AERCO CXT-E Retrofit Kit - Manual (Page 3)

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 3 of 76
1. INTRODUCTION
This document provides the procedures necessary to remove an existing Control Valve Actuator
and Control Box and replace it with a new CXT-E Electronic Control Valve Actuator and Electronic
Control System (ECS). These procedures are applicable to all AERCO Indirect-Fired Water
Heaters with Control Valves ranging in size from 1 inch to 4 inches and currently equipped with
pneumatic, electro-hydraulic or self-contained valve actuators. In addition, this document applies
to both steam-to-water (SW) and water-to-water (WW) heaters.
These instructions must be performed by a skilled service technician capable of exercising the
necessary safety precautions when working with high temperature, pressurized steam and water
systems.
1.1 SAFETY PRECAUTIONS
Installation, maintenance and operating personnel must, at all times, observe all safety
regulations. The following warnings are general and must be given the same attention as specific
precautions included in these instructions.
WARNING!
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO
PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED.
Shut off all incoming and outgoing steam and water stop
valves and carefully decrease all trapped pressures to zero
before performing any maintenance.
WARNING!
LIVE STEAM CAN CAUSE SEVERE BURNS
Never search for leakage in a live steam line by sight alone or
by “feel”. Use a mirror or other suitable polished object.
Always provide yourself with personal protective equipment,
(PPE) such as gloves, eye protection, dust mask, hard hat, etc.
1.2 TOOLS & SUPPLIES REQUIRED
The following tools are required to perform the retrofit procedures specified in this document:
• Combination Wrenches: 7/16”, 9/16”, 5/8”, 13/16”, 1-1/16”, 1-1/8”, 8 mm
• Pipe Wrenches: 12”, 24”
• Vise-Grip Pliers
• Flat Tip Screwdriver, 1/2” Blade
• Phillips Head Screwdriver, No. 3
• Brass Wire Brush
• Needle Nose Pliers
• Tape Measure
• Black Marker