valve Spool
Piece Assembly which connects to the Boiler Water Inlet on the Bottom Head Heater.

3. Install the Boiler Water Outlet Temperature Sensor in the tapped opening in the Valve Spool
Piece Assembly which connects to the Boiler Water Outlet on the Top Head of the Heater.

4. The electrical connector plugs on the Inlet and Outlet Boiler Water Temperature Sensors
will be connected after the ECS Control Box is installed (section 4.5).

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

BOILER WATER
OUTLET

BOILER WATER
INLET

CXT-E

CONTROL

VALVE

BOILER WATER
INLET SENSOR
LOCATION

BOILER WATER
OUTLET SENSOR
LOCATION

VALVE SPOOL

PIECE ASSEMBLY

VALVE SPOOL

PIECE ASSEMBLY

Technical Instruction Document TID-0141_0A

4.4.2 Water-to-Water Double-Wall Water Heaters

The sensor installation locations for a Water-to-Water Model WWDW-24 differ slightly from the
locations used for WWDW-45 and DW-68 Models as shown in Figure 4-10. DW-45 and WWDW­68 Sensors are mounted on the Boiler Water Inlet and Outlet Flanges. However, since these
flanges do not exist for the WWDW-24, the Sensors are mounted on the bottom of the Boiler
Water Inlet and Outlet as shown in Figure 4-10. Install the Boiler Water Inlet and Outlet Sensors
as follows for the Model being retrofitted:

Figure 4-9. E-Plus Boiler Water Inlet and Outlet Temperature Sensor Locations

1. Check to ensure that the capillary tubes and compression fittings have been removed from
the Boiler Inlet and Outlet Flanges shown in Figure 4-10. If they have not been previously
remove, disconnect and remove these items at this time.

2. For WWDW-45 and WWDW-68 Models, install the Boiler Water Inlet Temperature Sensor in
the tapped opening in the Boiler Water Inlet Flange shown in Figure 4-10. For a WWDW-24
Model, install the Sensor in the tapped hole at the bottom of the Boiler Water Inlet as
shown.

3. For WWDW-45 and WWDW-68 Models, install the Boiler Water Outlet Temperature Sensor
in the tapped opening in the Boiler Water Outlet Flange shown in Figure 4-10. . For a
WWDW-24 Model, install the Sensor in the tapped hole at the bottom of the Boiler Wat er
Inlet as shown.

4. The electrical connector plugs on the Inlet and Outlet Boiler Water Temperature Sensors
will be connected after the ECS Control Box is installed (section 4.5).

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

FAILURE IS INDICATED BY

DOUBLE WALL TUBE.

AN INNER OR OUTER TUBE

THIS IS A VENTED U - TUBE HEAT

EXCHANGER CONSTRUCTED WITH

PLUG OR OBSTRUCT !

LEAK DETECTION PORT

DO NOT

BOILER
WATER

IN

BOILER
WATER

OUT

BOILER WATER
INPUT SENSOR

BOILER WATER

OUTLET SENSOR

DW-24

BOILER
WATER

IN

BOILER
WATER

OUT

BOILER WATER
INPUT SENSOR

BOILER WATER

OUTLET SENSOR

DW-45, DW-68

LEAK DETECTION PORT

THIS IS A VENTED U - TUBE HEAT

AN INNER OR OUTER TUBE

FAILURE IS INDICATED BY

FLOW FROM THIS PORT.

DO NOT

DOUBLE WALL TUBE.

EXCHANGER CONSTRUCTED WITH

PLUG OR OBSTRUCT !

SWDW-24

Technical Instruction Document TID-0141_0A

SWDW-45, SWDW-68

Figure 4-10. Boiler Water Inlet and Outlet T emp erat u re Sen so r L o cati on s for

Water–to–Water Double-Wall Heaters

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

-E-

CXT

-E

ACTUATOR

LINKAGE
ASSY

CONTROL
VALVE

STEAM IN

SIDE VIEW

COMPOUND PRESSURE GAUGE

(SHOWN ROTATED FOR CLARITY)

PIG TAIL

1/4" COUPLING

SHELL

Technical Instruction Document TID-0141_0A

4.5 COMPOUND PRESSURE GAUGE

NOTE

Section 4.5 applies ONLY to Steam-to-Water Heater Models which
include A-Plus, B-Plus, B-Plus II Helitherm Models. For ALL Water-to­Water Heater Models disregard the procedures in this section and
proceed directly to section 4.6.

If the Water Heater being retrofitted is Steam-to-Water Model, a Compound Pressure Gauge is
included in the Retrofit Kit. The Compound Pressure Gauge range will be sized to match the
requirements of the Heater being retrofitted. In addition to the Gauge, all required fittings
necessary for installation will be included in the kit.

The Compound Pressure Gauge will be mounted downstream of the CXT-E Control Valve, as
shown in Figure 4-11.

Figure 4-11. Compound Pressure Gauge Installation – Helitherm S/W Unit

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

COLD WATER

INLET

FLOW

METER

ORIFICE

DISC

SPRING

RING

BOTTOM VIEW

Technical Instruction Document TID-0141_0A

4.5.1 Helitherm Steam-to-Water Units

For Helitherm Steam-to-Water un i ts, refer to Figure 4-11 which shows a typical B-Plus Heater.
Proceed as follows:

1. Remove the Compound Pressure Gauge (8356-[ ]), Pig Tail (8-20) and 1/4” Coupling (9-3)
from the Retrofit Kit.

2. Install the Pig Tail in the tapped hole downstream of the CXT-E Contr o l Valve.

3. Attach the 1/4” NPT Coupling and Pressure Gauge to the Pig Tail as shown in Figure 4-11.
Tighten all connections.

4.6 INSTALLATION OF NEW ORIFICE DISC

The Retrofit Kit contains a new Orifice Disc (part no. 49032-[ ]) sized for the applicable follow
range used by the Heater being retrofitted. The Orifice Disc is located in the Cold Water Inlet on
the Water Heater. For Helitherm Heater Models, the Cold Water Inlet is on the Bottom Head of the
Heater as shown in Figure 4-12. Howev er, for Water-to-Water Double-Wall Models, the Cold
Water Inlet is located on the Shell of the Heater, as shown in Figure 4-13.

Refer to the applicable Figure for the unit being modified and install the new Orifice Disc and
Spring Ring as follows:

1. Obtain the Orifice Disc and Spring Ring from the Retrofit Kit.

2. Insert the Orifice Disc fully into the Cold Water Inlet until it contacts the stops. Ensure that
the Orifice is seated evenly in the Inlet.

3. Using a pair of needle-nose pliers, compress the ends of the Spring Ring and insert it fully
into place.

4. This completes the installation of the new Orifice Disc.

Figure 4-12. Cold Water Inlet Orifice Location – Typical Helitherm Heater

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

COLD WATER INLET

(SEE VIEW “A - A”)

DW-45, DW-68

INSULATION

SHELL

FLOW

METER

A

A

ORIFICE

DISC

SPRING

RING

INLET

PIPE

VIEW “A - A”

SWDW-45, SWDW-68

Technical Instruction Document TID-0141_0A

Figure 4-13. Cold Water Inlet Orifice Location – Water-to-Water Double-Wall Heater

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

WATERWIZARD

TEMP CONTROLLER

B+II

OVER TEMP SWITCH

SHELL

ECS CONTROL

BOX

MOUNTING

BRACKET

MOUNTING
BRACKET
SCREWS

SHELL FLANGE

SOLENOID
VALVE

HEX NUTS

& STUD

TOP HEAD

Technical Instruction Document TID-0141_0A

4.7 ECS CONTROL BOX INSTALLATION

The ECS Control Box is attached to the Water Heater using the old Control Box Mounting Bracket
removed in Section 2. Install the new ECS Control Box in accordance with the following steps:

1. Attach the ECS Control Box to the Mounting Bracket using the two 1/4-20 x 1/2 “ screws
and washers provided in the Retrofit Kit.

2. Insert the top end of the Mounting Bracket under the previously loosened hex nut at the top
of the Heater Shell (Figure 4-14). After the Bracket is vertically aligned, t ighten the hex nut
to secure the Mounting Bracket and ECS Control Box to the Water Heater.

Figure 4-14. ECS Control Box Mounting Location

NOTE

External power at 120 to 240 VAC, 50/60 Hz is required to operate the
circuitry contained in the ECS Control Box. Power c onnections are made
internally by routing the power wiring through the cutout provided on the
right side of the Control Box.

3. Next, loosen the captive Phillips head screw on the right front portion of the Control Box
(Figure 4-15) to open the hinged door.

4. Swing open the door and loosen the captive Phillips head screw at the top of the recessed
panel (Figure 4-16). Swing down the panel to access terminal block TB-2 (Figure 4-17)

5. Feed the external 120 to 240 VAC, 60 Hz) power leads through the cutout in the right side
of the ECS Control Box.

6. Connect the Line, Neutral and Ground leads to the TB-2 terminals shown in Figure 4-17.

7. Close the swing-down panel after the power leads are secured to TB-2. Tighten the captive
screw to secure the recessed panel.

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

WATER HEATER

TEMP CONTROLLER

B-PLUS

TM

HOLD

RUNAUTO

MAN

2408

PT.NO.

PT.NO.

OVER TEMP SWITCH

PANEL
DOOR

CAPTIVE
SCREW

Technical Instruction Document TID-0141_0A

8. Close the front door of the ECS Control Box and tighten the captive screw to secure it in the
closed position.

9. Check the labels on the Control Box cables and connect them to the following components:

NOTE

The BOILER WATER IN and BOILER WATER OUT cables shown with an
asterisk (*) are used on Water-to-Water Heat ers ONLY (E-Plus or Water­to-Water Double-Wa ll Models).

Label Connect To:
VALVE ACTUATOR 3-Pin Molex Connector on Actuator
FLOWMETER 5-Pin Connector on Flow Meter
OUTLET TEMP 4-Pin Connector on Dual Sensor (Outlet Port)
*BOILER WATER IN 2-Pin Connector at Heating Fluid Inlet
*BOILER WATER OUT 2 Pin Connector at Heating Fluid Outlet

Figure 4-15. ECS Control Panel Front View

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

B-PLUS

TM

PT.NO.

SET

F

AUTO

RUN

MAN HOLD

OP 1

OP 2

SP2

REM

2408

OVER TEMP SWITCH

TEMP CONTROLLER

PT.NO.

WATER HEATER

CAPTIVE SCREW

(LOOSEN TO OPEN)

CONTROL BOX (BOTTOM - INTERNAL VIEW)

TB-2

GROUND

NEUTRAL

LINE

100

101

102

GND

EXTERNAL AC POWER

(120-240 VAC)

FRONT

REAR

VOLTAGE

REGULAOR

TERMINAL

BLOCK TB-2

Technical Instruction Document TID-0141_0A

Figure 4-16. Recessed Panel Behind Control Box Door

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Figure 4-17. ECS Control Box AC Power Connections

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

5. POST INSTALLATION CONNECTIONS AND ADJUSTMENTS

Figures 5-1 and 5-2 show a typical B-Plus Helitherm Water Heater and a Water-to-Water Double
Wall WWDW-68 Heater with all ECS and CXT-E Retrofit items installed. Upon completion of all
retrofit procedures in Section 4, the ECS Retrofit heater must be thoroughly checked to ensure
that all required external connections have been made to the modified Heater. In addition, CXT-E
Actuator and ECS Control system adjustments must be made prior to placing the Heater back into
service.

5.1 INPUT AND OUTPUT WATER HEATER CONNECTIONS

The following items must be checked to ensure the proper connections have been made:

1. Drain Connection
Ensure that the Drain Ball Valve has been replaced and that all external drain piping is
reconnected.

1. Cold Water Inlet
Ensure that the Cold Water Inlet Flange is connected to the cold water inlet piping.

2. Steam or Boiler Water Line
Ensure that the Steam or Boiler Water supply line is connected to the inlet of the CXT-E
Control Valve.

3. Condensate Line
Ensure it is connected to a nearby drain or condensate collection system.

4. Electrical Power
Ensure that AC power (120 to 240 volts) is connected to the ECS Control Box

5.2 ADJUSTMENTS

Prior to placing the unit into operation, the CXT-E Actuator, ECS Temperature Controller and ECS
Over-Temperature Switch must be set. The adjustment procedures for these items are provided in
Section 3 of Operation and Maintenance Manual AC-105. A copy of this manual is included in the
Retrofit Kit.

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 54 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

FRONT VIEW

WATERWIZARD

TEMP CONTROLLER

B+II

OVER TEMP SWITCH

HEAT
EXCHANGER

CXT-E
ACTUATOR

LINKAGE
ASSY

CONTROL
VALVE

FLOW

METER

ECS CONTROL

BOX

MOUNTING

BRACKET

Technical Instruction Document TID-0141_0A

Figure 5-1. B-Plus Package Water Heater With ECS Control System & CXT-E

Control Valve

(Sheet 1 of 2)

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 55 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

-E-

OFF

POWER ON

CXT-E
ACTUATOR

LINKAGE
ASSY

CONTROL
VALVE

ECS

CONTROL

BOX

MOUNTING

BRACKET

STEAM IN

SIDE VIEW

COMPOUND

PRESSURE

GAUGE

SOLENOID
VALVE

HOT WATER

OUTLET

Technical Instruction Document TID-0141_0A

Figure 5-1. B-Plus Package Water Heater With ECS Control System & CXT-E

Control Valve

(Sheet 2 of 2)

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 56 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

FRONT VIEW

Technical Instruction Document TID-0141_0A

Figure 5-2. WWDW-68 Double Wall Water Heater With ECS Control System & CXT-

E Control Valve

(Sheet 1 of 2)

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 57 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

COLD
WATER
INLET

SIDE VIEW

HOT WATER

OUTLET

FLOW

METER

DRAIN

ECS CONTROL
BOX

MOUNTING
BRACKET

P & T RELIEF
VALVE

Technical Instruction Document TID-0141_0A

Figure 5-2. WWDW-68 Double Wall Water Heater With ECS Control System & CXT-

E Control Valve

(Sheet 2 of 2)

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 58 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

APPENDIX A

ECS RETROFIT KIT CONTENTS

FOR

PART NO. 27004-[ ]

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 59 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

1

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-1

11

1

LABEL

ELECTRIC BOX

72010-2

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91018

18

1

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

90003

19

1

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

N/A

20

1

COUPLING, 1/4”

PRESSURE GAUGE

9-3

21

1

PIG TAIL

PRESSURE GAUGE

8-20

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

N/A

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

N/A

25

1

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

N/A

26

1

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122075

Technical Instruction Document TID-0141_0A
The basic ECS Retrofit Kit Contents for each type of AERCO Indirect Fired Water Heater are

listed in Tables A-1 through A-10, which follow.

TABLE A-1. RETROFIT KIT PART NO. 27004-1 FOR SW1-A PLUS WATER HEATERS

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 60 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

1

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-1

11

1

LABEL

ELECTRIC BOX

72010-3

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91018

18

1

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

1

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

90006

20

1

COUPLING, 1/4”

PRESSURE GAUGE

9-3

21

1

PIG TAIL

PRESSURE GAUGE

8-20

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

N/A

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

N/A

25

1

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

N/A

26

1

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122009

Technical Instruction Document TID-0141_0A

TABLE A-2. RETROFIT KIT PART NO. 27004-2 FOR SW1-B PLUS WATER HEATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 61 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

1

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-1

11

1

LABEL

ELECTRIC BOX

72010-4

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91018

18

1

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

1

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

90006

20

1

COUPLING, 1/4”

PRESSURE GAUGE

9-3

21

1

PIG TAIL

PRESSURE GAUGE

8-20

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

N/A

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

N/A

25

1

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

N/A

26

1

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122009

Technical Instruction Document TID-0141_0A

TABLE A-3. RETROFIT KIT PART NO. 27004-3 FOR B PLUS II WATER HEATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 62 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

3

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-2

11

1

LABEL

ELECTRIC BOX

72010-5

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91020

18

1

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

1

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

90006

20

1

COUPLING, 1/4”

PRESSURE GAUGE

N/A

21

1

PIG TAIL

PRESSURE GAUGE

N/A

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

N/A

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

N/A

25

2

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

61009-1

26

2

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122009

Technical Instruction Document TID-0141_0A

TABLE A-4. RETROFIT KIT PART NO. 27004-5 FOR WW 3E PLUS WATER HE ATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 63 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

2

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-2

11

1

LABEL

ELECTRIC BOX

72010-6

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91026

18

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

N/A

20

COUPLING, 1/4”

PRESSURE GAUGE

N/A

21

PIG TAIL

PRESSURE GAUGE

N/A

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

9-234

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

59032

25

2

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

61009-1

26

2

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122075

Technical Instruction Document TID-0141_0A

TABLE A-5. RETROFIT KIT PART NO. 27004-7 FOR 8” WW DOUBLE WALL WATER HE ATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 64 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

2

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-2

11

1

LABEL

ELECTRIC BOX

72010-6

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91023

18

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

N/A

20

COUPLING, 1/4”

PRESSURE GAUGE

N/A

21

PIG TAIL

PRESSURE GAUGE

N/A

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

9-234

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

59032

25

2

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

61009-1

26

2

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122009

Technical Instruction Document TID-0141_0A

TABLE A-6. RETROFIT KIT PART NO. 27004-9 FOR 10” WW DOUBLE WALL WATER HE ATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 65 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

ITEM

QTY PART DESCRIPTION

LOCATION

ON UNIT

PART

NUMBER

1

1

OUTLET FLANGE

TOP HEAD

95015 2 1

PLUG. 1”

TOP HEAD

9-76 3 1

PLUG. 3/4”

TOP HEAD

9-73 4 1

PLUG 1/2”

TOP HEAD

9-368 5 1

PLUG. 1/4”

TOP HEAD

9-40 6 1

J THERMOCOUPLE, DUAL

TOP HEAD

61008-1

7

2

COMP. FITTING, 1/4 NPT x 3/16” TUBE

TOP HEAD/
BOTTOM MANIFOLD

93029

8

1

OUTLET GASKET

TOP HEAD

16949 9 1

GASKET

TOP HEAD

122152

10

1

CONTROL BOX

ELECTRIC BOX

69012-2

11

1

LABEL

ELECTRIC BOX

72010-6

12

1

SOLENOID VALVE

TOP HEAD

92110

13

1

FLOW METER

BYPASS

64006

14

1

FLEXIBLE HOSE, SS BRAID

BYPASS

97009

15

1

COMP. FITTING, 1/2 NPT x 1/2” TUBE

BYPASS

93028

16

1

COMP. FITTING, 1/4 NPT x 1/2” TUBE

BYPASS

93027

17

1

INLET TUBE, FLOW METER

BYPASS

91028

18

NIPPLE, MODIFIED, 1-1/4”

BOTTOM HEAD

N/A

19

NIPPLE, MODIFIED 2 NPT SCH. 80

BOTTOM HEAD

N/A

20

COUPLING, 1/4”

PRESSURE GAUGE

N/A

21

PIG TAIL

PRESSURE GAUGE

N/A

22

1

NIPPLE, 1/4 NPT x 4” LG

PRESSURE GAUGE

N/A

23

1

CLOSE NIPPLE, 3/4”

SHELL

9-234

24

1

TEE, 3/4” x 1/4” 3/4”

SHELL

59032

25

2

J THERMOCOUPLE, SINGLE

VALVE LINE/ BOTTOM
MANIFOLD

61009-1

26

2

BUSHING, 1/2” x 1/4”

VALVE LINE/ BOTTOM
MANIFOLD

9-43

27

1

WIRING DIAGRAM

ECS

69008

28

2

BOLT, 1/4-20 x 1/2”

CONTROL BOX MTG.

6-138

29

4

FLAT WASHER, 1/4”

CONTROL BOX MTG.

124664

32

1

ORIFICE RETAINING CLIP

COLD WATER INLET

122009

Technical Instruction Document TID-0141_0A

TABLE A-7. RETROFIT KIT PART NO. 27004-11 FOR 12” WW DOUBLE WALL WATER HE ATER

VALVE LINE/

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 66 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

APPENDIX B

ECS RETROFIT KIT OPTIONAL ITEMS

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 67 of 76

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

INTRODUCTION

The information included in this Appendix lists optional items which may vary, depending on:

• Type of Water Heater being retrofitted

• Required Water Heater flow rate

• Type of Control Valve Actuator previously installed

• Control Valve size

Table B-1 and the Tables/Appendices referenced therein, list the applicable items included in the
Retrofit Kit for the specific Water Heater being retrofitted.

TABLE B-1. ECS RETROFIT KIT OPTIONAL ITEMS

ITEM

1 Orifice Disc Cold Water Inlet 1 Table B-2
2 Compound Pressure Gauge

(Steam-to Water Units ONLY)

3 Valve Flange Gaskets

(2.50” to 4.00” Valves ONLY)

4 Pneumatic or Electro-Hydraulic

Actuator Replacement Kit

5 Self-Contained Actuator

Replacement Kit

DESCRIPTION

LOCATION ON UNIT

Steam Inlet to Heater 1 Table B-3

Control Valve Inlet &
Outlet Flanges

Control Valve 1 Appendix C

Control Valve 1 Appendix D

QTY.

2 Table B-4

TABLE B-2. ORIFICE DISC OPTIONS (Table B-1, Item 1)

AERCO

PART NO.

49032-1 1 0 – 45 B-Plus, B-Plus II, E-Plus

49032-2 1 0 – 70 B-Plus, B-Plus II, E-Plus

QTY

WATER HEATER

FLOW RATE (GPM)

APPLICABLE UNITS

REFERENCE

TABLE/APPENDIX

49032-3 1 0 – 125 B-Plus, B-Plus II, E-Plus
49032-4 1 > 125 B-Pl us, B-Plus II, E-Plus
49032-5 1 0 – 45 A-Plus, WWDW-24
49032-6 1 0 – 70 A-Plus
49032-7 1 0 – 100 WWDW-45, WWDW-68
49032-8 1 0 – 45 WWDW-45, WWDW-68
49032-9 1 0 – 125 WWDW-45, WWDW-68

49032-10 1 > 125 WWDW-68

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

TABLE B-3. COMPOUND PRESSURE GAUGE OPTIONS (Table B-1, Item 2)

AERCO

PART NO.

8356-15 1 30” Vacuum to 15 ps1/kPa

8356-30 1 30” Vacuum to 30 ps1/kPa

8356-60 1 30” Vacuum to 60 ps1/kPa
8356-100 1 30” Vacuum to 100 ps1/kPa
8356-150 1 30” Vacuum to 150 ps1/kPa

QTY

PRESSURE RANGE

TABLE B-4. VALVE FLANGE GASKET OPTIONS (Table B-1, Item 3)

AERCO

VALVE

PART NO.

24036-1.00 1” CXT-E Control Valve N/A None
24036-1.25 1-1/4” CXT-E Control Valve N/A None
24036-1.50 1-1/2” CXT-E Control Valve N/A None

DESCRIPTION

FLANGE GASKET

PART NO.

FLANGE
GASKET

QTY

24036-2.00 2” CXT-E Control Valve N/A None
24036-2.50 2-1/2” CXT-E Control Valve 4-52 2
24036-3.00 3” CXT-E Control Valve 4-55 2
24036-4.00 4” CXT-E Control Valve 4-58 2

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

THIS PAGE INTENTIONALLY BLANK

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

APPENDIX C

VALVE KITS REQUIRED

FOR

PREVIOUSLY INSTALLED PNEUMATIC OR

ELECTRO-HYDRAULIC ACTUATOR

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PART NAME

1.00”

1.25”

1.50”

2.00”

1 1 ACTUATOR

69170

69170

69170

69170 2 1

LINKAGE

24038-1

24038-1

24038-1

24038-1

3 1 GASKET

81046

81046

81046

81046

4 2 BOLT, HEX 3/8-16 x 5/8 LG

54014

54014

54014

54014

5 1 SCALE

59028-1

59028-1.25

59028-1.50

59028-2

6 2 NUT, HEX, #8-32

123322

123322

123322

123322

7 2 HEX NUT, 1/4-20

6-226

6-226

6-226

6-226 8 1

PACKING ASSY

121567

121567

121567

121567

9 1 DISC SEAT

121541

121527

121510

121531

10 1 LOWER PILOT SEAT ASSY

121505

121505

121505

121505

11 LOWER SHAFT

121979

121980

121980

121982

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PART NAME

2.50 INCH

3.00 INCH

4.00 INCH

1 1 ACTUATOR

69170

69170

69170

2 1 LINKAGE

24038-1

24038-1

24038-2

3 1 GASKET

81046

81046

81046

4 2 3/8-16 x 5/8” LG. CAP SREWS

54014

54014

54014

5 1 SCALE

59028-2.50

59028-3

59028-4

6 2 8-32 HEX NUT

123332

123322

123322

7 2 1/4-20 NUT

6-226

6-226

N/A 8 2

3/8-16 HEX NUT

N/A

N/A

6-264

9 1 PACKING ASSY

121567

121568

121568

10

1

VALVE SEAT

121935

122032

122178

11

1

LOWER SHAFT

122223

122230

122224

Technical Instruction Document TID-0141_0A

TABLE C-1. VALVE KITS FOR PREVIOUSLY INSTALLED PNEUMATIC OR ELECTRO-

HYDRAULIC ACTUATOR

(FOR VALVE SIZES FROM 1.00” TO 2.00”)

TABLE C-2. VALVE KITS FOR PREVIOUSLY INSTALLED PNEUMATIC ACTUATOR

(FOR VALVE SIZES FROM 2.50” TO 4.00”)

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

APPENDIX D

VALVE KITS REQUIRED

FOR

PREVIOUSLY INSTALLED SELF-CO NT AINED ACTUATOR

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PART NAME

1.00”

1.25”

1.50”

2.00”

1 1 ACTUATOR

69170

69170

69170

69170 2 1

LINKAGE

24038-1

24038-1

24038-1

24038-1

3 1 GASKET

81046

81046

81046

81046

4 2 BOLT, HEX 3/8-16 x 5/8 LG

54014

54014

54014

54014

5 1 SCALE

59028-1

59028-1.25

59028-1.50

59028-2

6 2 NUT, HEX, #8-32

123322

123322

123322

123322

7 2 HEX NUT, 1/4-20

6-226

6-226

6-226

6-226 8 1

PACKING ASSY

121567

121567

121567

121567

9 1 VALVE TOP GASKET

122136

122136

122136

122136

10 1 VALVE TOP

16943

16943

16943

16943

11 1 LOWER SHAFT

121979

121980

121980

121982

12 1 PACKING NUT

122664

122664

122664

122664

13 2 HEX HEAD PLUG, 1/4”

9-22

9-22

9-22

9-22

14 6 HEX BOLT, 3/8-16

122405

122405

122405

122405

15 1 INNER PILOT ASSEMBLY KIT

29021-1.00

29021-1.25

29021-1.50

29021-2.00

16 1 VALVE PISTON ASSEMBLY KIT

121618-1.00

121618-1.25

121618-1.50

121618-2.00

Technical Instruction Document TID-0141_0A

TABLE D-1. VALVE KITS FOR PREVIOUSLY INSTALLED SELF-CONTAINED ACTUATOR

(FOR VALVE SIZES FROM 1.00” TO 2.00”)

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ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

VALVE SIZE AND PART NUMBERS

ITEM

QTY

PART NAME

2.50 INCH

3.00 INCH

4.00 INCH

1 1 ACTUATOR

69170

69170

69170

2 1 LINKAGE

24038-1

24038-1

24038-2

3 1 GASKET

81046

81046

81046 4 2

3/8-16 x 5/8” LG. CAP SREWS

54014

54014

54014 5 1

SCALE

59028-2.50

59028-3

59028-4

6 2 8-32 HEX NUT

123332

123322

123322

7 2 1/4-20 NUT

6-226

6-226

N/A

8 2 3/8-16 HEX NUT

N/A

N/A

6-264 9 1

PACKING ASSY

121567

121568

121568

10

1

VALVE TOP GASKET

122083

122204

122203

11

1

VALVE TOP

18781

18823

18824

12

1

LOWER SHAFT

122223

122230

122224

13

1

PACKING NUT

122664

122665

122665

14

2

HEX HEAD PLUG, 1/4”

9-22

9-22

9-22

15

4

CAP SCREW, 1/2-13 x 1-1/4”

6-24

N/A

N/A

16

4

CAP SCREW, 5/8-11 x 1-1/2”

N/A

6-310

6-310

17

1

MAIN VALVE ASSEMBLY KIT

27006-2.50

27006-3.00

27006-4.00

Technical Instruction Document TID-0141_0A

TABLE D-2. VALVE KITS FOR PREVIOUSLY INSTALLED SELF-CONTAINED ACTUATOR

(FOR VALVE SIZES FROM 2.50” TO 4.00”)

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--- END ---

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB

Technical Instruction Document TID-0141_0A

Change Log

Date Description Changed By

Rev A: Initial release (replacement for TSB-2006-02). Solenoid

12/30/2014

Valve 92110 replaced with 92110 (reference PIR 934-147);
Actuator Assembly 69009 replaced with 69170 (reference PIR

987).

Chris Blair

International Inc.

© AERCO International, Inc., 2014

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