AERCO HE-110 User Manual

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C

HE-110

USER MANUAL

Revised: 07/26/2013

Water Wizard

SW1B+II Packaged Water Heater with

Pneumatically Controlled Valve (CXT-P)

Installation, Operation, and Maintenance

Covers all 1B+ II models

Other applicable documentation includes:

including units with
pneumatically controlled valve
(Type CXT-P) or with an
Electronic Control System (ECS)
and electronically controlled
valve (CXT-E):

• B+03

• B+04

• B+05

• B+06

• B+07

• B+08

• B+09

• B+10

• B+11

• B+12

• B+13

• B+14

• B+15

Note: Number indicates number of
heating coils used (3 to 15).

Water Heaters

1B+ II

SB-2006-02: ECS Retrofit Instructions
AC-105: Electronic Controls System (ECS) Manual
AC-103: Pneumatic Temperature Controller Manual

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Technical Support:

1-800-526-0288

www.aerco.com

OMM-0063_0C Installation, Operation & Maintenance 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.

Page 2 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Installation, Operation & Maintenance Manual OMM-0063_0C

TABLE OF CONTEN TS

CHAPTER 1. SAFETY PRECAUTIONS ...................................................................................................... 5

CHAPTER 2. GENERAL INFORMATION.................................................................................................... 6

2.1. MODEL NAMES .......................................................................................................................... 6

2.2. HEAT EXCHANGER CONFIGURATIONS .................................................................................. 6

2.3. ACCESSORIES ........................................................................................................................... 6

2.4. ALL OTHER ITEMS ..................................................................................................................... 7

CHAPTER 3. INSTALLATION ................................................................................................................... 12

3.1. INSTALLING THE WATER WIZARD ......................................................................................... 12

CHAPTER 4. PRINCIPLE OF OPERATION .............................................................................................. 17

4.1. HEAT EXCHANGER OPERATION WITH PNEUMATIC CONTROL ......................................... 17

4.2. HEAT EXCHANGER OPERATION WITH ELECTRONIC CONTROL SYSTEM (ECS) ............ 18

CHAPTER 5. OPERATING PROCEDURES .............................................................................................. 19

CHAPTER 6. ROUTINE MAINTENANCE .................................................................................................. 22

6.1. DRAINING THE HEATER .......................................................................................................... 22

6.2. CHECKING THE DRAINED WATER ......................................................................................... 22

6.3. CHECKING THE TEMPERATURE CONTROL ......................................................................... 22

CHAPTER 7. TROUBLESHOOTING ......................................................................................................... 23

CHAPTER 8. CORRECITVE MAINTENANCE .......................................................................................... 24

CHAPTER 9. DE-SCALING BY THERMAL SHOCK METHOD ................................................................ 26

CHAPTER 10. MAINTENANCE DISASSEMBLY ...................................................................................... 27

10.1. TOOLS AND EQUIPMENT ........................................................................................................ 27

1.1.1. Common Tools and Equipment ............................................................................................. 27

1.1.2. Special Tools and Equipment Required: ............................................................................... 27

10.2. ISOLATING THE HEATER ........................................................................................................ 29

10.3. DISCONNECTING THE HEATER FROM THE FACILITY ......................................................... 30

10.4. ANTICIPATOR CHECK VALVE DISASSEMBLY ...................................................................... 31

11.5.1. Special Tools Required ..................................................................................................... 31

10.5. PREPARING TO REMOVE THE HEATER SHELL.................................................................... 32

10.6. REMOVING THE HEATER SHELL ........................................................................................... 33

10.7. REMOVING COILS AND RISERS ............................................................................................. 33

CHAPTER 11. CLEANING AND INSPECTION ......................................................................................... 34

11.1. PREPARATION OF BOTTOM HEAD ........................................................................................ 34

11.2. PREPARATION OF RISER AND RETURN ............................................................................... 34

11.3. PREPARATION OF COIL ASSEMBLIES .................................................................................. 35

11.4. PREPARATION OF COIL GASKETS ........................................................................................ 37

CHAPTER 12. MAINTENANCE REASSEMBLY ....................................................................................... 38

MC2: 07/26/13 Page 3 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C Installation, Operation & Maintenance Manual

12.1. REASSEMBLY OF RISERS, SUB-COOLING COIL, AND STEAM COILS ............................... 38

12.2. SUB-COOLING COIL INSTALLATION ...................................................................................... 40

12.3. STEAM COIL INSTALLATION ................................................................................................... 40

12.4. HYDROSTATICALLY TESTING COILS & RISERS ............................................................................... 42

12.5. ANTICIPATOR CHECK VALVE REASSEMBLY .................................................................................... 42

12.6. REASSEMBLY OF SHELL ................................................................................................................ 43

12.7. REINSTALLING HEATER I N FACILITY ............................................................................................... 43

12.8. STARTUP PROCEDURE ................................................................................................................. 43

CHAPTER 13. RECOMMENDED SPARE PARTS .................................................................................... 44

Page 4 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

! ! !

!

Installation, Operation & Maintenance Manual OMM-0063_0C

CHAPTER 1. SAFETY PRECAUTIONS

Installing or operat ing pers onnel m ust, at al l times , observe all safet y regulat ions. T he followin g warni ngs
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.

SHUT OFF ALL INCOMING AND OUTGOING STEAM AND HOT WATER STOP VALVES AND

CAREFULLY DECREASE ALL TRAPPED TRESSURES TO ZERO (see SHUTDOWN IN

OPERATERING PROCEDURES) 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 SUITIBLE POLISHED OBJECT. ALSO, ALWAYS WEAR GLOVES AND LONG

SLEEVES.

MC2: 07/26/13 Page 5 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C Installation, Operation & Maintenance Manual

This instruction covers the AERCO Helitherm Model B+ WATER WIZARD Steam to Water
Heat Exchangers. STEAM is the PRIMARY or TUBE SIDE FLUID. The WATER BEING
HEATED is the Heat Exchanger (service or domestic water or other fluid) is the SECONDARY
or SHELL SIDE FLUID.

2.1. MODEL NAMES

The number of coils in a particular Heat Exchanger is denoted by the two digits following the
“B+” in the Heat Exchanger Model Number. That is: B+03 = 3 coils, B=07 = 7 coils, B+11 = 11
coils, and B+15 = 15 coils.

The Style designation for a Heat Exchanger denotes materials of construction for the various
components of the assembly. If this information is required for a specific Heat Exchanger,
contact the nearest AERCO Sales Representative.

2.2. HEAT EXCHANGER CONFIGURATIONS

There are three basic heat exchanger configurations; those with a pneumatically controlled
valve (CXT-P), those with Electronic Control System (ECS) with an electronically controlled
valve (CXT-E), and a “bare” heat exchanger without controls or valve. See separate ECS
Controls manual, AC-105, for information about the Electronic controls System and
electronically operated CXT-E valve. See Section 3 for available accessories.

2.3. ACCESSORIES

CHAPTER 2. GENERAL INFORMATION

Accessories included in the AERCO B+ Heater Package Assembly (See Figures 1a, 1b, 1c,
21, 22, and 23) include:

• Steam Flow Control Valve – either Air-Operated or Self-Contained as ordered and
furnished, sized as required for the service.

• Temperature Controller – installed in the Control Box when an Air Operat ed Control Valve is
furnished (See Fig. 20, Item 134).

• Over-Temperature Limit System, including the following:

• Temperature Switch – installed in the Control Box (Figure 20, Item 126).

• Solenoid Valves:

o Water – installed in the Heater Top Head.
o Air – installed in the Control Box when an Air Operated Control Valve is furnished

(Fig. 20, Item 135).

o Steam – installed on the Self-Contained Control Valve when such valve is furnished.
o Indicator Lights: “Power On” and “Tripped” – installed in the Control Box (Figure 20,

Items 129 and 130).

• Steam Compound Pressure Gage – mounted below the Control Box (Figure 20, Item 133).

• Shell Hot Water Outlet Temperature Gage – mounted below the Control Box (Figure 20,

Item 1 32).

• Pressure & Temperature Relief Valves – size and number furnished as required in
accordance with the design BTU output of the heater – first two located in the heater Top

Page 6 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Installation, Operation & Maintenance Manual OMM-0063_0C

Head as shown in Figure 1a, 1b, 1c, and 1d. The third, if furnished, to be installed in the hot
water outlet piping by the user as shown in Figure 2.

• Union Orifice – located in the Condensate Outlet (Figure 12, Item 55) – required in place of
a steam trap to ensure complete condensation of the steam within the heater.

• Check Valve – located in the Condensate Outlet (Figure 12, Item 53).

2.4. ALL OTHER ITEMS

Stop valves, check valves, strainers, unions or flanges, and other piping and f ittings as s hown in
Figures 3 through 6 – are to be furnished by USER.

NOTE:

This instruction covers only the heat exchanger portion of the model B+
packaged heater assembly. Separate instructions are included in this package
covering steam control valve, the over-temperature limit system and its
components, and other accessories included in the heater package.

NOTE:

The AERCO Helitherm heat exchanger carries the standard AERCO warranty
against defective material and workmanship. However, AERCO cannot honor its
warranty if the installer or user deviates in any way from the instructions and
precautions included herein and/or make any alteration of the equipment from
that furnished without the written approval of AERCO.

MC2: 07/26/13 Page 7 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Chapter 2

OMM-0063_0C Installation, Operation & Maintenance Manual

General Information

Figure 1a – Dimensions for AERCO Helitherm Heat Exchanger (Packaged Water Heater),

Model Water Wizard SW1B+II with Pneumatic CXT-P Valve

Page 8 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Installation, Operation & Maintenance Manual OMM-0063_0C

Figure 1b – Dimensions for AERCO Helitherm Heat Exchanger (Packaged Water Heater),

Model Water Wizard SW1B+II with Bronze Heads, ECS, and CTX-E Valve

MC2: 07/26/13 Page 9 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C Installation, Operation & Maintenance Manual

Figure 1c – Dimensions for AERCO Helitherm Heat Exchanger (Packaged Water Heater),

Model Water Wizard SW1B+II with Stainless Steel Heads, ECS, and CTX-E Valve

Page 10 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Chapter 3

Installation, Operation & Maintenance Manual OMM-0063_0C

Installation

Figure 1d – Dimensions for AERCO Bare Helitherm Replacement Heat Exchanger for

Model Water Wizard SW1B+II

MC2: 07/26/13 Page 11 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C Installation, Operation & Maintenance Manual

CHAPTER 3. INSTALLATION

3.1. INSTALLING THE WATER WIZARD

To install the Water Wizard SW1B+II water Heater, follow the steps below:

Installing the Water Wizar d H eat er Instructions

1) Dimensions for three versions of AERCO Model SW1B+II are shown in Figures 1a, 1b, and

1c.

2) Uncrate the Heater carefully. Set the Heater upright by using a block and tackle or hoist
attached to the lifting lug on the top of the Heater (the eye-bolt s s hown in Fig ur e 15). Always
use the lifting lugs to lift and/or move the Heater.

3) If possible, for easy in-place maintenance, locate the Heater where there is at least 2 feet
clearance all around the Heater and where the head room clearance from the top of
dimension B in Figure 1 is at least equal to dimension A for the Heater Model, less 24
inches.

4) It is suggested that the Heater stand assembly be secured to the floor, however, any other
means for securing the Heater may be used. If piping is used to secure the Heater, the
piping must include ample provision for expansion.

5) Make all piping connections as instructed in Step 6 below and per the appropriate Figures
shown:

a) Single Heater – Figure 3
b) Parallel Heaters – Figure 4
c) Single Heater used with an Accumulator – Figure 5
d) Single Heater used with a Stratified Storage Tank – Figure 6

or with any specific piping diagram which may have been furnished by AERCO for this
installation.

6) For the best Heater performance, OBSERVE THE FOLLOWING VERY CAREFULLY in
making the piping installation:

a) Do not use cement or red lead in making up pipe joints
b) For Heater connection types, sizes, and exact locations, see Figure 1.
c) All piping to the Heater top head should be provide with unions or flanges which are

LOCATED BEYOND THE OUTSIDE DIAMETER OF THE HEATER HEAD to permit
removal of the head and shell for in-place maintenance.

d) Include all of the stop valves, check valves, steam traps, and other elements in the

piping as shown in Figure 3, 4, 5, or 6, or as separately specified by AERCO. Note
that the check valve shown at the Heater in the Condensate return line is furnished in
the piping package assembly by AERCO.

e) The Condensate return piping MUST be arranged to permit Condensate to drain

freely by gravity from the Heater Bottom Head. Failure to do so may result in
improper Heater operation and/or in damage to the Heater Steam/Condensate
system.

(Continued)

Page 12 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Installation, Operation & Maintenance Manual OMM-0063_0C

Installing the Water Wizar d H eat er I nst ructions (Cont.)

f) All drain discharges – relief valve(s) in the Top Head of the Heater, outlet of the

Water Solenoid Valve in the top head of the Heater, and Drain Valve in the Bottom
Head of the Heater – should be piped directly to a convenient floor drain.

7) When a third P&T Relief Valve is furnished with the Heater (the first two furnished have
been assembled in the top head of the Heater by AERCO), the t hird Valve is to be installed
in the Heater hot water outlet piping, by the user, as illustrated in Figure 2.

8) Before making final piping connections to and from the Heater and Cont rol Valve, blow out
all piping thoroughly.

9) If an air-operated Control Valve is furnished in the Heater package, make the necessary
supply air connection to the connector through the side of the Control Box (see Figure 20,
Item 136). The supply air pressure must be maintained at 20 PSIG.

10) Connect 110 volt 60 Hz power supply wiring through the side of the Control Box to the
electrical Junction Box (see Figure 20, Item 127).

Figure 2 – P&T Relief Valve Located in the Heater Hot Water Outlet Piping

MC2: 07/26/13 Page 13 of 50

HE-110 1B+ II Water Wizard Water Heat er s

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

OMM-0063_0C Installation, Operation & Maintenance Manual

Figure 3 – Piping Connections for a Single Heater

Page 14 of 50 MC2: 07/26/13

1B+ I I Wa t er Wiza rd Water Heaters HE-110

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Installation, Operation & Maintenance Manual OMM-0063_0C

MC2: 07/26/13 Page 15 of 50