Aerco B+03 User Manual
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Aerco B+03 User Manual

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Covers all 1B+ II models
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).
Other applicable documentation includes:
SB-2006-02: ECS Retrofit Instructions
AC-105: Electronic Controls System (ECS) Manual
AC-103: Pneumatic Temperature Controller Manual
Revised: 11/28/2018
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
USER MANUAL
Installation, Operation, and Maintenance
Water Wizard
1B+ II
Water Heaters
SW1B+II Packaged Water Heater with
Pneumatically Controlled Valve (CXT-P)
HE-110
OMM-0063_0D

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Jefferson Stall
March 31, 2025

Part number for the polycarbonate meter cover

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Jefferson Stall
March 31, 2025

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Summary of Contents for Aerco B+03

  • Page 1 SB-2006-02: ECS Retrofit Instructions AC-105: Electronic Controls System (ECS) Manual SW1B+II Packaged Water Heater with AC-103: Pneumatic Temperature Controller Manual Pneumatically Controlled Valve (CXT-P) Revised: 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288...
  • Page 2 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.

  • Page 3: Table Of Contents

    ALVE EASSEMBLY 12.6............................. 43 EASSEMBLY OF HELL 12.7........................43 EINSTALLING EATER IN ACILITY 12.8............................43 TARTUP ROCEDURE 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 3 of 50 • Phone: 800-526-0288...
  • Page 4 HE-110 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D CHAPTER 13. RECOMMENDED SPARE PARTS ....................... 44 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 4 of 50 • Phone: 800-526-0288...

  • Page 5: Chapter 1. Safety Precautions

    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. 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 5 of 50 • Phone: 800-526-0288...

  • Page 6: Chapter 2. General Information

    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.

  • Page 7: All Other Items

    AERCO. 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 7 of 50 • Phone: 800-526-0288...
  • Page 8 Installation, Operation & Maintenance Manual OMM-0063_0D Chapter 2 General Information Figure 1a – Dimensions for AERCO Helitherm Heat Exchanger (Packaged Water Heater), Model Water Wizard SW1B+II with Pneumatic CXT-P Valve AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 8 of 50 •...
  • Page 9 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 1b – Dimensions for AERCO Helitherm Heat Exchanger (Packaged Water Heater), Model Water Wizard SW1B+II with Bronze Heads, ECS, and CTX-E Valve 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 9 of 50 •...
  • Page 10 Installation, Operation & Maintenance Manual OMM-0063_0D 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 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913...
  • Page 11 Installation, Operation & Maintenance Manual OMM-0063_0D Chapter 3 Installation Figure 1d – Dimensions for AERCO Bare Helitherm Replacement Heat Exchanger for Model Water Wizard SW1B+II 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 11 of 50...

  • Page 12: Chapter 3. Installation

    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.
  • Page 13 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 third Valve is to be installed in the Heater hot water outlet piping, by the user, as illustrated in Figure 2.
  • Page 14 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 3 – Piping Connections for a Single Heater AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 14 of 50 • Phone: 800-526-0288...
  • Page 15 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 4 – Piping Connections for Parallel Heaters 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 15 of 50 • Phone: 800-526-0288...
  • Page 16 Chapter 4 Principal of Operation Figure 6 – Piping Connections for a Single Heater used with a Stratified Storage Tank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 16 of 50 • Phone: 800-526-0288...

  • Page 17: Chapter 4. Principle Of Operation

    Cold Water, and provides FEED-FORWARD temperature control at all times. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288...

  • Page 18: Heat Exchanger Operation With Electronic Control System (Ecs)

    HE-110 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 7 – Schematic of AERCO Model B+II Water Heater showing Anticipator Temperature Control 4.2. HEAT EXCHANGER OPERATION WITH ELECTRONIC CONTROL SYSTEM (ECS) The Electronic Control System (ECS) available for the Water Wizard SW1B+II offers features and functions not described in this manual.

  • Page 19: Chapter 5. Operating Procedures

    Over- Temperature Limit System – usually 15°F to 20°F higher than the desired hot water outlet temperature. (Continued) 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 19 of 50 • Phone: 800-526-0288...
  • Page 20 4) stop valves in the Steam inlet line and Condensate outlet lines. 14) After each startup, check the temperature control. If necessary, make adjustments per Steps 4 through 9. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 20 of 50...
  • Page 21 Installation, Operation & Maintenance Manual OMM-0063_0D Figure 8 – Model B+II Heater Control Box Figure 9 – Over-Temperature Limit System Wiring Diagram 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 21 of 50 • Phone: 800-526-0288...

  • Page 22: Chapter 6. Routine Maintenance

    Check the temperature control at least once every 3 months. Make any necessary adjustments per Steps 4 through 8 under OPERATING PROCEDURES, Chapter 5. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 22 of 50...

  • Page 23: Chapter 7. Troubleshooting

    Loud banging in heater or in Steam or Condensate piping 6, 7, 9, 10 (not to be confused with normal clicking noise). 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 23 of 50 • Phone: 800-526-0288...

  • Page 24: Chapter 8. Correcitve Maintenance

    14. The Anticipator Unit system is not operating properly. Check to make sure that the temperature sensing element has not failed (see Item 13, above), that the shunt tube (item AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 24 of 50 •...
  • Page 25 19. The Heater is being utilized at a rate higher than its design capacity. Contact the nearest AERCO Representative for advice in remedying this problem. 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 25 of 50 • Phone: 800-526-0288...

  • Page 26: Chapter 9. De-Scaling By Thermal Shock Method

    9) If Cold Water conditions are so severe that thermal shocking does not remove scale deposits, consult the nearest AERCO Representative for advice. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 26 of 50...

  • Page 27: Chapter 10. Maintenance Disassembly

    Coil Spacing Tool (Figure 1) • Short-Length Wrenches: 1-1 /4”, 1-5/16”, 1-1/2” (Overall wrench lengths should be approx. 6 inches or less) 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 27 of 50 • Phone: 800-526-0288...
  • Page 28 Installation, Operation & Maintenance Manual OMM-0063_0D Figure 10: Tool Fabrication Details: Coil Spacing and Retaining Tools Recommended Material: 1018 steel AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 28 of 50 • Phone: 800-526-0288...

  • Page 29: Isolating The Heater

    7) While holding the Relief Valve open to prevent creating a vacuum in the Shell, open the Drain Valve in the Bottom Head on the Heater. Completely drain the potable water from the Heater. 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 29 of 50 • Phone: 800-526-0288...

  • Page 30: Disconnecting The Heater From The Facility

    Steam Valve. 15) If controlled by a Self-contained Valve, remove the thermal well from the Top Head that is attached to the Valve. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 30 of 50...

  • Page 31: Anticipator Check Valve Disassembly

    Clean all parts and gasket surfaces thoroughly, and repair or replace any part necessary to make the Check Valve operate properly (open on water flow through the Heater). 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 31 of 50 • Phone: 800-526-0288...

  • Page 32: Preparing To Remove The Heater Shell

    6. Disconnect the Compression Fitting (59), located at the bottom of the Shunt Tubing (69) from the Heater Bottom Head. Figure 12: Part Reference for Heater Shell Removal AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 32 of 50...

  • Page 33: Removing The Heater Shell

    4) Using a light source, visually inspect the inside of the Heater Shell for evidence of damage to the Copper Shell Liner. If any area of the Copper Liner is damaged, replace the Shell down on the Bottom Head and contact your local AERCO Representative to process return of the Heater to AERCO for repair.

  • Page 34: Chapter 11. Cleaning And Inspection

    1) Visually inspect all Steam Riser and Condensate Return Spuds, (Figure 2) threads and sealing surfaces for damage, scratches, braze material and cleaning deposits. If defects are found with the Spud threads or sealing surfaces, contact your AERCO Representative for instruction to return the defective Riser.

  • Page 35: Preparation Of Coil Assemblies

    (Figure 14). 3) Contact your local AERCO Representative for replacement of the Coil if obstructions prohibit the rotation of the Union Nut. 4) Using a brass wire brush, clean the internal threads of the Union Nut.
  • Page 36 Installation, Operation & Maintenance Manual OMM-0063_0D DETAIL ‘A’ TAILPIECE SEATING SURFACE HEADER SEALING SURFACE UNION DETAIL ‘A’ Figure 14: Coil Assembly Preparation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 36 of 50 • Phone: 800-526-0288...

  • Page 37: Preparation Of Coil Gaskets

    2 to 3 degrees as shown in Figure 16. This will secure the Gasket into the Spud’s inside diameter. 2 - 3° Figure 16: Coil Gasket Preparation 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 37 of 50 • Phone: 800-526-0288...

  • Page 38: Chapter 12. Maintenance Reassembly

    13) If the Coil Gasket is loose in the Spud, remove it and reform the six tabs to create a positive connection into the Spud. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 38 of 50...
  • Page 39 SPUD HEADER UNION NUT STEAM RISER OR CONDENSATE RETURN Figure 18: Assembly of Coil to Steam Riser or Condensate Return 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 39 of 50 • Phone: 800-526-0288...

  • Page 40: Sub-Cooling Coil Installation

    14) Recheck all Union Nuts for the 75 ft/lbs setting without holding the Coil. 15) If a Union Nut or Coil rotates during this step, repeat steps 10 and 11. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 40 of 50 •...
  • Page 41 TOP VIEW (PARTIAL CUT-AWAY) RISER COIL ASSEMBLY INSERT COIL RETAINING TOOL HERE HEADER SIDE VIEW Figure 19: Positioning of Coil Retaining Tool 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 41 of 50 • Phone: 800-526-0288...

  • Page 42: Hydrostatically Testing Coils & Risers

    Reassemble the Anticipator Check Valve assembly as follows: Anticipator Check Valve Reassembly 1) Insert the Valve Plug (36), the Washer (35), the Spring (34), and the Gasket (32). AERCO recommends that a new Gasket (32) be use whenever the Check Valve is reassembled.

  • Page 43: Reassembly Of Shell

    7) Remove the leaking Coil and inspect for causes for leak. 8) If the leak is due to debris, clean the Coil and reinstall. 9) If there are damages to any surfaces, contact your AERCO Representative for instruction for returning the failed Coil.
  • Page 44 Item No. Shown in Figure No. Temperature Controller Air Solenoid Valve P&T Relief Valve*** Water Solenoid Valve Asbestos Flange Gasket**** AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 44 of 50 • Phone: 800-526-0288...
  • Page 45 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 20 – AERCO Model SW1B+II Control Box Assembly and Parts List 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 45 of 50...
  • Page 46 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D Figure 21 – AERCO Model B+II Water Heater w/Pneumatic Valve - Assembly and Parts List AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 46 of 50 •...
  • Page 47 HE-110 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 47 of 50 • Phone: 800-526-0288...
  • Page 48 HE-110 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 48 of 50 • Phone: 800-526-0288...
  • Page 49 HE-110 1B+ II Water Wizard Water Heaters Installation, Operation & Maintenance Manual OMM-0063_0D NOTES: 11/28/2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 49 of 50 • Phone: 800-526-0288...

  • Page 50: 11/28/2018 Aerco International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913

    Rev D: Clarified reference to Startup procedure in Section 12.8 Startup 11/28/2018 Chris Blair Procedure. © AERCO International, Inc., 2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/28/2018 Page 50 of 50 • Phone: 800-526-0288...

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