HE-109 TID-0004_0A TECHNICAL INSTRUCTIONS Hardware Procedure: Coil and Riser Replacement Procedures for All Styles of A, B, C, and D Indirect-Fired Water Heaters Applies to: Indirect-Fire Water Heaters. Description of Document: This Technical Instruction Document provides the instructions necessary for removal and replacement of Coil Assemblies and Risers contained in AERCO Indirect-Fired Heat Exchangers.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A Technical Support: (Mon–Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer 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.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 1. Introduction This document provides the instructions necessary for removal and replacement of Coil Assemblies and Risers contained in AERCO Indirect-Fired Heat Exchangers. 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.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 4.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 5. Heater Isolation and Disassembly NOTE The procedures in the following paragraphs are arranged to isolate, disconnect and disassemble the unit to the extent necessary to repair or replace defective items. These procedures should be performed in the order specified to minimize repair time. 5.1 Isolating Heater To isolate the Heater from all facility energy sources (steam, water, electrical, etc.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 5.2 Disconnecting Heater From the Facility To disconnect the Heater from the facility piping and wiring connections, proceed as follows: Section 5.2 Instructions Disconnecting the Heater from the Facility 1) First, check the ceiling height to determine if the Heater Shell and Top Head can be hoisted up with the Heater remaining in position.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 5.3 Shell Removal Remove the Heater Shell as follows: Section 5.3 Instructions 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.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 6.2 Preparation of Riser and Return Section 6.2 Instructions Preparation of Riser and Return 1) Visually inspect all Steam Riser and Condensate Return Spuds, (Figure 2) threads and sealing surfaces for damage, scratches, braze material and cleaning deposits. If defects are found with the Spud threads or sealing surfaces, contact your AERCO Representative for instruction to return the defective Riser.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 6.3 Preparation of Coil Assemblies Section 6.3 Instructions Preparation of Coil Assemblies 1) Visually inspect all Tail Piece sealing surfaces for cleanliness and evidence of damage. (Figure 3). 2) Pull the Union Nut forward against the seating surface of the Tail Piece and rotate the Union Nut several turns to check for any obstructions around the perimeter of the seating surface. (Figure 3).
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 1/8" MINIMUM 1/8" MINIMUM TOP VIEW 1/8" TO 1/4" 1/8" TO 1/4" SIDE VIEW Figure 4: Coil Assembly Spacing 6.4 Preparation of Coil Gaskets Two 6-tab gaskets are provided with each replacement Coil Assembly. Proceed as follows: Section 6.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 2 - 3° Figure 5: Coil Gasket Preparation 7. Reassembly of Risers & Coil Bundle Following preparation of all Heater components as described in Section 6, the Heater is ready for reassembly as described in paragraphs 7.1 through 7.3. 7.1 Installing the Risers Section 7.1 Instructions Installing the Risers 1) Thread the Steam Riser into the Bottom Head.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A CONDENSATE RISER SUB-COOLING COIL STUD B* A* STUD LOWER HEAD * MEASUREMENTS A & B SHOULD BE EQUAL Figure 6: Sub-Cooling Coil Alignment SPUD COIL GASKET BOX HEADER UNION NUT STEAM RISER OR CONDENSATE RETURN Figure 7: Assembly of Coil to Steam Riser or Condensate Return PR2: 04/01/11 AERCO International, Inc. • 100 Oritani Dr.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A NOTE The procedure in paragraph 7.2 are not required for Regular A, B, C or D Type Heaters. 7.2 B+ II Wizard Sub-cooling Coil Installation 1) 2) 3) 4) 5) Section 7.2 Instructions B+ II Wizard Sub-cooling Coil Installation For Wizard Sub-cooling Coil, align the Union Nuts with the two Spuds on the Condensate Riser. Hand thread the Unions Nuts down to the seating surface.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A COIL ASSEMBLY UNION NUT RISER BOX HEADER COIL RETAINING TOOL TOP VIEW (PARTIAL CUT-AWAY) RISER COIL ASSEMBLY INSERT COIL RETAINING TOOL HERE BOX HEADER SIDE VIEW Figure 8: Positioning of Coil Retaining Tool PR2: 04/01/11 AERCO International, Inc. • 100 Oritani Dr.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A 8. Hydrostatically Testing Coils & Risers Section 8. Instructions Hydrostatically Testing Coils & Risers 1) Install fittings into the inlet and outlet of the Bottom for the Risers that can supply a hydrostatic pressure source. 2) One fitting should have a valve for the release of internal air pressure.
Coil/Riser Replace Instructions for Helitherm Water Heaters HE-109 Technical instructions TID-0038_0A © AERCO International, Inc., 2011 PR2: 04/01/11 AERCO International, Inc. • 100 Oritani Dr.
