AERCO CXT-E Retrofit Kit - Manual (Page 2)

ECS and CXT-E Retrofit Instructions Kit # 27004-TAB
Technical Instruction Document TID-0141_0A
12/30/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 2 of 76
1. INTRODUCTION ................................................................................................................... 3
1.1 SAFETY PRECAUTIONS ............................................................................................... 3
1.2 Tools & Supplies Required ............................................................................................. 3
1.3 Retrofit Kit Contents ....................................................................................................... 4
2. EQUIPMENT ISOLATION AND REMOVAL PROCEDURES ................................................ 5
2.1 Isolating Water Heater ...................................................................................................11
2.2 Draining Water Heater ...................................................................................................11
2.3 Removal of Components on Top Head Assembly .........................................................12
2.4 Removal of Items Connected to Bottom Head ...............................................................13
2.5 Control Valve Actuator Removal ....................................................................................14
2.5.1 Pneumatic Control Valve Actuator Removal .........................................................14
2.5.2 Electro-Hydraulic Control Valve Actuator Removal ...............................................16
2.5.3 Self-Contained Control Valve Actuator Removal ...................................................18
2.6 Control Box Removal ....................................................................................................21
3. RECOMMENDED REPLACEMENT OF VALVE ASSEMBLY PARTS .................................24
3.1 Valves Previously Equipped With Pneumatic or Electro-Hydraulic Actuators .................24
3.1.1 Valve Disassembly Procedure ..............................................................................24
3.1.2 Valve Reassembly Procedure ...............................................................................30
3.2 Valves Previously Equipped With Self-Contained Actuators ..........................................31
4. INSTALLATION OF RETROFIT KIT ITEMS .........................................................................35
4.1 Installation of Control Valve Actuator and Linkage Assembly ........................................35
4.1.1 Linkage Assembly Installation ...............................................................................36
4.1.2 Actuator Installation ..............................................................................................38
4.2 Installation of ECS Components on Top Head Assembly ..............................................40
4.2.1 Outlet Flange ........................................................................................................40
4.2.2 Outlet Temperature Dual Sensor ..........................................................................40
4.2.3 Water Solenoid .....................................................................................................40
4.2.4 NPT Plugs ............................................................................................................41
4.3 Flow Meter Installation...................................................................................................41
4.3.1 Flow Meter Installation For Helitherm Heaters ......................................................43
4.3.2 Flow Meter Installation For Water-to-Water Double-Wall Heaters .........................44
4.4 Boiler Water Inlet and Outlet Temperature Sensors – (Water-to-Water Heaters) ...........45
4.4.1 E-Plus Water Heaters ...........................................................................................45
4.4.2 Water-to-Water Double-Wall Water Heaters .........................................................46
4.5 Compound Pressure Gauge ..........................................................................................48
4.5.1 Helitherm Steam-to-Water Units ...........................................................................49
4.6 Installation of New Orifice Disc ......................................................................................49
4.7 ECS Control Box Installation .........................................................................................51
5. POST INSTALLATION CONNECTIONS AND ADJUSTMENTS ..........................................54
5.1 Input and Output Water Heater Connections .................................................................54
5.2 Adjustments ..................................................................................................................54