AERCO KC1000 Heater Mar 2011 - Manual (Page 56)

MAINTENANCE
6-12
28. Replace the gasket between the manifold and the combustion chamber (Part Number GP-122537).
The use of Permatex or a similar gasket adhesive is recommended. Replace the gasket between the
manifold and tubesheet (Part No. GP-18900). Do not use any gasket adhesive; this gasket has an
adhesive backing.
29. Beginning with the manifold, reinstall all the components in the reverse order that they were removed.
6.9 HEAT EXCHANGER INSPECTION AND CLEANING
Inspecting the Heat Exchanger
The water-side of the heating surfaces may be inspected by removal of the top heater head. (See Fig.
6.17). The following gaskets will be needed prior to performing the inspection:
GP-18556 Release Gasket
GP-18532 Shell Gasket
To inspect the heat exchanger watersides:
1. Disconnect the electrical power to the unit.
2. Close the water inlet, outlet, and recirculation shut-off valves to the unit.
3. Open the drain valve carefully while opening the relief valve on the right side of the unit shell to
relieve pressure and allow air into the shell.
CAUTION!
Do not drain the unit without venting the shell! A vacuum in the unit may
displace the liner causing serious damage not covered by warranty.
4. Remove the wing nut from the top center of the shell cap and remove the cap.
5. Remove the nuts and cap screws from the upper head. Remove the upper head and upper head-
liner, (See Fig. 6.17). Remove scale from all shell penetration points and sensors.
6. Inspect and, if necessary, clean the heat exchanger tubes of scale and all gasket surfaces thoroughly
before reassembling the upper head.. AERCO recommends that NEW gaskets be used when
reassembling.
7. Place a shell head gasket on top of the shell ring first, then place the release gasket on top of the
shell head gasket. Align the gasket holes with those in the shell ring.
8. Place the upper head liner on top of the gaskets.
9. Place the upper head on next aligning the holes.
10. Reassemble the cap screws and nuts through the upper head and shell ring. Cross tighten the nuts to
approximately 75 ft./lb. torque to obtain a uniform seating, then progressively tighten the nuts to 150
ft./lb.
11. Replace the unit Cap. Close the drain valve and reopen the inlet, outlet, and recirculation valves to
refill the unit.