AERCO Electronic Controls System (ECS) User Manual

Electronic Control System (ECS) and Type CXT-E Valve

USER MANUAL

Revised: 02/28/2014

Electronic Control

Electronic Control System

Installation, Operation, and Maintenance

Type CXT-E Electronic Valve

User Manual

System (ECS) and

Type CXT-E

Electronic Valve

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 1 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

Technical Support:

1-800-526-0288

www.aerco.com

User Manual

(Mon–Fri, 8am-5pm EST)

Disclaimer

The information containe d in this manual is subject to c hange without notice from AERCO Inter national,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness f or a particular application. AE RCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS.................................................................................................. 3

SAFETY PRECAUTIONS ............................................................................................... 5

1. GENERAL INFORMATION ..................................................................................... 7

1.1 INTRODUCTION ................................................................................................................... 7

1.2 ELECTRONIC CONTROL SYSTEM (ECS) ................................................................................. 7

1.2.1 Control Box Assembly............................................................................................................................. 9

1.2.2 Feed-Forward Flow Sensor ................................................................................................................... 11

1.2.3 Outlet Temperature Sensors ................................................................................................................ 11

1.2.4 Heating Fluid Inlet/Outlet Temperature Sensors ................................................................................. 11

1.2.5 Over-Temperature Solenoid Valve ....................................................................................................... 11

1.3 ELECTRONIC CONTROL VALVE CXT-E................................................................................. 12

1.3.1 Control Valve Accessories .................................................................................................................... 12

1.4 REFERENCE DOCUMENTS.................................................................................................. 14

1.4.1 AERCO Documents ............................................................................................................................... 14

1.4.2 Eurotherm Documents – (Available at www.eurotherm.com) ............................................................ 14

2. INSTALLATION ..................................................................................................... 15

2.1 INTRODUCTION ................................................................................................................. 15

2.2 ELECTRONIC CONTROL VALVE TYPE CXT-E INSTALLATION ................................................ 15

2.3 ELECTRONIC CONTROL SYSTEM (ECS) INSTALLATION ....................................................... 17

2.4 CHANGING COMMUNICATION ADDRESSES ON AERCO EUROTHERM TEMPERATURE

CONTROLLER ............................................................................................................................. 21

2.5 ENABLING REMOTE SETPOINT CONFIGURATION ON THE AERCO EUROTHERM

TEMPERATURE CONTROLLER .................................................................................................... 24

3. ADJUSTMENT ...................................................................................................... 25

3.1 INTRODUCTION ................................................................................................................. 25

3.2 CONTROL VALVE TYPE CXT-E ADJUSTMENT ...................................................................... 25

3.3 ELECTRONIC CONTROL SYSTEM (ECS) ADJUSTMENT ........................................................ 27

3.3.1 Setpoint Temperature Adjustment ...................................................................................................... 28

3.3.2 Over-Temperature Alarm Limit Adjustment ........................................................................................ 29

3.3.3 Over-Temperature Switch Sensor Adjustment ..................................................................................... 30

4. OPERATION .......................................................................................................... 31

4.1 INTRODUCTION ................................................................................................................. 31

4.2 PRE-OPERATIONAL CHECKS .............................................................................................. 31

4.3 INITIAL START-UP .............................................................................................................. 31

4.4 CHECKING WATER HEATER FLOW RATE ............................................................................ 32

4.5 CHECKING THE VALVE POSITION OUTPUT IN AUTO MODE ............................................... 32

5. FUNCTIONAL DESCRIPTION .............................................................................. 33

5.1 INTRODUCTION ................................................................................................................. 33

5.2 FUNCTIONAL OVERVIEW ................................................................................................... 33

5.3 OVER-TEMPERATURE CONTROL AND SAFETY FEATURES ................................................. 33

6. ROUTINE MAINTENANCE ................................................................................... 35

6.1 INTRODUCTION ................................................................................................................. 35

6.2 CXT-E CONTROL VALVE ROUTINE MAINTENANCE ............................................................ 35

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AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

TABLE OF CONTENTS

6.2.1 Monthly Maintenance ......................................................................................................................... 35

6.2.2 Semi-Annual Maintenance: .................................................................................................................. 35

6.3 ELECTRONIC CONTROL SYSTEM (ECS) ROUTINE MAINTENANCE ...................................... 36

6.3.1 Quarterly Maintenance: ....................................................................................................................... 36

6.3.2 Annually: .............................................................................................................................................. 36

6.3.3 Temperature Sensors: .......................................................................................................................... 36

6.3.4 Flow Sensor: ......................................................................................................................................... 37

6.4 HEAT EXCHANGER ROUTINE MAINTENANCE CLEANING .................................................. 38

6.4.1 Pumping System Set-Up Instructions: .................................................................................................. 38

6.4.2 Cleaning Procedure: ............................................................................................................................. 39

6.4.3 Testing HydroSkrub Effectiveness ........................................................................................................ 40

6.4.4 Calcium Carbonate Spot Test: .............................................................................................................. 40

6.4.5 pH Trend Charting: ............................................................................................................................... 40

7. TROUBLESHOOTING ........................................................................................... 41

7.1 INTRODUCTION ................................................................................................................. 41

7.1.1 Electronic Control System (ECS) Preliminary Check: ............................................................................. 41

7.1.2 Electronic Control Valve, CXT-E Preliminary Check: ............................................................................. 41

7.2 TROUBLESHOOTING PROCEDURES ................................................................................... 41

8. CORRECTIVE MAINTENANCE ............................................................................ 47

8.1 INTRODUCTION ................................................................................................................. 47

8.2 PART 1 - CXT-E CONTROL VALVE CORRECTIVE MAINTENANCE ......................................... 47

8.2.1 Valve Shaft Seal Retainer Replacement: .............................................................................................. 47

8.2.2 Valve Disassembly ................................................................................................................................ 48

8.2.3 Valve Reassembly ................................................................................................................................ 50

8.2.4 Actuator Replacement ......................................................................................................................... 58

8.2.5 Linkage Assembly Replacement ........................................................................................................... 59

8.3 PART 2 - ECS CORRECTIVE MAINTENANCE ........................................................................ 61

8.3.1 Control Box Assembly and Components .............................................................................................. 61

8.3.2 Control Box Assembly Replacement ..................................................................................................... 62

8.3.3 Temperature Controller Replacement ................................................................................................. 62

8.3.4 Over-Temperature Switch and Temperature Indicator Replacement .................................................. 63

8.3.5 DC Power Supply Replacement ............................................................................................................ 64

8.3.6 DC Voltage Regulator Replacement ..................................................................................................... 65

9. RECOMMENDED SPARE PARTS ........................................................................ 73

9.1 CXT-E CONTROL VALVE RECOMMENDED SPARE PARTS ................................................... 73

9.2 ELECTRONIC CONTROL SYSTEM RECOMMENDED SPARE PARTS ...................................... 73

APPENDIX A ................................................................................................................ 75

9.3 PROCESS ALARMS: ............................................................................................................ 76

9.4 EUROTHERM 2408 PROCESS ALARMS ........................................................................................ 76

9.5 DIAGNOSTIC ALARMS ........................................................................................................ 76

9.6 EUROTHERM 2408 DIAGNOSTIC ALARMS ................................................................................... 76

9.6.1 Clearing Hardware Error (Hw.Er) Display............................................................................................. 77

APPENDIX B ................................................................................................................ 79

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

! ! !

!

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

Installing or operating personnel must, at all times, observe all saf ety regulat ions. The following
warnings are general and must be given the same attention as specific precautions included in
the instructions.

WARNING

FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO
PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED.

CLOSE ALL SHUTOFF VALVES AND CAREFULLY DECREASE
ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING
ANY MAINTENANCE. TAG THE PRESSURE SOURCE “OUT OF
SERVICE” WHILE PERFORMING MAINTENANCE TASKS.

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
SUITIBLE POLISHED OBJECT. ALSO, ALW AYS WEAR GLOVES
AND LONG SLEEVES.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 5 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

SAFETY PRECAUTIONS

(This page intentionally blank)

Page 6 of 82 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] VD2: 02/28/14

OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

1. GENERAL INFORMATION

1. GENERAL INFORMATION

1.1 INTRODUCTION

This Instruction Manual provides detailed coverage for both the AERCO Electronic Control
System (ECS) and the Electronic Control Valve CXT-E. This Control System and Valve
combination can be used with all models and sizes of AERCO Indirect Fired Water Heaters
which include the following Models:

• SW1A PLUS,

• SW1B PLUS, SW1B PLUS II,

• WW3E PLUS

Double- W all Heater Models DW-24, DW -45, DW-68 (Refer to HE-111 for SWDW-24 , S W DW­45 & SWDW-68 Models)

Figure 1-1 shows a typical installation with a Water Wizard, Model SW1B-Plus II Packaged
Water Heater. The remaining paragraphs in this section provide descriptions of the units,
assemblies and sub-assemblies included with the Electronic Control System (ECS) and the
Electronic Control Valve CXT-E.

NOTE:

This Instruction Manual provides detailed Installation, Operation,
Maintenance and Parts information and procedures for the Electronic
Control System and Electronic Control Valve. A separate Instruction
Manual for the Heat Exchanger is included with the Packaged W ater
Heater. Also, refer to the paragraph titled REFERENCE
DOCUMENTS at the end of this Section for additional documentation
which may be required for accessories or options provided with your
order.

1.2 ELECTRONIC CONTROL SYSTEM (ECS )

The Electronic Control System contains a Control Box Assembly which includes all of the
electronic circuitry for the ECS. In addition, the ECS includes several sensors and safety
devices which provide temperature and flow control information to the Control Box circuitry. The
Control Box and the additional devices included in the ECS are shown in Figure 1-2. The
additional devices included in the ECS include:

• Feed-Forward Flow Sensor (Flowmeter)

• Outlet Dual Temperature Sensors (Type J Thermocouples)

• Heating Fluid Inlet/Outlet Temperature Sensors (Type J Thermocouples) – For Water-to-

Water Heat Exchangers Only

• Over-Temperature Solenoid Valve

If desired, the Electronic Control System (ECS) can be ordered with a Modbus Communication
Option. This option permits the ECS to be externally controlled by an Energy Management
System (EMS), Building Automation System (BAS), or Computer supplied by other
manufacturers.

A Gateway option exists to link with other communication protocols. Check with your AERCO
sales representative for more information.

The Electronic Control System assemblies and components are described in the following
paragraphs.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 7 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

1. GENERAL INFORMATION

Figure 1-1. Typical ECS & CXT-E Installation With a Packaged Water Heater

Page 8 of 82 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] VD2: 02/28/14

OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

1. GENERAL INFORMATION

Figure 1-2. Electronic Control System (ECS)

1.2.1 Control Box Assembly

The Control Box Assembly is available in two models; one for Steam-to-Water Heaters and one
for Water-to-Water Heaters. The only difference between these two models are the Display
devices provided on the front panels. The panel of the Control Box model for W ater -to-Water
applications contain two additional Display devices which display the heating fluid (hot boiler
water) inlet and outlet temperatures. The Control Box front panels for both models are shown in
Figure 1-3.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 9 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

MODEL 69012-1

FRONT PANEL FOR STEAM-TO-WATER HEATERS

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

MODEL 69012-2

FRONT PANEL FOR WATER-TO-WATER HEATERS

SET

F

SET

F

SET

F

AUTO

RUN

MAN HOLD

OP 1

OP 2

SP2

REM

2408

PT.NO.

OVER TEMP SWITCH

BOILER WATER TEMPTEMP CONTROLLER

E-PLUS

WATER HEATER

TM

PT.NO.

OUT

IN

1. GENERAL INFORMATION

Figure 1-3. ECS Control Box Models Showing Front Panel Differences

The Control Box is the heart of the ECS. It contains the Temperature Controller, an Over­Temperature Switch and, when required, Inlet/Outlet Temperature Indicators for Water-to-Water
applications. The Temperature Controller is the “brain” of the ECS which processes data
received from the temperature and flow sensors. Using PID (Proportional Integral Derivative)
algorithms, the Temperature Controller provides a 4-to-20 mA control signal to the Control Valve
Actuator which precisely modulates the Control Valve for optimum outlet temperature control.

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

1. GENERAL INFORMATION

An Over-Temperature Switch is also included in the Control Box to constantly monitor the Water
Heater outlet temperature to ensure the Heater does not exceed the preset high temperature
limit. Typically, the over-temperature limit is set 20°F above the desired Heater setpoint
temperature. If an over-temperature condition occurs, this Switch sounds an audible alarm,
activates the Over-Temperature Solenoid and cuts off power to the Control Valve Actuator. This
closes the Control Valve and shuts off the heating fluid (steam or hot boiler water) to the Heat er.
In addition, activation of the Over-Temperature Solenoid allows over-temperature water to be
dumped from the Heater shell.

The Control Box also contains a DC Power Supply and Voltage Regulator to provide the voltag e
levels required by the ECS Control Box circuitry, flow sensor and safety devices. It also provides
24 VDC power to the Control Valve CXT-E Actuator.

The Control Box components are housed in a steel enclosure with a hinged front door. This
door contains a clear polycarbonate window which permits maintenance personnel to view the
controls and displays of the Temperature Controller, and other display devices mounted on a
recessed panel behind the door. All sensor and control signal connections are made via cable
connections at the bottom of the Control Box. External AC power (120 to 240 VAC, 50/60 Hz) is
supplied via a cutout on the right side of the Control Box.

1.2.2 Feed-Forward Flow Sensor

The Feed-Forward Flow Sensor is installed between the cold water inlet and the drain valve on
the Water Heater as shown in Figure 1-1. The Flow Sensor monitors a portion of the inlet flow to
the Heater and provides a feed-forward signal to the Temperature Controller which is
proportional to the change in flow through the Heater.

1.2.3 Outlet Temperature Sensors

The Control System includes a Dual Temperature Sensor which is installed in the hot water
outlet of the Water Heater. This sensor contains two identical Type J thermocouples. The first
thermocouple connects directly to the Temperature Controller in the Control Box to provide the
outlet water temperature. The second thermocouple connects to the Over-Temperature Switch
in the Control Box.

1.2.4 Heating Fluid Inlet/Outlet Temperature Sensors

When the Heater utilizes hot (boiler) water as the heating fluid, two additional Temperature
Sensors (Type J thermocouples) are provided with the Control System. One temperature
Sensor is installed at the heating fluid inlet and t he other is installed at the heating fluid outlet.
These two Sensors are connected to two identical Temperature Display Indicators in the Control
Box to provide real-time indications of the inlet and outlet heating fluid temperatures. These
Temperature Indicators are physically identical to the Over-Temperature Switch, however they
are “Indicator-Only” devices and do not provide any switching functions.

1.2.5 Over-Temperature Solenoid Valve

As previously mentioned, the Over-Temperature Solenoid Valve operates in conjunction with
the Over-Temperature Switch in the Control Box. An over-temperature alarm is activated when
the preset high temperature limit is exceeded, thereby energizing and opening the Solenoid
Valve. This allows over-heated water and pressure build-up to be expelled from the Heater Shell
and relieve pressure build-up.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 11 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

ACCESSORY

REQUIREMENT

•

- Mandatory

•

Suggested for ease of
maintenance. Required if a

•

Mandatory

•

Recommended for adjustment

• Low Side Pressure Gauge,

Compound Type for steam flow

Recommended for adjustment

1. GENERAL INFORMATION

1.3 ELECTRONIC CONTROL VALVE CXT-E

Each Control Valve is comprised of three major sections; the Valve Body, Linkage Assembly
and the Valve Actuator. The Control Valves are available in sizes ranging from 1 inch to 4
inches. An identical Actuator Assembly is used with each size Valve Body. The Linkage
Assembly used with each size Valve Body is identical, except for minor differences in the Shaft
Adapter stroke of the mechanical linkage. Figure 1-4 shows the basic dimensions for each size
AERCO Control Valve CXT-E.

It should be noted that the Control Valves used for steam flow are identical to those used for hot
(boiler) water flow.

1.3.1 Control Valve Accessories

The accessories required for use with AERCO Electronic Control Valves, Type CXT-E will
depend on the specific application. Detailed installation instructions, including typical installation
drawings are provided in the INSTALLATION Section of this manual. However, please note the
items listed below and ensure that ALL mandatory items are available:

Upstream Shutoff Valve
Downstream Shutoff Valve

Bypass Line is used.

Strainer and Blow-Off Valve
High Side Pressure Gauge

and maintenance

and maintenance.

If any of these items have been furnished by AERCO with the Control Valve, the
necessary drawings and/or instructions should be included with the shipment.

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

A

B

C

D

13.375

6.60"

4.50"

DIM. 1.00"

1.25" 1.50" 2.00" 2.50" 3.00" 4.00"
A
B
C
D

21.12 21.12 21.12 24.25 24.25

24.25

24.25

7.75 7.75

7.75

7.75 10.87 10.87 10.87

3.56

3.56

3.56 3.56 6.38 6.38 6.38

6.00

6.00 6.00 6.00 10.87 10.87 10.87

VALVE SIZES (INCHES)

POSITION
SCALE

1. GENERAL INFORMATION

Figure 1-4. Reference Dimensions for AERCO Control Valves, Type CXT-E

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 13 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

HE-104

SW1B-Plus Heat Exchanger Installation, Operation & Maintenance Manual

HE-105

WW3E Heat Exchanger Installation, Operation & Maintenance Manual

HE-106

DW-24, DW-45, DW-68 Double Wall Heat Exchanger Installation, Operation &
Maintenance Manual

HE-107

SW1A-Plus Heat Exchanger Installation, Operation & Maintenance Manual

HE-110

B-Plus II Water Wizard Heat Exchanger Installation, Operation & Maintenance
Manual

HA025132

2404/2408 Installation & Operation Handbook

HA02630

Series 2000 Communications Handbook

!

!

1. GENERAL INFORMATION

1.4 REFERENCE DOCUMENTS

Refer to the following documents as necessary for additional information and procedures for the
applicable AERCO Heat Exchanger provided with your Electronic Control System (ECS) and CXT-E
Control Valve. In addition, if the ECS is provided with the Modbus Com munication option, refer to the
referenced Eurotherm documents listed.

1.4.1 AERCO Documents

1.4.2 Eurotherm Documents – (Available at www.eur ot herm.com)

CAUTION

DO NOT use the Actuator Linkage Frame at the top of the Control
Valve Body for leverage when installing The Control Valve. Use pipe
wrenches on the inlet and outlet hex of the Valve Body.

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

2. INSTALLATION

2. INSTALLATION

2.1 INTRODUCTION

Normally, the Electronic Control System (ECS) is shipped already installed on the Packaged
Water Heater. However, the Control Valve, Type CXT-E is packed separately. For smaller size
Valves (1” to 2”), the packaged Valve is attached to the base of the shipping crate. For larger
size Valves (2 ½” to 4”), the packaged Valve may be shipped separately due to space
limitations within the Heater shipping crate. Therefore, the installation procedures consist
basically of:

• Installing the Electronic Control Valve, Type CXT-E and associated steam or hot (boiler)
water piping and components.

• Connecting external power to the ECS Control Box

• Connecting and checking electrical connections to the CXT-E Actuator and other ECS

components

IMPORTANT NOTE!

For Water-to-Wat er Doub le -Wall (WWDW) heaters equipped with the
ECS, the following minimum recirculation flow must be provided to
achieve ±4°F temperature control under normal diversified domestic
load conditions:

Double-Wall Model Minimum System Recirculation

WWDW24 10 gpm
WWDW45 15 gpm
WWDW68 20 gpm

2.2 ELECTRONIC CONTROL VALVE TYPE CX T-E INSTALLATION

The following procedures apply to all sizes of AERCO Electronic Control Valves Type CXT-E
ranging from 1 inch to 4 inches. In addition, the following steps can be us ed for both st eam and
hot (boiler) water flow systems. Proceed as follows:

1) Refer to Figure 1-3 for dimensions of the Control Valve furnished with the Packaged W ater
Heater.

2) Next, refer to the recommended installation drawing in Figure 2-1 for steam flow, or Figure
2-2 for hot (boiler) water flow.

3) Install the Control Valve with the Actuator Linkage in the vertical, upright position as shown
in Figure 2-1 or 2-2.

4) For maintenance purposes, unions are required with threaded ends to simplify removal
from the steam or hot boiler water line.

5) Blow out all pipe lines to clear them of dirt chips, scale or other foreign matter which could
adversely affect Valve operation when in service.

6) Install an in-line strainer upstream of the Valve as shown in Figure 2-1 (steam) or Figure 2­2 (hot boiler water). This will protect against foreign matter reaching the Valve during
service operation.

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AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

STRAINER WITH 0.020

FOR CLARITY

PIPING PITCH DIRECTION

1 TO 40 RATIO MINIMUM

2. INSTALLATION

7) If the Valve is controlling steam, ensure that the steam line is pr operly trapped to prevent
accumulation of condensate ahead of the Valve.

8) Install Shutoff Valves (metal-seated, g ate-type) upstream and downstream of the Control
Valve to permit removal from the line for maintenance.

9) Pressure gauges should be installed on both sides of the Control Valve as shown in Figure
2-1 (steam) or Figure 2-2 (hot water).

10) The gauge on the high pressure side of the Valve is for adjustment and maintenance
purposes. The gauge on the low pressure side is to ensure that the correct pressure is
being introduced to the Control Valve. For either steam or water flow, the low side gauge
denotes the pressure of the fluid in the line which may create a hazardous condition.

11) A temperature gauge should be installed in the high pressure side of a hot (boiler) water
line as shown in Figure 2-2.

12) Install the Control Valve with the arrow on the Valve Body pointing in the direction of flow.

13) After the Control Valve has been installed in the steam or hot water line, ensure that all
piping connections are secure and leak tight.

14) This completes the installation procedures for the Control Valve. Proceed to the next
paragraph titled ELECTRONIC CONTROL SYSTEM INSTALLATION.

Figure 2-1. Recommended Control Valve, CXT-E Installation For Steam Flow

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OMM-0003_0D AC-105

MEST STAINLESS

STEEL BASKET,

SHOWN ROTATED

DOWN 90 DEGREES

Electronic Control System (ECS) and Type CXT-E Valve

2. INSTALLATION

Figure 2-2. Recommended Control Valve, CXT-E Installation For Hot (Boiler)

Water Flow

2.3 ELECTRONIC CONTROL SYSTEM (ECS ) INSTALLATION

As previously mentioned, the Control Box and all other Electronic Control System (ECS)
components are installed on the Packaged Water Heater prior to shipment from the factory.
Therefore, ECS installation basically consists of connecting external AC power to the System
and providing the necessary power and control signal connections to the Control Valve Type
CXT-E. However, if your ECS was ordered with the Modbus Communication option, several
additional signal lead connections will need to be made inside the Control Box. These signal
leads will permit the ECS to be controlled by an external Energy Management System (EMS),
Building Automation System (BAS), or Computer.

NOTE:

Following installation, a lock (Not Supplied) can be installed on the
front door of the Control Box, if desired, to prevent unauthorized
access to ECS settings.

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AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

WATER HEATER

TEMP CONTROLLER

B-PLUS

TM

HOLD

RUN

AUTO

MAN

2408

PT.NO.

PT.NO.

OVER TEMP SWITCH

PANEL
DOOR

CAPTIVE
SCREW

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

PANEL CAPTIVE

SCREW

2. INSTALLATION

1) Loosen the captive screw on the right-front portion of the Control Box (Figure 2-3) to open
the hinged panel door.

Figure 2-3. ECS Control Panel Front View

2) Next, open the door and loosen the captive screw at the top of the recessed panel (Figure
2-4). Swing down the recessed panel to access Terminal Block TB-2 on the bottom interior
surface of the Control Box shown in Figure 2-5.

3) Feed the external 120/240 VAC power leads through the cutout labeled “POWER IN” on the
right side of the Control Box.

Figure 2-4. Recessed Panel Behind Control Box Door

Page 18 of 82 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] VD2: 02/28/14

OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

CONTROL BOX - INTERIOR BOTTOM VIEW

REAR

TB-2

LINE

NEUTRAL

GROUND

100

101

102

GND

FRONT

VOLTAGE

REGULATOR

TERMINAL

BLOCK TB-2

EXTERNAL POWER WIRING

(120 – 240 VAC)

2. INSTALLATION

4) Connect the LINE, NEUTRAL and GROUND leads to the TB-2 terminals shown in Figure 2-

5.

Figure 2-5. ECS Control Box AC Power Connections

5) Connect the Control Box cable labeled ACTUATOR to the 3-pin connector plug on the
Control Valve Actuator.

6) Check to ensure that all cable harness connectors and wire leads between the Control Box
and the following ECS components are secure:

a) Flow Sensor
b) Over-Temperature Solenoid
c) Outlet Dual Temperature Sensor
d) Heating Fluid Inlet/Outlet Temperature Sensors (Water-to-Water Heaters Only)

7) If the ECS was ordered with the Modbus Communication Option, proceed to step 8.
However, if this option is not included, no further steps are required for ECS installation.

NOTE:

Step 8 applies ONLY to Electronic Control Systems which include a
Temperature Controller (Eurotherm, Model 2408) equipped with a
Communications Board which allows connection to Modbus
Networks. The required signal connections will depend on the ports
available on the Energy Management System (EMS), Building
Automation System (BAS), or Computer being used with the ECS.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 19 of 82

AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

COMPUTER CONTROL CABLE

RS232/9-PIN

RS232/25-PIN

RS485

SIGNAL NAME

PIN NO.

SIGNAL NAME

PIN NO.

PIN NO.

PIN NO.

GROUND

HD

GROUND

5

7

GROUND

RECEIVE

HE

TRANSMIT

3

2

A (-)

TRANSMIT

HF

RECEIVE

2

3

B (+)

2. INSTALLATION

CAUTION!

DO NOT route Modbus communication wiring in the same
conduit as power wiring. Attempting to do so may result in
excessive noise on the signal lines. Also, ensure that the RS232
or RS485 signal cable connections do not exceed the following
lengths:

RS232 Cable: 50 feet maximum
RS485 Cable: 4,000 feet maximum

8) To permit Modbus control of the ECS, refer to Table 2-1 and connect the appropriate wire
leads to the Temperature Controller terminals listed. Refer to the Temperature Controller
(Eurotherm 2408) pinouts shown in Figure 2-6 to locate the required terminals. Also, refer
to Appendix A for a listing of active Modbus data addresses for the 2408 Controller. In
addition, the Eurotherm documents referenced in this Appendix provide additional
communication information related to Modbus.

NOTE:

The complete wiring diagram for the Electronic Control System is
provided in Appendix B of this Instruction Manual. In addition, the
wiring connections for Terminal Block s TB-1 and TB-2 are provided
for reference purposes.

AERCO recommends that shielded, twisted-pair cable be used for
communication wiring. Examples of suitable wiring are: Belden 9841,
8761, 3105A, or equivalent.

Table 2-1. Modbus Communication Signal Connections

2408 TEMP. CONTROLLER

NOTE:

Page 20 of 82 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] VD2: 02/28/14

OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

1A

HA

1B

HB

1C

HC

2A
2B

1D

HE
HF

HD

3B

3D

3C

2D
3A

2C

JD

JF

JE

JB
JC

JA

LA
LB
LC
AA
AB
AC

VI
V+
V-

In1
In2

C

2408 CONTROLLER

L
N

SEE TABLE 2-1 FOR COMM CONNECTIONS

Page

Scroll

Down

Arrow

UP

Arrow

2. INSTALLATION

Figure 2-6. Temperature Controller (Eurotherm 2408) Terminal Connection

2.4 CHANGING COMMUNICATION ADDRESS E S O N AERCO EUROTHERM TEMPERATURE CONTROLLER

The address is defaulted t o 1 from the factory. Refer to the Button map below for all panel
navigation instructions.

VD2: 02/28/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] Page 21 of 82

AC-105 OMM-0003_0D

Diagram

Button Map

Electronic Control System (ECS) and Type CXT-E Valve

2. INSTALLATION

To change the modbus address:

1) Page to the ACCS list and Scroll down the list to codE.

2) Enter 24 using the Up Arrow. The number will display and flash PASS.

3) Scroll to Goto (current value is OPEr) and use the Down Arrow t o enter a value of Full. The

entry is confirmed by the flashing of the lower display momentarily off and then on.

Page 22 of 82 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone] VD2: 02/28/14

OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

2. INSTALLATION

4) Go to the home screen by pressing the Page and Scroll buttons at the same time.

5) Page to the cmS list.

6) Scroll to the Addr screen

7) Use the Up Arrow to select the desired address number.

8) Go to the home screen by pressing the Page and Scroll buttons at the same time.

9) Page to the ACCS List and change the code to anything other than 24. The codE number

you have entered will flash off and then on to 0 to confirm that access is now set to OPEr
level and it is safe to return to use.

10) Confirm that the Addr is set properly by pressing Page button until the cmS list is

displayed and Scroll to Addr. If the value is correct, you are done. If not, then repeat the
steps over again.

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AC-105 OMM-0003_0D

Electronic Control System (ECS) and Type CXT-E Valve

2. INSTALLATION

2.5 ENABLING REMOTE SETPOINT CONFIG URATION ON THE AERCO EUROTHERM TEMPERATURE CONTRO LLE R

The setpoint may be programmed to be remotely configured by executing the following steps.
See the previous instructions for changing communication addresses in the AERCO Eurotherm
Temperature Controller for more detailed directions for programming the controller.

1) Page to “ACCS”.

2) Scroll and enter code of 1.

3) Scroll and at the “GOTO” menu choose “Conf”.

4) At t he “Conf” screen enter the code of 2

5) Press the Scroll button once and then the Page button until you find “SP”.

6) Scroll until you find “rmt” and set the parameter value to “SP”.

7) Press the Page and Scroll button together at the same time to go to “exit”.

8) Press the Up arrow to select “yes” and then the instrument will reboot.

9) Onc e the instrument has returned to its normal state, press the Page button until you see

“SP”.

10) Scroll until you see “L-r” and using the Up arrow select “rmt”.

11) Once you have selected “rmt” press the Page and Scroll buttons at t he same t ime to return

to the normal temp display.

You should now be able to control the set point remotely.

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OMM-0003_0D AC-105

Electronic Control System (ECS) and Type CXT-E Valve

!

!

3. ADJUSTMENT

3. ADJUSTMENT

3.1 INTRODUCTION

This Section provides adjustment procedures for both the Control Valve, Type CXT-E and t he
Electronic Control System (ECS).

Prior to shipment, from AERCO, all CXT-E Control Valve Actuators are adjusted (auto-stroked)
to ensure that they properly position the Control Valve from the fully-open to the fully-closed
positions. In addition, the ECS is adjusted to the Setpoint Temperature specified on the Sales
Order. If no setting was specified, the default is 140°F.

It is recommended that the following procedures be performed to the extent necessar y, prior to
placing the system into operation. Also, the applicable procedures MUST be performed
following replacement of the CXT-E Control Valve or other ECS components. In addition, the
following procedure must be performed following maintenance or adjustment of linkage,
actuator or packing nut.

CAUTION

As a precaution, ensure that all heating fluid (steam or hot
(boiler) water) shutoff valves are fully closed prior to performing
any of the following adjustment procedures.

3.2 CONTROL VALVE TYPE CXT-E ADJUSTMENT

All CXT-E Actuators are powered by 24 VDC and are contr olled by a linear 4-to-20 mA control
signal. A 4 mA control signal input places the Control Valve in the fully-closed position(Valve
shaft down); while a 20 mA signal strokes the Valve to the fully-open position (Valve shaft up).

The Control Valve Actuators are self-calibrating for all Valve sizes. Therefore, simply proceed as
follows to automatically adjust the Actuator:

NOTE:

The following adjustment procedure must be performed any time that
the CXT-E Actuator is replaced or a mechanical adjustme nt is ma de
to the Linkage Assembly or Valve.

1) Refer to Figure 3-1 and loosen the Actuator cover set screw.

2) Remove the Actuator cover to access the PC Board containing the terminal connections,

DIP switches, Auto-Stroke (Reset) button and LED shown in Figure 3-1.

NOTE:

When properly connected to the ECS, +24 VDC power is supplied to
the Control Valve Actuator when the Control Box POWER switch is
set to the ON position. This switch is located on the right side of the
Control Box.

3) Set the ECS Control Box POWER switch to the ON position to apply 24 VDC power to the

Actuator (pin 2 = +24 VDC, pin 1 = Common). The LED will light indicat ing that power is
applied.

4) Wait approximately 10 seconds while the unit performs a self-test. The LED will blink fr om

one to four times depending on the size of the valve as follows:

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AC-105 OMM-0003_0D