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3 shell removal, 4 removal of coils and risers, Assembly preparation – AERCO Coil & Riser Replacement User Manual

Page 7: 1 preparation of bottom head, He-109

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PR2: 04/01/11 Page 7 of 16

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288

Coil/Riser Replace Instructions for Helitherm Water Heaters

Technical instructions

TID-0038_0A

HE-109

5.3 Shell Removal

Remove the Heater Shell as follows:












5.4 Removal of Coils and Risers

The Coil Assemblies, Riser and Condensate Return are removed as follows:




6. Assembly Preparation

Prior to reassembling Heater components, the Bottom Head, Steam Riser, Condensate Return and Coils

must be cleaned, inspected and prepared as described in the following paragraphs:

6.1 Preparation of Bottom Head

The Bottom Head of the Heater must be cleaned, inspected and prepared for reassembly as follows:










Shell Removal

1) Using a black marker, mark the edge of the Heater Bottom Head flange and Shell flange in order to

indicate their correct relative positions upon reassemble. The Top Head can remain attached to the

Shell.

2) Using the 1-1/16” combination wrench, unbolt the sixteen studs and nuts around the bottom ring of the

Shell. The two nuts located in-line with the mounting skid legs are to be removed with the stud left in

place.

3) Attach a chain hoist to the two lifting lugs on the Top Head. Lift the Shell up to clear the internal coil

bundle.

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.

5) Move the heat exchanger bundle a few feet to the side so that the Shell can be lowered to the floor.

Set the Shell on clean surface. Use care to avoid damaging the bottom edge of the Copper Shell Liner.


Section 5.3 Instructions

END

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Removal of Coils and Risers

1) Using the proper size open-end wrench, loosen the two Union Nuts securing the Coils to the Steam

Riser and Condensate Return.

2) Using a pipe wrench, remove the Steam Riser and Condensate Return from the Bottom Head.


Section 5.4 Instructions

END

Preparation of Bottom Head

1) Clean off all debris from the topside of the Bottom Head.
2) Visually inspect the internal pipe threads where the Risers are connected. The overall depth of

threads should measure, (1-1/8” for 2” NPT and 1” for 1” NPT)

3) If the threads are less then the required depth, use the appropriate 1” or 2” NPT tap to clean out the

threads.

4) Using the gasket removal tool, remove the Shell Gasket from the Bottom Head. Use care to avoid

creating scratches or indents in the Bottom Head casting’s gasket surface area. Any linear scratches

can potentially create a leak.

5) Apply pipe dope to the internal NPT threads in the Bottom Head.


Section 6.1 Instructions

END