Electronic Control System (ECS) and Type CXT-E Valve User Manual USER MANUAL Installation, Operation, and Maintenance Electronic Control System (ECS) and Type CXT-E Electronic Valve Electronic Control System Type CXT-E Electronic Valve Revised: 02/28/2014 VD2: 02/28/14 AC-105 AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve User Manual 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. AERCO International is not liable for errors appearing in this manual.
Electronic Control System (ECS) and Type CXT-E Valve TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS.................................................................................................. 3 SAFETY PRECAUTIONS ............................................................................................... 5 1. GENERAL INFORMATION ..................................................................................... 7 1.1 INTRODUCTION ..........................................................
Electronic Control System (ECS) and Type CXT-E Valve TABLE OF CONTENTS 6.2.1 6.2.2 Monthly Maintenance .........................................................................................................................35 Semi-Annual Maintenance:..................................................................................................................35 6.3.1 6.3.2 6.3.3 6.3.4 Quarterly Maintenance:..............................................................................................
Electronic Control System (ECS) and Type CXT-E Valve SAFETY PRECAUTIONS SAFETY PRECAUTIONS Installing or operating personnel must, at all times, observe all safety regulat ions. The following warnings are general and must be given the same attention as specific precautions included in the instructions. ! WARNING ! FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED.
Electronic Control System (ECS) and Type CXT-E Valve SAFETY PRECAUTIONS (This page intentionally blank) Page 6 of 82 AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION 1. GENERAL INFORMATION 1.1 INTRODUCTION This Instruction Manual provides detailed coverage for both the AERCO Electronic Control System (ECS) and the Electronic Control Valve CXT-E.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION Figure 1-1. Typical ECS & CXT-E Installation With a Packaged Water Heater Page 8 of 82 AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION Figure 1-2. Electronic Control System (ECS) 1.2.1 Control Box Assembly The Control Box Assembly is available in two models; one for Steam-to-Water Heaters and one for Water-to-Water Heaters. The only difference between these two models are the Display devices provided on the front panels.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION PT.NO. 2408 OP 1 OP 2 F SET SP2 REM OVER TEMP SWITCH AUTO RUN MAN HOLD TEMP CONTROLLER B-PLUS TM WATER HEATER PT.NO. MODEL 69012-1 FRONT PANEL FOR STEAM-TO-WATER HEATERS OVER TEMP SWITCH PT.NO. F 2408 OP 1 OP 2 SET F OUT SET SP2 REM AUTO RUN MAN HOLD F IN SET TEMP CONTROLLER E-PLUS BOILER WATER TEMP TM WATER HEATER PT.NO. MODEL 69012-2 FRONT PANEL FOR WATER-TO-WATER HEATERS Figure 1-3.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION An Over-Temperature Switch is also included in the Control Box to constantly monitor the Water Heater outlet temperature to ensure the Heater does not exceed the preset high temperature limit. Typically, the over-temperature limit is set 20°F above the desired Heater setpoint temperature.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION 1.3 ELECTRONIC CONTROL VALVE CXT-E Each Control Valve is comprised of three major sections; the Valve Body, Linkage Assembly and the Valve Actuator. The Control Valves are available in sizes ranging from 1 inch to 4 inches. An identical Actuator Assembly is used with each size Valve Body.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION VALVE SIZES (INCHES) DIM. 1.00" 1.25" 1.50" 2.00" 2.50" 3.00" 4.00" A 21.12 21.12 21.12 24.25 24.25 24.25 24.25 B 7.75 7.75 7.75 7.75 10.87 10.87 10.87 C 3.56 3.56 3.56 3.56 6.38 6.38 6.38 D 6.00 6.00 6.00 6.00 10.87 10.87 10.87 4.50" 6.60" 13.375 POSITION SCALE A B C D Figure 1-4.
Electronic Control System (ECS) and Type CXT-E Valve 1. GENERAL INFORMATION 1.4 REFERENCE DOCUMENTS Refer to the following documents as necessary for additional information and procedures for the applicable AERCO Heat Exchanger provided with your Electronic Control System (ECS) and CXT-E Control Valve. In addition, if the ECS is provided with the Modbus Communication option, refer to the referenced Eurotherm documents listed. 1.4.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 2. INSTALLATION 2.1 INTRODUCTION Normally, the Electronic Control System (ECS) is shipped already installed on the Packaged Water Heater. However, the Control Valve, Type CXT-E is packed separately. For smaller size Valves (1” to 2”), the packaged Valve is attached to the base of the shipping crate.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 7) If the Valve is controlling steam, ensure that the steam line is properly trapped to prevent accumulation of condensate ahead of the Valve. 8) Install Shutoff Valves (metal-seated, gate-type) upstream and downstream of the Control Valve to permit removal from the line for maintenance. 9) Pressure gauges should be installed on both sides of the Control Valve as shown in Figure 2-1 (steam) or Figure 2-2 (hot water).
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION Figure 2-2. Recommended Control Valve, CXT-E Installation For Hot (Boiler) Water Flow 2.3 ELECTRONIC CONTROL SYSTEM (ECS) INSTALLATION As previously mentioned, the Control Box and all other Electronic Control System (ECS) components are installed on the Packaged Water Heater prior to shipment from the factory.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 1) Loosen the captive screw on the right-front portion of the Control Box (Figure 2-3) to open the hinged panel door. PANEL DOOR CAPTIVE SCREW PT.NO. 2408 AUTO RUN MAN HOLD OVER TEMP SWITCH TEMP CONTROLLER B-PLUS TM WATER HEATER PT.NO. Figure 2-3. ECS Control Panel Front View 2) Next, open the door and loosen the captive screw at the top of the recessed panel (Figure 2-4).
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 4) Connect the LINE, NEUTRAL and GROUND leads to the TB-2 terminals shown in Figure 25. REAR EXTERNAL POWER WIRING (120 – 240 VAC) LINE NEUTRAL GROUND TERMINAL BLOCK TB-2 VOLTAGE REGULATOR 100 101 102 GND TB-2 FRONT CONTROL BOX - INTERIOR BOTTOM VIEW Figure 2-5. ECS Control Box AC Power Connections 5) Connect the Control Box cable labeled ACTUATOR to the 3-pin connector plug on the Control Valve Actuator.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION CAUTION! DO NOT route Modbus communication wiring in the same conduit as power wiring. Attempting to do so may result in excessive noise on the signal lines.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 2408 CONTROLLER 1A HA L 1B HB N 1C HC 1D HD LA 2A HE LB 2B HF LC 2C JA AA 2D JB AB 3A JC AC 3B JD VI 3C JE V+ JF V- 3D In1 In2 C SEE TABLE 2-1 FOR COMM CONNECTIONS Figure 2-6. Temperature Controller (Eurotherm 2408) Terminal Connection Diagram 2.4 CHANGING COMMUNICATION ADDRESSES ON AERCO EUROTHERM TEMPERATURE CONTROLLER The address is defaulted to 1 from the factory.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION To change the modbus address: 1) Page to the ACCS list and Scroll down the list to codE. 2) Enter 24 using the Up Arrow. The number will display and flash PASS. 3) Scroll to Goto (current value is OPEr) and use the Down Arrow to enter a value of Full. The entry is confirmed by the flashing of the lower display momentarily off and then on. Page 22 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 4) Go to the home screen by pressing the Page and Scroll buttons at the same time. 5) Page to the cmS list. 6) Scroll to the Addr screen 7) Use the Up Arrow to select the desired address number. 8) Go to the home screen by pressing the Page and Scroll buttons at the same time. 9) Page to the ACCS List and change the code to anything other than 24.
Electronic Control System (ECS) and Type CXT-E Valve 2. INSTALLATION 2.5 ENABLING REMOTE SETPOINT CONFIGURATION ON THE AERCO EUROTHERM TEMPERATURE CONTROLLER The setpoint may be programmed to be remotely configured by executing the following steps. See the previous instructions for changing communication addresses in the AERCO Eurotherm Temperature Controller for more detailed directions for programming the controller. 1) Page to “ACCS”. 2) Scroll and enter code of 1.
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT 3. ADJUSTMENT 3.1 INTRODUCTION This Section provides adjustment procedures for both the Control Valve, Type CXT-E and the Electronic Control System (ECS). Prior to shipment, from AERCO, all CXT-E Control Valve Actuators are adjusted (auto-stroked) to ensure that they properly position the Control Valve from the fully-open to the fully-closed positions.
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT NOTE: DO NOT PRESS THE RESET BUTTON before the 10 second period has ended. Blinks Valve Size 1 1” 2 1.25” and 2.5” 3 1.5” and 3” 4 2” and 4” 5) For Full-Stroke automatic adjustment, press the Reset button. The LED will light. 6) The Actuator will then rotate in both directions to find its open and closed Valve position stops.
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT 3.3 ELECTRONIC CONTROL SYSTEM (ECS) ADJUSTMENT The Electronic Control System (ECS) is preset at the setpoint temperature specified on the Sales Order. The over-temperature alarm limit is normally set 20°F above the specified setpoint. If no setpoint or over-temperature alarm limit is specified, the ECS will be set to the Factory Default values of 140°F (setpoint) and 160°F (over-temperature alarm limit).
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT 3.3.1 Setpoint Temperature Adjustment The setpoint temperature is adjusted using the controls and displays provided on the Temperature Controller. These controls and displays are illustrated and described in Figure 3-3 and Table 3-1. If necessary, setpoint temperature adjustment is accomplished as follows: 1) With the Control Box door open, set the ON/OFF POWER switch on the right side to the ON position.
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT Table 3-1.
Electronic Control System (ECS) and Type CXT-E Valve 3. ADJUSTMENT 4) If the display does not show the desired over-temperature alarm setting, press the ▲ or ▼ arrow button to change the display to the desired temperature setting. 5) Once the desired over-temperature alarm setting is displayed, press the SET button to store the setting in memory. 6) To exit the programming mode, press the SET and ▼ buttons simultaneously, or simply wait one minute.
Electronic Control System (ECS) and Type CXT-E Valve 4. OPERATION 4. OPERATION 4.1 INTRODUCTION This Section provides the pre-operational checks, initial start-up procedures for the AERCO Water Heater, Electronic Control System (ECS) and CXT-E Control Valve. In addition, procedures are included to check the hot water outlet flow through the heater. 4.
Electronic Control System (ECS) and Type CXT-E Valve 4. OPERATION 8) When in the AUTO mode, the ECS will stabilize at the selected setpoint temperature (see Section 3). Once stabilized, the ECS is set for unattended operation with no further operator intervention. IMPORTANT NOTE: In order to accurately measure the outlet flow rate of the AERCO Water Heater, it is imperative that the properly sized inlet orifice be installed in the cold water inlet.
Electronic Control System (ECS) and Type CXT-E Valve 5. FUNCTIONAL DESCRIPTION 5. FUNCTIONAL DESCRIPTION 5.1 INTRODUCTION The AERCO Electronic Control System (ECS) and Electronic Control Valve Type CXT-E provide a highly responsive control system which provides virtually constant hot water flow at the selected setpoint temperature. A simplified functional block diagram for the ECS and CXT-E is shown in Figure 5-1. The following paragraphs provide a top-level functional overview of system operation. 5.
Page 34 of 82 OMM-0003_0D 120 VAC IN 24 VDC AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 6. ROUTINE MAINTENANCE 6.1 INTRODUCTION The following paragraphs provide the AERCO recommended routine maintenance procedures for the Electronic Control Valve Type CXT-E and the Electronic Control System (ECS). 6.2 CXT-E CONTROL VALVE ROUTINE MAINTENANCE 6.2.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 6.3 ELECTRONIC CONTROL SYSTEM (ECS) ROUTINE MAINTENANCE 6.3.1 Quarterly Maintenance: Every three months, check the operation of the Over-Temperature Switch as follows: ! WARNING ! THIS PROCEDURE WILL RELEASE HOT WATER. TAKE APPROPRIATE PRECAUTIONS TO AVOID BURNS.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 6.3.4 Flow Sensor: The Flow Sensor is installed between the Heater water inlet line and the Heater drain (refer to Figures 1-1 & 5-1). Check this sensor for evidence of blockage or scale build-up as follows: 1) Disconnect the electrical connector from the Flow Sensor. 2) Loosen the fittings at the Sensor inlet and outlet connections and completely remove the Sensor.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 5) After cleaning, reassemble the Flow Sensor as follows: IMPORTANT NOTE! Ensure that the paddle wheel magnets are installed facing the internal wall of the Flow Sensor. If not correctly installed, the Sensor will not function properly. a) Reinstall the paddle wheel. b) Apply a thin film of silicone grease on the O-ring in the groove of the clear polycarbonate window. c) Reinstall the polycarbonate window.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 5) Install a valve and hose connection in the outlet piping of the heater (Figure 6-3) and route the hose back to the top of the circulation bucket. CLOSE THE HOT WATER OUTLET ISOLATION VALVE HOSE CONNECTION CIRCULATED HYDROSKRUB SOLUTION FROM TOP OF HEAT EXCHANGER INTO BUCKET NOTE: IF A HOSE CONNECTION IS NOT AVAILABLE IN THE HOT WATER OUTLET PIPING, UNUSED PORT AT THE TOP OF THE HEAT EXCHANGER, IF AVAILABLE, MAY BE USED.
Electronic Control System (ECS) and Type CXT-E Valve 6. ROUTINE MAINTENANCE 7) Periodically test the solution for effectiveness to determine if more HydroSkrub is needed. Refer to “Testing hydroSkrob Effectiveness” in the next paragraph for details. If the cleaning solution is expended before circulation time is up, additional HydroSkrub will be needed and circulation time may be extended to complete the cleaning.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING 7. TROUBLESHOOTING 7.1 INTRODUCTION This Section provides the troubleshooting procedures necessary to isolate faults to the most probable cause(s) for a malfunction of the Electronic Control System (ECS) or Electronic Control Valve Type CXT-E.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING Table 7-1. Troubleshooting – Control Valve CXT-E NO. T1 FAULT INDICATION System not operating. Control Valve is closed and outlet water temp. is far below setpoint. PROBABLE CAUSE CORRECTIVE ACTION 1. No power supplied to Control Valve 1. Disconnect Valve Actuator plug and verify that 24 VDC power is present at pin 2 of Actuator cable. Restore power if necessary.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING Table 7-1. Troubleshooting – Control Valve CXT-E (Continued) NO. FAULT INDICATION PROBABLE CAUSE 3. Steam pressure, or heating fluid temperature too low. T3 (Continued) System outlet water temperature is below desired setpoint CORRECTIVE ACTION 3. Check the high side steam pressure to the Control Valve to ensure it is correct. For high temperature (HT) water, ensure there is good circulation. a.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING Table 7-2. Troubleshooting – Electronic Control System (ECS) NO. FAULT INDICATION PROBABLE CAUSE 1. External 120 VAC power disconnected. 2. Defective ON/OFF switch on Control Box. T6 System not operating. All displays are blank. Power Supply. 1. Temp. Controller is not properly set. T7 1. Ensure external circuit breaker is ON. Check for 120 VAC power across TB-2 terminal leads 101 (Line) and 102 (Neutral). 2.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING Table 7-2. Troubleshooting – Electronic Control System (ECS)- Continued NO. FAULT INDICATION PROBABLE CAUSE 1. Shorted Outlet CORRECTIVE ACTION 1. Replace Outlet Temp, Sensor. Temp. Sensor. Over-Temp. Alarm condition cannot be cleared. T9 Over-Temp Switch displays erroneous temperature readings 2. Defective Over3. A “No-Flow” condition caused a gradual buildup of heat to the water in vessel. 4.
Electronic Control System (ECS) and Type CXT-E Valve 7. TROUBLESHOOTING Table 7-2. Troubleshooting – Electronic Control System (ECS)- Continued NO. T13 T14 T15 T16 FAULT INDICATION Wide fluctuations in outlet water temperature under low flow conditions. Temp Controller displays Loop break (Lbr) error message PROBABLE CAUSE CORRECTIVE ACTION 1. Outlet Temp Sensor connected to Temp Controller is intermittent 1. Replace Outlet Temp Dual Sensor at Heater outlet port. 2. Obstruction in Flow Sensor.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE 8. CORRECTIVE MAINTENANCE 8.1 INTRODUCTION The Corrective Maintenance procedures are divided into two Parts. Part 1 provides corrective maintenance for all sizes of Electronic Control Valves Type CXT-E. Part 2 provides corrective maintenance for the Electronic Control System (ECS). 8.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 7) Measure and record the current position of the Hex Nuts (17) from the end of the Valve Shaft (16). This will simplify adjustment of the Actuator Linkage during reassembly. 8) Next, completely remove the Hex Nuts (17) from the Valve Shaft (16). 9) Remove the Packing Nut (18) and the Packing Assembly (20) from the Valve Body.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE 7) For Control Valves, 1-inch through 2-inch (Figure 8-1), disassemble the Shaft/Seat/Piston assembly in the following order: a) Lock Washer (23) b) Retaining Ring (11) c) Pilot Spring (10) d) Valve Stem Retaining Nut (35) e) Lower Shaft (16) and Valve Stem (12) f) Retaining Disc (8) g) Disc Seat (7) h) Seat Retainer (34) i) Valve Plug Shaft (5) 8) For Control Valves, 2.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 15) If the Cage (2) must be removed from the Valve Body (1), it will be necessary to fabricate a tool, such as shown in Figure 8-3 for Cage removal. Insert the tool into the slots on top of the Cage (2) and turn the Cage out of the Valve Body. To obtain a Cage Removal tool, contact AERCO or your nearest Sales Representative. 8.2.3 Valve Reassembly Refer to Figure 8-1 or Figure 8-2 when performing the following procedures.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE 8) 9) provide a uniform seal and prevent Valve leakage. d) NEW Packing Assembly (20) e) Packing Nut (18) f) Hex Nuts (17) g) Indicator Plate (See Figure 8-1 or 8-2) Replace the Actuator (27), Linkage (26) and Gasket (29) onto the Valve Top (21) and secure with Cap Screws (19). Position the Hex Nuts (17) at the original location noted during the removal process (CM7).
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS THIS PIN LOCATION TO BE USED ON ALL 1.0" TO 2.0" VALVE ASSEMBLY CONFIGURATIONS ACTUATOR 27 LINKAGE 26 SHAFT PIN LINKAGE ADAPTER FAR SIDE 17 28 1 INDICATOR PLATE 16 30 18 14 19 29 20 21 12 13 11 23 10 33 35 34 8 24 7 6 32 2 5 3 1 31 Figure 8-1. Valve Assemblies, Type CXT-E (Sizes 1.00” To 2.00”) Parts List Table For Valve Assemblies, Type CXT-E ( Sizes 1.00” To 2.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE VALVE SIZE AND PART NUMBERS ITEM QTY 1 1 VALVE BODY 20762 20759 20758 20761 2 1 SEAT CAGE 16844 16845 16837 16843 3 1 BOTTOM PISTON 121540 121525 121502 121529 4 PART NAME 1.00 INCH 1.25 INCH 1.50 INCH 2.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 90 0 ACTUATOR 27 LINKAGE 26 SHAFT PIN 30 LINKAGE ADAPTER 15 28 OR 17 16 0 INDICATOR PLATE 18 14 19 29 13 20 21 12 23 11 31 10 22 9 8 7 24 6 3 5 2 4 1 Figure 8-2. Valve Assemblies, Type CXT-E (Sizes 2.50” To 4.00”) Page 54 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE Parts List Table For Valve Assemblies, Type Cxt-E ( Sizes 2.50” To 4.00”) VALVE SIZE AND PART NUMBERS ITEM QTY 1 1 2 2.50 INCH 3.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS ALL DIMENSIONS SHOWN ARE IN INCHES HANDLE – 1 /2" DIA COLD ROLLED STEEL BAR 1/4" SQUARE TOOL STEEL WELD 9-1/2 C A B WELD D WELD ON INSIDE ONLY B C D 1" SCH. 40 PIPE 1.11 1-5/8 7-1/2 1-1/4 INCH 1-1/4" SCH. 40 PIPE 1.42 2 7-1/2 1-1/2-INCH 1-1/2" SCH. 40 PIPE 1.67 2-3/8 8 2-INCH 2-1/2" OD x .120" WALL SEAMLESS STEEL TUBING 2.40 2-5/8 8 2-1/2-INCH 2-1/2" OD x .120" WALL SEAMLESS STEEL TUBING 2.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE 1 SHAFT PIN LOCATION LINKAGE ADAPTER 2 INDICATOR PLATE (CURVED END) LINKAGE ASSEMBLY SCALE 1 MID-POINT HEX NUTS (2) VALVE SHAFT INDICATOR PLATE 8-32 HEX NUT 3 (FAR SIDE) 0 PACKING NUT CAP SCREW 4 LINKAGE GASKET 5 VALVE TOP VALVE BODY ITEM QTY 1 1 PART DESCRIPTION LINKAGE ASSEMBLY PART NUMBER 24038-1 (1” TO 3” VALVES) 24038-2 (4” Valve) 59028-1 (1” VALVE) 59028-1.25 (1.25” VALVE) 59028-1.5 (1.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 8.2.4 Actuator Replacement There are no repairable parts contained in the Actuator. Therefore, if the Troubleshooting procedures in this Instruction Manual isolate the cause of the fault to the Actuator, it must be replaced as described in the following steps: 1) Disconnect and lock-out/tag-out AC power going to the Control Box. Use a voltmeter to ensure that all voltages are zero before continuing.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE DIAL & POINTER 90 0 LINKAGE SHAFT COVER CLUTCH neptronic COVER SET SCREW CABLE CONNECTOR CENTER SLOT 123 Figure 8-5. Actuator Replacement 8.2.5 Linkage Assembly Replacement As Figure 8-6 shows, the Linkage Assembly Part No. will vary, depending on valve size. CXT-E valve sizes from 1.00 to 3.00 inches utilize Linkage Assembly Part No. 24038-1. However, 4.00 inch CXT-E Valves utilize Linkage Assembly Part No. 24038-2.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 4–1/2 IN. x 1-15/16 IN. WIDE USE THIS PIN LOCATION FOR 1 - 2 IN. VALVES USE THIS PIN LOCATION FOR 4 IN. VALVES USE THIS PIN LOCATION FOR 2 -1/2 & 3 IN. VALVES 13 - 3/8 IN. ADAPTER INDICATOR PLATE ADAPTER INDICATOR PLATE PART NO. 24038-1 (FOR 1 TO 3 IN. VALVES) PART NO. 24038-2 (FOR 4 IN. VALVE ONLY) Figure 8-6.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE ! CAUTION ! Ensure that the replacement Linkage Assembly, Adapter and Scale are identical to those removed in the previous steps. Also, ensure that the Linkage Pin (Figure 8-6) is set to the proper position for the Control Valve size. Failure to observe this precaution may result in improper Control Valve operation. 8) Using a new Gasket (29), position the replacement Linkage Assembly on the Valve Top (21).
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS • Temperature Indicators (Water-to-Water Heat Exchangers Only) • DC Power Supply • DC Voltage Regulator The following paragraphs reference Figures in previous Sections as well as Figures in this Section. Refer to the applicable Figures as necessary when performing the replacement procedures which follow. 8.3.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE TERMINAL COVERS SLEEVE RATCHETS DISPLAY LABEL PANEL RETAINING CLIPS LATCHING EARS PANEL SEALING GASKET Figure 8-7. Temperature Controller Installation 4) Close and secure Control Box front door. 8.3.4 Over-Temperature Switch and Temperature Indicator Replacement The Over-Temperature Switch and Temperature Indicators are actually identical devices, however they perform different functions.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS Figure 8-8a. Over-Temperature Switch & Temperature Indicator To uninstall push tab to release clip retainer. Slide clip back and off. Remove assembly through front panel. Figure 8-8b. Over-Temperature Switch & Temperature Indicator Installation 5) If the replaced unit is an Over-Temperature Switch, set the desired over-temperature alarm limit using the Adjustment procedures in Section 3.
Electronic Control System (ECS) and Type CXT-E Valve 8. CORRECTIVE MAINTENANCE 8.3.6 DC Voltage Regulator Replacement The DC Voltage Regulator is mounted on the bottom interior surface of the Control Box chassis. Replacement is accomplished as follows: 1) Open the Control Box door and loosen the captive screw on the recessed panel behind the door. 2) Open the swing-down panel and locate the DC Voltage Regulator on the bottom of the chassis interior (Figure 8-9, View D – D).
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 1 B A 3 4 PT.NO. NOTE: 2408 12 AUTO RUN MAN HOLD SEE SHEET 5 FOR PARTS LIST OVER TEMP SWITCH TEMP CONTROLLER B-PLUS WATER HEATER B A 69012-1 2 13 C E POWER ON 4 POWER IN 3 OVER TEMPERATURE SWITCH OFF PT.NO. 12 2408 5 OUT AUTO RUN MAN HOLD IN TEMP CONTROLLER BOILER WATER TEMP E-PLUS WATER HEATER D D 69012-2 C E 6 OR 7 SIDE VIEW - TYPICAL Figure 8-9.
AC-105 Electronic Control System (ECS) and Type CXT-E Valve User Manual OMM-0003_0D CORRECTIVE MAINTENANCE DC OUTPUT CONNECTOR POWER SUPPLY 6 -+ AC INPUT CONNECTOR 14 15 INTERIOR LEFT WALL VIEW A -A 2 1 1A 5 AC POWER CABLE CUTOUT AC POWER ON/OFF SWITCH INTERIOR RIGHT WALL VIEW B -B Figure 8-9. ECS Control Box Assembly Component Locations (Sheet 2 of 6) VD2: 02/28/14 AC-105 AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS TERMINAL BLOCK TB-1 16 9 17 16 INTERIOR BACK WALL NOTE: SEE APPENDIX B FOR WIRING CONNECTIONS VIEW C - C 22 AC POWER TERMINAL BLOCK TB-2 21 REAR 7 20 14 15 18 19 8 TB-2 VOLTAGE REGULATOR INTERIOR BOTTOM SURFACE INPUT/OUTPUT CONNECTOR 17 16 VIEW D - D Figure 8-9. ECS Control Box Assembly Component Locations (Sheet 3 of 6) Page 68 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
AC-105 Electronic Control System (ECS) and Type CXT-E Valve User Manual OMM-0003_0D CORRECTIVE MAINTENANCE TEMPERATURE CONTROLLER L N 1A 1B 3 G 4 OVERTEMP SWITCH 1 2 7 8 9 10 11 3A 3D V+ V- PANEL REAR VIEW E – E (CONTROL BOX 69011-1) NOTE: SEE APPENDIX B FOR WIRING CONNECTIONS OVERTEMP SWITCH 1 2 7 8 9 10 11 TEMPERATURE CONTROLLER 1A 1B 3 L N 4 G 4 1 2 7 8 9 10 11 1 2 7 8 9 10 11 OUT 4 3A IN 3D V+ V- BOILER WATER TEMP PANEL REAR VIEW E – E (CONTROL BOX 69011-2) Figure 8-9
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS ECS Control Box Assembly Parts List ITEM 1 CONTROL BOX ASSY. 69012-1 69012-2 (STEAM/ (WATER/ WATER) WATER) QTY QTY 1 2 PART NO.
AC-105 Electronic Control System (ECS) and Type CXT-E Valve User Manual OMM-0003_0D CORRECTIVE MAINTENANCE Table A – Programmed Temperature Controllers PART NUMBER PROGRAMMED TEMPERATURE CONTROLLER USED ON: 64028-1 HELITHERM HEATER MODELS: A+, B+, B+ II, E+ *64028-2 DOUBLE-WALL HEATER MODELS: SWDW24, SWDW45 64028-3 DOUBLE-WALL HEATER MODEL: WWDW24 64028-4 DOUBLE-WALL HEATER MODEL: WWDW45 *64028-5 DOUBLE-WALL HEATER MODEL: SWDW68 65028-6 DOUBLE-WALL HEATER MODEL: WWDW68 *Refer to HE-111 for
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS (This page intentionally blank) Page 72 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS 9. RECOMMENDED SPARE PARTS 9.1 CXT-E CONTROL VALVE RECOMMENDED SPARE PARTS AERCO recommends that the CXT-E Spare Parts listed in Table 9-1 be kept on hand for maintenance replacement purposes The Recommended Quantity for the parts shown apply to each 1 to 5 Control Valves of the same size. NOTE: For Part Numbers of the items listed below, refer to Figure 8-1 for Control Valve sizes ranging from 1.00” to 2.00”.
Electronic Control System (ECS) and Type CXT-E Valve 9. RECOMMENDED SPARE PARTS * Part No. 24051-3 is only used for applications where the water pressure is greater than 200 psig. Page 74 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve APPENDIX A APPENDIX A TEMPERATURE CONTROLLER INFORMATION MODBUS Communication information (Eurotherm 2408) NOTE: The Eurotherm 2400 Controller supports the MODBUS RTU mode of transmission. The default settings are as follows: 9600 Baud Rate, one start bit, eight data bits, one stop bit, & no parity bit. IMPORTANT NOTE: All Modbus addresses specified in this manual are written generically in decimal format.
Electronic Control System (ECS) and Type CXT-E Valve APPENDIX A REFERENCE DOCUMENTS for MODBUS Points information: (www.eurotherm.com) • • Eurotherm 2000 Series Communications Handbook, # HA026230 Eurotherm 2404/2408 Control Setpoint Programmer Installation and Operation Handbook, # HA025132 9.3 PROCESS ALARMS: 9.4 Eurotherm 2408 Process Alarms DISPLAY MEANING _FSL* PV Full Scale Low Alarm. _FSH* PV Full Scale High Alarm.
Electronic Control System (ECS) and Type CXT-E Valve APPENDIX A Eurotherm 2408 Diagnostic Alarms (Continued) DISPLAY MEANING WHAT TO DO` Err1 Error 1: ROM self-test fail Return Controller for repair Err2 Error 2: RAM self-test fail Return Controller for repair Err3 Error 3: Watchdog fail Return Controller for repair Err4 Error 4: Keyboard failure.
Electronic Control System (ECS) and Type CXT-E Valve APPENDIX A (This page intentionally blank) Page 78 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
2 100 102 NEUTRAL LINE 104 -V -V P/O TB-1 104 105 - + 104 10 11 105 105 24VDC + INPUT - - + 12VDC - RED + HC JE V+ JF V- 3C 104 + - 106 NC P/O TB-1 RED WHITE NO 260 V 2A RELAY + 109 110 - C In2 In1 8 9 10 11 AERCO International, Inc. • 100 Oritani Dr.
Page 80 of 82 OMM-0003_0D 101 102 GROUND 100 GROUND LINE NEUTRAL AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve NOTES: VD2: 02/28/14 AC-105 AERCO International, Inc. • 100 Oritani Dr.
Electronic Control System (ECS) and Type CXT-E Valve Change Log Date Description Changed By 11/20/2012 Rev C: 02/28/2014 Rev D: PIR-934-35, Added notes to Fig 2-2, clarified instructions for adjusting the Over-Temperature Switch sensor in section 3.3.3. Chris Blair © AERCO International, Inc. 2014 Page 82 of 82 OMM-0003_0D AERCO International, Inc. • 100 Oritani Dr.
