AERCO ECS Upgrade for SW Double Wall Heaters User Manual

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

TECHNICAL INSTRUCTIONS

Technical Instruction Document TID-0142_0A

This document provides instructions for upgrading the Electronic

Control System (ECS)
numbers 27035, 27036 and 27037.

for Steam-to-Water (SW) Double Wall Heaters using kit

These instructions apply to the following Steam-To-Water (SW)
Double-Wall (DW) heater models:

This document replaces the following document (01/25/2011):

TSB-11-007_0A_SWDW_Recirculator-ECS_Upgrade

• SWDW-24

• SWDW-45

• SWDW-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 Upgrade for SW Double Wall Heaters, Kits 27035, 27036, 27037

Technical Instruction Document TID-0142_0A

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

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

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

1.3 Upgrade Kit Contents ........................................................................................................... 4

2. EQUIPMENT ISOLATIO N AND REMOVAL PROCEDURES ...................................................... 4

2.1 Isolating Water Heater .......................................................................................................... 7

2.2 Draining Water Heater .......................................................................................................... 7

2.3 Removal Of Hot Water Outlet Piping .................................................................................... 7

2.4 Removal Of Items Connected To Heater Shell ..................................................................... 8

2.5 Installation Of ECS Components On Top Head Assembly .................................................... 8

2.5.1 Thermocouple & Circulator Installation For SWDW Heaters – Brazed Fittings ............. 8

2.5.2 Thermocouple & Circulator Installation For SWDW Heaters – Compression Fittings . 12

2.5.3 Temperature Controller Replacement ........................................................................ 13

2.5.4 Setpoint Temperature Adjustment ............................................................................. 13

2.5.5 Wiring the ECS Control Box for the Circulator and Temperature Control ................... 15

3. POST INSTALLATION CONNECTIO NS AND ADJUSTMENTS ............................................... 18

3.1 Input and Output Water Heater Connections ...................................................................... 18

3.2 Adjustments ....................................................................................................................... 18

4. APPENDICES ............................................................................................................................ 21

4.1 APPENDIX A: 8" SWDW ECS RECIRC. LOOP UPGRADE ............................................... 21

4.2 APPENDIX B: 10" SWDW ECS RECIRC. LOOP UPGRADE ............................................. 22

4.3 APPENDIX C: 12" SWDW ECS RECIRC. LOOP UPGRADE ............................................. 23

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

Technical Instruction Document TID-0142_0A

1. INTRODUCTION

This document applies to steam-to-water (SW) Double Wall (DW) heaters. It provides instructions
for upgrading an existing SWDW water heater with an ECS (Electronic Control System) system
and a flow sensor to an ECS system using a circulation pump.

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.

Operations and Maintenance Manual HE-111 is the required manual for SWDW models and is
available from the O&M Manuals section of the AERCO International website, www.aerco.com

The following paragraphs in this Section describe the safety precautions to be followed, the tools
and test equipment required to perform all procedures in this document and the contents of
the Upgrade Kits for all Heater Models.

1.1 Safety Precautions

Installation, maintenance and operating personnel must, at all times, observe all safety
regulations. The following warnings are general and must be given the same attention as
specific precautions included in these instructions.

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.

LIVE STEAM CAN CAUSE SEVERE BURNS

Never search for leakage in a live steam li ne 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.

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.

Burn permits may be required for certain installations

WARNING!

WARNING!

WARNING!

NOTICE:

requiring

braising.

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

Technical Instruction Document TID-0142_0A

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”

• Plumbers tools to handle pipe sizes up to 3”

• Vise-Grip Pliers

• Flat Tip Screwdriver, 1/2” Blade

• Phillips Head Screwdriver, No. 3

• Brass Wire Brush

• Needle Nose Pliers

• Tape Measure

• Black Marker

• Loctite 565 or equivalent

• Manufactures’ installation instructions referenced in text

• Brazing equipm ent for assembling P/N 97049 (if burn permit available)

1.3 Upgrade Kit Contents

The contents of the Upgrade Kits, P/N 27035, 27036, and 27037 are included in Appendices A
through C at the end of this document.

2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES

Figure 1 shows component locations for a typical Double-Wall, Model DW-24. The actual size and
location of affected components and assemblies may vary, depending on Packaged Water Heater
model and size. Refer to the applicable AERCO Heat Exchanger Manual provided with your
installation for additional details.

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

Hot Water

Outlet

Remove existing

ECS Control Box

Remove Flow Sensor

Plug vacated hole

Condensate

Outlet

Steam Inlet
Leak Detection Por t

Technical Instruction Document TID-0142_0A

temperature controller

and replace with P/N

64028-12

assembly and discard.

Install 61009-1 (Type J

Thermocouple) and 93029

(1/4” NPT x 3/16” Tube

Compression Fitting)

(Drain Hole) with 9-

22 (1/4” NPT Hex

Head Plug)

Figure 2-1:

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

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

ECS Control Box

Plug vacated hole
Condensate

Outlet

Leak Detection Port

Orifice Disc and Snap

Cold Water Inlet

Remove Flow Sensor

Hot Water

Outlet

Technical Instruction Document TID-0142_0A

assembly and discard.

Replace with P/N 61009-1

(Type J Thermocouple

and P/N 93029 (1/4” NPT

x 3/16” Tube Compression

Fitting)

Ring Within Cold

Water Inlet Opening

with P/N 9-22 (1/4”
NPT Hex Head Plug)

Figure 2-1: Before Upgrade - Double-Wall Heater Component Locations (Sheet 2 of 2)

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

Technical Instruction Document TID-0142_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 t he Relief Valve located on the Top Head to relieve pressure in the Heater
Shell. Water should stop flowing from the valve within one minute. If water continues to flow
from the Relief Valve, one of the water stop valves is not securely closed.

2.2 Draining Water Heater

Allow the unit to cool sufficiently prior to draining the unit. When sufficiently cooled, drain as
follows:

1. After ensuring there is no pressure build-up in the Heater Shell (section. 2.1, step 6), block
open the Relief Valve in the 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. Remove Plug or
open Drain Ball Valve as applicable.

CAUTION

DO NOT DISCARD ANY OF THE REMOVED PARTS OR ASSEMBLIES
UNLESS IT IS SPECIFICALLY INDICATED THAT THEY WILL NO
LONGER BE USED. IT IS RECOMMENDED THAT ALL REQUIRED
ITEMS BE REMOVED AS INDICATED IN THE FOLLOWING STEPS
PRIOR TO PERFORMING ANY OF THEREPLACEMENT
PROCEDURES IN SECTION 3.

2.3 Removal of Hot Water Outlet Piping

Disconnect the union and any external piping connected to the flange in the hot water outlet
piping (located beyond the outside diameter of the Top Head).

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

Technical Instruction Document TID-0142_0A

2.4 Removal of Items Connected to Heater Shell

In order to install several new ECS components, the Flow Sensor and associated fittings/tubing
and the Cold Water Inlet Orifice Disc must be removed. Proceed as follows:

1. Disconnect any external piping connected to the Cold Water Inlet.

2. Disconnect the Flow Sensor and associated fittings/tubing and discard.

3. Take the ¼” NPT hex plug (9-22) from the kit and plug the side of the drain valve where
the Flow Sensor tubing was located.

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

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

6. Remove the clip and the Orifice Disc from the Inlet Nozzle and discard.

2.5 Installation of ECS Components on Top Head Assembly

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

• Cold Water Inlet

• Thermocouple and Circulator Installation

Note that brazing is preferred method of assembling P/N 970049. However, if a burn permit or
brazing equipment is not available, then compression fittings are acceptable. See sections 2.5.1
and 2.5.2.

2.5.1 Thermocouple & Circulator Installation For SWDW Heaters – Brazed Fittings NOTE: This is the preferred method if a burn permit is available.

Use Loctite™ 565 or equivalent on all threaded potable water fittings. Loctite 567 may also be
used. Refer to Figure 2-3 for proper positioning.

1. Obtain the following from the upgrade kit:

• 2” union (93326)

• 2” Nipple (90074)

• 3”/2” Reducing coupling (93325) x 2

• 3” Tee for Cold Water Inlet (22102) x1

• 1.5” x 7” Nipple (90058)

• 1.5” Flange w/ 2 3/8” x 16 bolts and nuts (59095) set hardware aside for use in Step 17.

2. Attach 2” Union to the Cold Water Inlet (Figure 2-2).

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