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

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 22 of 76

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

12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 23 of 76