Aerco SWDW-24 Technical Instructions
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Aerco SWDW-24 Technical Instructions

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ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters
TECHNICAL INSTRUCTIONS
This document provides technical instructions for removing an
existing Control Valve Actuator and Control Box and replacing it with
a new CXT-E Electronic Control Valve Actuator and Electronic
Control System (ECS).
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 (Dec. 6, 2010):
TSB-2010-06_0A_SWDW_Recirculator-CXT-E-ECS_Retrofit_Inst
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-0140_0A
Page 1 of 58

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Summary of Contents for Aerco SWDW-24

  • 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

    APPENDIX D VALVE KITS REQUIRED FOR UPGRADED PNEUMATIC OR ELECTRO- HYDRAULIC ACTUATOR ....................55 APPENDIX E VALVE KITS REQUIRED FOR UPGRADED ..........56 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 2 of 58...

  • Page 3: Introduction

    (PPE) such as gloves, eye protection, dust mask, hard hat, etc. 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 58...

  • Page 4: Tools & Supplies Required

    WITHIN EQUIPMENT. SERIOUS PERSONAL INJURY OR DEATH MAY OCCUR IF THIS WARNING IS NOT OBSERVED. FOLLOW OSHA APPROVED LOCKOUT/TAGOUT PROCDURES. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 4 of 58...

  • Page 5: Equipment Isolation And Removal Procedures

    Technical Instruction Document TID-0140_0A 2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES The locations of the major items to be removed from an AERCO SWDW are shown in Figure 2-1. These items include: • Currently Installed Control Valve Actuator (Pneumatic, Self-Contained or Electro- Hydraulic) •...
  • Page 6 3/4" PLUGGED DRAIN CONTROL VALVE STEAM/BOILER CONDENSATE/BOILER WATER INLET WATER OUTLET Figure 2-1. 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 6 of 58...
  • Page 7 COLD WATER INLET ORIFICE DISC & SPRING RING STEAM/BOILER WATER INLET Figure 2-1. 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 7 of 58...

  • Page 8: Isolating Water Heater

    LONGER BE USED. IT IS RECOMMENDED THAT ALL REQUIRED ITEMS BE REMOVED AS INDICATED IN THE FOLLOWING STEPS PRIOR PERFORMING THEREPLACEMENT PROCEDURES IN SECTION 3. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 8 of 58...

  • Page 9: Removal Of Components On Top Head Assembly

    GASKET HOT WATER OUTLET FLANGE SPRING PLATE ASSEMBLY VALVE PLUG ASSEMBLY SPRING Figure 2-2. Anticipator Check Valve (Load Alert) Assembly 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 9 of 58...

  • Page 10: Removal Of Items Connected To Heater Shell

    5. Remove the two 3/8-16 cap screws securing the Pneumatic Actuator to the Valve Body. Remove the entire Actuator from the Valve. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 10 of 58...
  • Page 11 HEX NUT LOWER SHAFT CAP SCREWS (2) VALVE TOP VALVE BODY DETAIL “A” Figure 2-3. Pneumatic Control Valve Actuator Removal 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 11 of 58...

  • Page 12: Electro-Hydraulic Control Valve Actuator Removal

    BOLTS (4) LOWER HEX NUT ACTUATOR GASKET VALVE TOP VALVE BODY DETAIL “A” Figure 2-4. Electro-Hydraulic Control Valve Actuator Removal 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 12 of 58...
  • Page 13 Valve Stem counterclockwise and separate it from the Actuator Connecting Shaft. Replacement of all required Valve parts will be accomplished using the appropriate instructions and illustrations in Section 3. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 13 of 58...
  • Page 14 DOWNSTREAM TUBE TUBE VALVE HEX HEAD BODY CAP SCREWS 1/4" NPT COMPRESSION ELBOW Figure 2-5. Self-Contained Control Valve Actuator Removal 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 14 of 58...
  • Page 15 VALVE STEM HOLE RETAINING VALVE PLUG VALVE SHAFT BODY Figure 2-7. Self-Contained Control Valve Actuator Removal – 1” to 2” 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 15 of 58...

  • Page 16: Control Box Removal

    If you have the weld studs proceed as follows. Note that the new box will be mounted directly on the studs. 1. Remove nuts. 2. Remove box. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 16 of 58...
  • Page 17 HEX NUT MOUNTING BRACKET (SAVE) TOP HEAD SHELL FLANGE CONTROL HEX NUT DETAIL “A” Figure 2-8. Control Box Mounting Details 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 17 of 58...
  • Page 18 SHELL OUTLET STEAM PRESS. °F PSIG CONTROL BOX USED WITH PNEUMATIC CONTROL VALVE Figure 2-9. Control Box With Door Open 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 18 of 58...

  • Page 19: Recommended Replacement Of Valve Assembly Parts

    Lower Shaft (16) and Valve Stem (12) Retaining Disc (8) Disc Seat (7) Seat Retainer (34) Valve Plug Shaft (5) 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 19 of 58...
  • Page 20 Next, proceed to the Valve Reassembly procedures in paragraph 3.1.2 and replace the items indicated with the new parts provided in the Retrofit Kit. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 20 of 58...
  • Page 21 ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters Technical Instruction Document TID-0140_0A Figure 3-1. Valve Assembly Sizes 1.00” to 2.00” 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 21 of 58...
  • Page 22 LOWER PILOT SEAT ASSY 121505 121505 121505 121505 SEAT RETAINER 121559 121506 121506 VALVE STEM RETAINING NUT 121503 121503 121503 121503 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 22 of 58...
  • Page 23 ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters Technical Instruction Document TID-0140_0A Figure 3-2. Valve Assembly Sizes 2.50” to 4.00” 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 23 of 58...
  • Page 24 122328 LOCKWASHER 122666 122667 122667 SEAT CAGE GASKET 123084 123085 123086 ITEMS NOT SHOWN THRU PILOT SPRING BACKUP WASHER 122246 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 24 of 58...

  • Page 25: Valve Reassembly Procedure

    Kit. However, 4 inch Valves contain two 3/8-16 Hex Nuts in the Kit. Replace the appropriate Hex nuts on the Valve Shaft. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 25 of 58...

  • Page 26: Valves Previously Equipped With Self-Contained Actuators

    Refer to Figure 3-1 (1” to 2” Valves) or Figure 3-2 (2.5” to 4” Valves) for the locations of these items. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 26 of 58...
  • Page 27 121545 121545 122666 122666 122666 122666 LOCKWASHER Figure 3-3. Inner Pilot Assembly Kit (29021-[ ]) for 1.00” to 2.00” Valves 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 27 of 58...
  • Page 28 121618-1.00 (1.00 PARTS LIST) NOTES: REQUIRED FOR 1.00 VALVE Figure 3-4. Valve Piston Assembly Kit (121618-[ ]) for 1.00” to 2.00” Valves 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 28 of 58...
  • Page 29 2 1/2" 3" 4" QTY. DESCRIPTION PARTS LIST Figure 3-5. Main Valve Assembly Kit (27006-[ ]) for 2.50” to 4.00” Valves 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 29 of 58...

  • Page 30: Installation Of Retrofit Kit Items

    1 and -2 used with different sizes of AERCO Control Valves. Linkage Assembly, part no. 24038-1 is used on AERCO Valve sizes ranging from 1 inch to 3 inches. The 24038-2 Linkage Assembly is used only on 4 inch Valves. The primary difference between these two assemblies is the Linkage Assembly Adapter shown in Figure 4-1.

  • Page 31: Linkage Assembly Installation

    Position the Hex Nuts so they are snug against the Indicator Plate. 11. Proceed to paragraph 4.1.2 to install the Actuator Assembly. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 31 of 58...
  • Page 32 HEX HEAD BOLTS (2) INDICATOR PLATE GASKET VALVE SHAFT HEX NUTS (2) VALVE TOP Figure 4-2. Actuator and Linkage Installation Details 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 32 of 58...
  • Page 33 59028-4 (4” VALVE) 8-32 HEX NUT 123322 3/8-16 X 5/8 LONG CAP SCREW 54014 GASKET 81046 Figure 4-3. Linkage Installation Details 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 33 of 58...

  • Page 34: Actuator Installation

    COVER CLUTCH neptronic COVER SET SCREW CABLE CONNECTOR CENTER SLOT 1 2 3 Figure 4-4. Actuator Assembly, Part No. 69170 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 34 of 58...

  • Page 35: Installation Of Ecs Components On Top Head Assembly

    Reconnect the previously installed drain piping to the Solenoid Valve outlet. Electrical connection of the Solenoid Valve will be accomplished following installation of the ECS Control Box. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 35 of 58...

  • Page 36: Npt Plugs

    These plugs are installed in the remaining tapped holes in the Top Head where components used with the previous Control System were installed. The location and size of the required Plugs may vary depending on the specific AERCO Heater Model being retrofitted. Refer to Figure 2-1 for reference.
  • Page 37 -- CUT AT ASSEMBLY TO SUITE -- Brazed 97049 59095 Compression 97052 69101 59095 90058 90074 93326 93325 22102 93325 Figure 4-6: Circulator Sub-assembly 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 37 of 58...
  • Page 38 • Bolts and Nuts for flanges from Step 10 17. Place pump seal in channel in flange on lower assembly. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 38 of 58...

  • Page 39: Thermocouple And Circulator Installation For Swdw - Compression Fittings

    Check for length—Size to accommodate the installation of the adaptor, the flange and the pump. Cut 1.5” copper tube to length 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 39 of 58...

  • Page 40: Compound Pressure Gauge

    The Gauge will be mounted on the steam inlet flange as shown in Figure 4-7. Figure 4-7. Compound Pressure Gauge Installation – Double-Wall S/W Unit 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 40 of 58...

  • Page 41: Ecs Control Box Installation

    ECS CONTROL MOUNTING BRACKET OVER TEMP SWITCH SHELL TEMP CONTROLLER SCREWS B+II WATERWIZARD Figure 4-8. ECS Control Box Mounting Location 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 41 of 58...
  • Page 42 15. Close the front door of the ECS Control Box and tighten the captive screw to secure it in place. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 42 of 58...
  • Page 43 OVER TEMP SWITCH AUTO HOLD TEMP CONTROLLER B-PLUS WATER HEATER PT.NO. Figure 4-10. Typical Recessed Panel Behind Control Box Door 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 43 of 58...
  • Page 44 ECS & CXT-E Control Valve Retrofit for SW Double Wall Heaters Technical Instruction Document TID-0140_0A Figure 4-11. 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 44 of 58...

  • Page 45: 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 Retrofit Kit. 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 45 of 58...
  • Page 46 TID-0140_0A Figure 5-1. 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 46 of 58...
  • Page 47 TID-0140_0A Figure 5-1. 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 47 of 58...

  • Page 48: Appendices

    APPENDIX D VALVE KITS REQUIRED FOR UPGRADED PNEUMATIC OR ELECTRO- HYDRAULIC ACTUATOR ......................55 APPENDIX E VALVE KITS REQUIRED FOR UPGRADED .............56 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 48 of 58...

  • Page 49: Appendix A 8" Swdw Ecs Recirc. Loop Retrofit

    93325 REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97049 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 49 of 58...
  • Page 50 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 50 of 58...

  • Page 51: Appendix B 10" Swdw Ecs Recirc. Loop Retrofit

    93325 REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97049 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 51 of 58...
  • Page 52 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 52 of 58...

  • Page 53: Appendix C 12" Swdw Ecs Recirc. Loop Retrofit

    93325 REDUCING COUPLING, 3" NPT X 2" NP 93326 UNION, 2" NPT THREADED 97049 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 53 of 58...
  • Page 54 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 54 of 58...

  • Page 55: Appendix Dvalve Kits Required For Upgraded Pneumatic Or Electro-Hydraulic Actuator

    6-226 3/8-16 HEX NUT 6-264 PACKING ASSY 121567 121568 121568 VALVE SEAT 121935 122032 122178 LOWER SHAFT 122223 122230 122224 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 55 of 58...

  • Page 56: Appendix E Valve Kits Required For Upgraded

    122405 122405 122405 122405 INNER PILOT ASSEMBLY KIT 29021-1.00 29021-1.25 29021-1.50 29021-2.00 VALVE PISTON ASSEMBLY KIT 121618-1.00 121618-1.25 121618-1.50 121618-2.00 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 56 of 58...
  • Page 57 CAP SCREW, 1/2-13 x 1-1/4” 6-24 CAP SCREW, 5/8-11 x 1-1/2” 6-310 6-310 MAIN VALVE ASSEMBLY KIT 27006-2.50 27006-3.00 27006-4.00 --- END --- 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 57 of 58...
  • Page 58 12/30/2014 Chris Blair 934-147); Actuator Assembly 69009 replaced with 69170 (reference PIR 987). International Inc. © AERCO International, Inc., 2014 12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 58 of 58...

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