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Aerco 27035 Technical Instructions

Ecs upgrade for sw double wall heaters
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ECS Upgrade for SW Double Wall Heaters, Kits 27035, 27036, 27037
TECHNICAL INSTRUCTIONS
This document provides instructions for upgrading the
Control System (ECS) for Steam-to-Water (SW) Double Wall Heaters using kit
numbers 27035, 27036 and 27037.
These instructions apply to the following Steam-To-Water (SW)
Double-Wall (DW) heater models:
• SWDW-24
• SWDW-45
• SWDW-68
This document replaces the following document (01/25/2011):
TSB-11-007_0A_SWDW_Recirculator-ECS_Upgrade
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 the furnishing, performance, or use of these
materials.
Creation Date: 12/30/2014
12/30/2014
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
Technical Instruction Document
DISCLAIMER
AERCO Technical Support:
(Mon–Fri, 8am-5pm EST)
1 (800) 526-0288
TID-0142_0A
Electronic
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Summary of Contents for Aerco 27035

  • Page 1 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.

  • Page 2: Table Of Contents

    4.2 APPENDIX B: 10" SWDW ECS RECIRC. LOOP UPGRADE ..........22 4.3 APPENDIX C: 12" SWDW ECS RECIRC. LOOP UPGRADE ..........23 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 2 of 24...

  • Page 3: Introduction

    DEATH MAY OCCUR IF THIS WARNING IS NOT OBSERVED. FOLLOW OSHA APPROVED LOCKOUT/TAGOUT PROCDURES. NOTICE: Burn permits may be required for certain installations requiring braising. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 3 of 24...

  • Page 4: Tools & Supplies Required

    Brazing equipment for assembling P/N 97049 (if burn permit available) 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.
  • Page 5 22 (1/4” NPT Hex Steam Inlet Head Plug) Condensate Outlet Figure 2-1: Before Upgrade - Double-Wall Heater Component Locations (Sheet 1 of 2) 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 5 of 24...
  • Page 6 Water Inlet Opening Condensate Outlet Leak Detection Port Figure 2-1: Before Upgrade - Double-Wall Heater Component Locations (Sheet 2 of 2) 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 6 of 24...

  • Page 7: Isolating Water Heater

    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). 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 7 of 24...

  • Page 8: Removal Of Items Connected To Heater Shell

    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). 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 8 of 24...
  • Page 9 ECS Upgrade for SW Double Wall Heaters, Kits 27035, 27036, 27037 Technical Instruction Document TID-0142_0A Figure 2-2: Location of Cold Water Inlet 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 9 of 24...
  • Page 10 59095 90058 90074 93326 93325 22102 93325 Figure 2-3. Circulator Sub-assembly 3. Assemble remaining items as shown in Figure 2-3 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 10 of 24...
  • Page 11 14. Braise one (1) 1.5” tube x 1.5” male NPT adapter to other end of tube. 15. Attach flange to 1.5” male NPT adapter 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 11 of 24...

  • Page 12: Thermocouple & Circulator Installation For Swdw Heaters - Compression Fittings

    1.5” Flange w/ 2 3/8”-16 nuts (59095) 5. Following Manufacturer’s instructions, attach one (1) 1.5” tube ODx 1.5” male NPT adapter to one end of tube. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 12 of 24...

  • Page 13: Temperature Controller Replacement

    Controller. These controls and displays are illustrated and described in Figure 2-6 and Table 2-1. If necessary, setpoint temperature adjustment is accomplished as follows: 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 13 of 24...
  • Page 14 4. Two seconds after the ▲ or ▼ arrow button is released, the display will blink to indicate that the Temperature Controller has accepted and stored the displayed value. Figure 2-6. Temperature Controller Installation 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 14 of 24...

  • Page 15: Wiring The Ecs Control Box For The Circulator And Temperature Control

    (common) power supply wire and either the yellow or blue wire to the black (hot) power supply wire. The pump cannot run backwards. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 15 of 24...
  • Page 16 12. Close the front door of the ECS Control Box and tighten the captive screw to secure it. Figure 2-7: Typical ECS Control Panel Front View 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 16 of 24...
  • Page 17 Technical Instruction Document TID-0142_0A Figure 2-8: Typical Recessed Panel Behind Control Box Door Figure 2-9: Typical ECS Control Box AC Power Connections 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 17 of 24...

  • Page 18: Post Installation Connections And Adjustments

    Over-Temperature Switch must be set. The adjustment procedures for these items are provided in Section 3 of Operation and Maintenance Manual HE-111. A copy of this manual is included in the Upgrade Kit. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 18 of 24...
  • Page 19 TID-0142_0A Figure 3-1. DW-68 Double Wall Water Heater With ECS Control System & CXT-E Control Valve (Sheet 1 of 2) 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 19 of 24...
  • Page 20 SIDE VIEW Figure 3-1. DW-68 Double Wall Water Heater With ECS Control System & CXT-E Control Valve (Sheet 2 of 2) 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 20 of 24...

  • Page 21: Appendices

    93325 REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97052 ADAPTER, MALE PIPE, 1-1/2" TUBE X 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 21 of 24...

  • Page 22: Appendix B: 10" Swdw Ecs Recirc. Loop Upgrade

    93325 REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97052 ADAPTER, MALE PIPE, 1-1/2" TUBE X 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 22 of 24...

  • Page 23: Appendix C: 12" Swdw Ecs Recirc. Loop Upgrade

    REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97052 ADAPTER, MALE PIPE, 1-1/2" TUBE X --- END --- 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 23 of 24...
  • Page 24 Description Changed By 12/30/2014 Rev A: Initial release (replacement for TSB-11-007). Chris Blair International Inc. © AERCO International, Inc., 2014 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 24 of 24...

This manual is also suitable for:

2703627037Swdw-24Swdw-45Swdw-68

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