TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS 24-Month Maintenance Kit Instructions for RECON 500 / 1000 Water Heaters Flame Detector Kit P/N Ignitor- Injector Kit P/N Exhaust Manifold Seal P/N GP Manifold Tubesheet Gasket P/N GP Burner Gasket P/N GP (2 each) Head Gasket P/N GP Head Release Gasket P/N GP Air Filter Cleaning Kit P/N (1 Each) Condensate Trap O-Ring P/N (1 Each) Gas Train Gasket P/N LWCO Capacitor Kit P/N Air Filter P/N Intake Manifold Flange Gasket P/N Burner/Shield Gasket P/N Baffle Seal P/N Month Kit Part Numbers: (version with new Air Filter) (version with Air Filter Cleaning Kit) Revised: 09/28/15 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, nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of these materials. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 20

2 Table of Contents 1. INTRODUCTION RECON 24-Month Maintenance Operations RECON 24-Month Maintenance Kit Contents List of Tools Unit Preparation RECON 24-MONTH MAINTENANCE PROCEDURES Fireside Inspection Disassembly Fireside Inspection Reassembly and Maintenance Waterside Inspection Condensate Drain Trap Inspection Air Filter Replacement Gas Train Gasket Replacement LWCO (Low Water Cut Off) Probe Assembly Replacement LWCO (Low Water Cutoff) Testing LWCO Capacitor Electrical Short Test Standard C-More LWCO Test END OF MAINTENANCE RETURN TO SERVICE IMPORTANT! These instructions describe the 24-month maintenance procedure as a single operation. Read ALL instructions and do not use any of these instructions out of context to perform individual maintenance tasks outside the 24-month maintenance procedure. Contact AERCO technical support if you need specific information. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 20

3 1. INTRODUCTION RECON Month Maintenance Kits The RECON 500 and RECON 1000 water heaters require specific maintenance every twelve and twenty four months to ensure continued reliable operation throughout the service life of the unit. 1.1 RECON 24-Month Maintenance Operations This Technical Instruction Document (TID) provides instructions for performing recommended 24-month maintenance on RECON 500 and RECON 1000 water heaters. The various operations involved are shown in the table below: RECON 24-Month Maintenance Operations SECTION PROCEDURE ACTIVITY LABOR TIME 2.1 Fireside Disassembly 2.2 Fireside Maintenance and Inspect, clean & replace gaskets 2 hrs. Reassembly 2.3 Waterside Inspection Inspect, clean & replace gaskets 1 hr. 2.4 Condensate Drain Trap Inspect, clean & replace gasket 30 min. 2.5 Air Filter (59139) Replace 5 min. 2.6 Gas Train Gasket Replace if the gas train is disassembled from A/F valve or a gas 30 min. leak is detected. 2.7/2.8 LWCO Probe Replace and test 30 min. 1.2 RECON 24-Month Maintenance Kit Contents The table below shows parts for two kits; P/N , which includes a replacement air filter, and P/N , which includes an air filter cleaning kit instead of a replacement air filter. RECON 24-Month Maintenance Kit Contents (P/N / -03) -02 QTY -03 QTY ITEM PART # DESCRIPTION IGNITER-INJECTOR ASSEMBLY FLAME DETECTOR, FRU KIT GP EXHST MANIFOLD/CC GASKET GP MANIFOLD/TUBESHEET GASKET GP BURNER GASKET GP HEAD GASKET GP HEAD RELEASE GASKET CONDENSATE TRAP COVER O-RING GAS TRAIN GASKET LWCO/CAPACITOR ASSY KIT AIR FILTER 1 N/A INTAKE MANIFOLD FLANGE GASKET BURNER/SHIELD GASKET BAFFLE SEAL AIR FILTER CLEANING KIT N/A 1 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 20

4 1.3 List of Tools The following tools are required to perform the instructions in these instructions. Flat-head screwdriver or 5/16 nut driver Phillips head screwdriver #2 Torque wrench The following wrenches (open-end, box or socket) are used: o 3/8 o 7/16 o 1/2 1.4 Unit Preparation o 9/16 o 3/4" o 1 Preparing the Unit 1. Turn power switch on the control panel to OFF, disconnect AC power from the unit, and turn external gas supply valves OFF. 2. Turn OFF all supply and return water valves. 3. Remove all nine panels, as shown in Figure 1-1. TOP FRONT UPPER LEFT CONSOLE TOP UPPER RIGHT LOWER REAR LOWER LEFT LOWER RIGHT CONSOLE Figure 1-1: RECON Covers Exploded View WARNING! To avoid personal injury, prior to servicing ensure that the following guidelines are strictly observed: Disconnect the AC supply by turning off the service switch and AC supply circuit breaker. Shut off the gas supply at the manual shut-off valve provided with the Unit Allow the Unit to cool to a safe water temperature to prevent burning or scalding 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 20

5 2. RECON 24-MONTH MAINTENANCE PROCEDURES 2.1 Fireside Inspection Disassembly After 24-months of service, the RECON unit should receive a detailed fireside inspection, which will includes removal of the exhaust manifold, blower-side intake manifold, and the burner assembly from the RECON water heater. Fireside maintenance includes replacement of the parts shown in Table 2-1. Table 2-1: Fireside Inspection Replacement Parts PART NUMBER DESCRIPTION GP Burner Gasket (QTY = 2) Flame Detector & Gasket GP Manifold-To-Heat Exchanger Gasket Igniter-Injector Assembly CAUTION! The blower-side intake manifold may be hot. Therefore, allow the unit to cool sufficiently before starting the removal process described in the following steps. Fireside Inspection Disassembly 1. Ensure power switch on the control panel is set to OFF, AC power is disconnected from unit, and external gas supply valve is turned OFF. 2. Remove the exhaust vent from the exhaust manifold (Figure 2-2). 3. Use a scraper or blade to separate the high temperature silicon sealant between the exhaust manifold and vent connector and remove all sealant from both surfaces in preparation for reassembly. 4. Refer to Figure 2-2 to locate the blower-side intake manifold at the bottom of the unit's heat exchanger. 5. Disconnect the lead wire from the flame detector, installed on the intake manifold flange (Figure 2-1). 6. Remove the two (2) stand-off screws securing the flame detector to the intake manifold (Figure 2-1). 7. Remove the flame detector and gasket from the flange (Figure 2-1). 8. Disconnect the cable from the igniter-injector (Figure 2-1). 9. Loosen and remove compression nut and elbow from the gas injector tube (Figure 2-1), removing entire staged ignition assembly (nut/elbow, solenoid valve, hose nipple, and gas flex hose) from the manifold flange. 10. Next, loosen and remove the igniter/injector from the intake manifold flange using a 1" openend wrench. Retain the clocking washers (if present), for later reassembly (Figure 2-1). 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 20

6 STEP 7: REMOVE FLAME DETECTOR & GASKET STEP 4: INTAKE MANIFOLD STEP 5: DISCONNECT LEAD FROM FLAME DETECTOR TERMINAL OBSERVATION PORT MANIFOLD FLANGE Fireside Inspection Disassembly Continued Figure 2-1: Blower-Side intake Manifold with Igniter-Injector & Flame Detector 11. Refer to Figure 2-2. Loosen and remove the four (4) 1/4-20 cap screws securing the blower side of the intake manifold. DO NOT REMOVE the two 1/4-20 screws and nuts securing the manifold support bracket. EXHAUST SENSOR HEAT EXCHANGER STEP 6: REMOVE STAND-OFFS STEP 10: REMOVE IGNITER/INJECTOR & CLOCKING WASHERS (1 TO 3 EACH) STEP 8: DISCONNECT CABLE FROM IGNITER TERMINAL GAS INJECTOR TUBE STEP 9: REMOVE COMPRESSION ELBOW & NUT, ATTACHED STAGED IGNITION SOLENOID VALVE, NIPPLE, & HOSE) STAGED IGNITION SOLENOID VALVE FLEX GAS HOSE & NIPPLE STEP 2: REMOVE EXHAUST VENT FROM HERE (EXHAUST MANIFOLD) STEP 11: CAP SCREWS 1/4-20 x 7/8 LG. (4 each) EXHAUST MANIFOLD BLOWER SIDE OF INTAKE MANIFOLD STEP 12: 5/16-18 HEX NUTS (6 EACH) STEP 11: DO NOT REMOVE THESE TWO SCREWS ON THE MANIFOLD SUPPORT BRACKET PARTIAL RIGHT-SIDE VIEW (SUPPORT BRACKETS REMOVED FOR CLARITY) Figure 2-2: Blower-Side Intake Manifold & Exhaust Manifold Locations 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 20

7 Fireside Inspection Disassembly Continued CAUTION! The intake manifold, burner and exhaust manifold assemblies weigh approximately 25 pounds. Use care when removing these assemblies in the following steps. 12. While supporting the intake manifold, loosen and remove the six (6) 5/16-18 hex nuts securing it to the studs protruding from the exhaust manifold (Figures 2-2 & 2-3). 13. Carefully lower and remove the intake manifold, burner assembly, burner mounting plate, and two burner gaskets from the unit. See Figure After removing everything from the unit in step 13, separate the mounting plate from the burner flange by removing the eight burner mounting screws so the burner shield gasket (P/N GP-81197) and second burner gasket (P/N GP-18899) may be removed for replacement at reassembly. Discard all three gaskets, as they will be replaced in a later step. BURNER ASSEMBLY INTAKE MANIFOLD FLANGE GASKET (P/N 81136) EXHAUST MANIFOLD STEP 14: DISASSEMBLY x 3/8 BURNER MOUNTING SCREWS BURNER FLANGE BURNER SHIELD GASKET (P/N GP-81197) BURNER GASKET (P/N GP-18899) BURNER MOUNTING PLATE BURNER GASKET (P/N GP-18899) INTAKE MANIFOLD FLANGE INTAKE MANIFOLD STEP 12: REMOVE SIX 5/16-18 HEX NUTS WHILE SUPPORTING INTAKE MANIFOLD. Figure 2-3: Intake Manifold and Burner Disassembly NOTE Support the intake manifold as it is carefully lowered from the blower plenum and heat exchanger. NOTE All the gaskets referenced in Figures 2-3 and 2-4 will be replaced with new ones from the kit at reassembly. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 7 of 20

8 Fireside Inspection Disassembly Continued 15. Disconnect the exhaust temperature sensor (Figure 2-4) by unscrewing it from the exhaust manifold. 16. While supporting the exhaust manifold, remove the two (2) side nuts (Figure 2-4) securing the manifold to the heat exchanger. Loosen, but do not remove the third nut nearest to the front of the unit. 17. Remove the exhaust manifold from the unit. 18. Remove the manifold seal gasket (Figure 2-4), and discard as it will be replaced at reassembly. Remove any residual silicone adhesive from the chamber rim. 19. Remove the manifold tubesheet gasket (Figure 2-4), and discard, as it will be replaced at reassembly. 20. Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as necessary. 21. This completes the fireside inspection and cleaning of the unit. Proceed to the next set of instructions for reassembly of the exhaust and intake manifolds, as well as the replacement of gaskets and components. HEAT EXCHANGER SHELL STEP 19: REMOVE TUBESHEET GASKET (P/N GP-18900) STEP 15: REMOVE TEMP. SENSOR STEP 18: REMOVE MANIFOLD SEAL GASKET STEP 17: REMOVE EXHAUST MANIFOLD Figure 2-4: Exhaust Manifold Disassembly STEP 16: DISASSEMBLY REMOVE SIDE 1/4 NUTS & WASHERS (2 EACH) LOOSEN, BUT DO NOT REMOVE FRONT 1/4 NUT/WASHERS 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 8 of 20

9 2.2 Fireside Inspection Reassembly and Maintenance Fireside Inspection Reassembly and Maintenance 1. Install a NEW manifold tubesheet gasket (P/N GP-18900). See Figure Carefully center and reassemble the exhaust manifold to the underside of the heat exchanger, ensuring that a NEW exhaust manifold seal gasket (P/N GP ) is held in place using a High Temp RTV Silicone sealant. See Figures 2-4 and Affix exhaust manifold to the heat exchanger with 1/4 nuts and washers (Figure 2-5). WARNING! The exhaust manifold seal gasket must be held in place with High Temp RTV Silicone then carefully raised into place, centered, and leveled to insure the gasket makes a good seal between the manifold and heat exchanger. 4. Reinstall the exhaust temperature sensor. See Figures 2-4 and On the burner mounting plate, place a NEW burner gasket (P/N GP-18899), then a NEW burner shield gasket (P/N GP-81197), and then affix the burner mounting plate to the flange of the burner using the eight x 3/8 mounting screws. See Figure Place a NEW burner gasket (P/N GP-18899) onto intake manifold flange (align holes). 7. Affix intake manifold to the underside of the exhaust manifold using the 5/16-18 hex nuts. 8. Place a NEW intake manifold flange gasket (P/N GP-81136) between intake manifold and blower outlet, then affix with the four 1/4-20 7/8 LG cap screws and nuts. Figures 2-5 & 2-2. STEP 1: NEW MANIFOLD TUBESHEET GASKET (P/N GP-18900) STEP 2: NEW EXHAUST MANIFOLD SEAL GASKET (P/N GP ) USE HIGH TEMP RTV SILICONE STEP 4: REINSTALL EXHAUST TEMPERATURE SENSOR. STEP 3: AFFIX MANIFOLD W/ 1/4 NUTS & WASHERS (3 EACH). INTAKE MANIFOLD STEP 5: ASSEMBLY x 3/8 BURNER MOUNTING SCREWS BURNER FLANGE NEW BURNER SHIELD GASKET (P/N GP-81197) NEW BURNER GASKET (P/N GP-18899) BURNER MOUNTING PLATE STEP 6: NEW BURNER GASKET (P/N GP-18899) EXHAUST-SIDE INTAKE MANIFOLD FLANGE STEP 7: INSTALL SIX 5/16-18 HEX NUTS TO MANIFOLD STUDS WHILE SUPPORTING INTAKE MANIFOLD. STEP 8: APPLY NEW INTAKE MANIFOLD FLANGE GASKET (P/N 81136) AND THEN AFFIX INTAKE MANIFOLD TO BLOWER OUTLET WITH (x4) 1/4-20 7/8 CAP SCREWS AND NUTS. Figure 2-5: Intake and Exhaust Manifold Reassembly and Gasket Locations 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 9 of 20

10 Fireside Inspection Reassembly and Maintenance Continued 9. Retrieve a NEW igniter-injector assembly with compression nut (P/N 58023) from the kit and apply a high temperature, conductive, anti-seize compound to the threads. CAUTION! During reassembly, you MUST apply high-temperature, anti-seize lubricant to the threads of the igniter and grounding screw. 10. Install the igniter/injector into the intake manifold flange using a 1" open-end wrench. Use the included one to three clocking washers to orient the igniter-injector assembly so that the injector tube exits from the assembly within the 120 angle as shown in Figure 2-6. Torque to in-lbs. DO NOT over tighten. NOTE When installing the igniter-injector assembly (P/N 58023), a new compression nut containing a built-in ferrule is included with the replacement part. DO NOT USE the old compression nut. Three indexing washers are also included if needed, to ensure the gas injector tube is properly position within the 120 angle range (see Figure 2-6) when the igniter-injector is secured in place. FLAME DETECTOR STANDOFF SCREWS GAS INJECTOR TUBE PROJECTION 120 GAS INJECTOR TUBE MUST PROJECT OUTWARD WITHIN THIS 120 ANGLE SECTION FLAME DETECTOR GASKET CLOCKING WASHERS IGNITER- INJECTOR FLAME OBSERVATION PORT Figure 2-6: Igniter-Injector Orientation (Viewed Looking Up from Below) 11. Connect the staged ignition assembly to the gas injector tube of the igniter-injector by securing the compression nut to the elbow of the ignition assembly. See Figure Connect igniter cable to the igniter terminal on the igniter-injector. See Figure Retrieve the NEW flame detector and gasket (P/N ) from the kit and install into the appropriate hole in the burner flange using the two standoff screws removed at disassembly. See Figures 2-6 and 2-1. NOTE Evenly tighten both flame rod screws to avoid uneven distortion of gasket resulting in a tilted rod angle. Do not over-tighten. 14. Connect the flame detector lead to the flame detector terminal. See Figure This concludes the Fireside Inspection Reassembly and Maintenance procedures. You may now proceed to the next section for instructions for the Waterside Inspection procedures. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 10 of 20

11 2.3 Waterside Inspection After 24-months of service, the RECON unit should receive a detailed waterside inspection, which will include removal of the top heater head of the RECON Water Heater. Waterside maintenance includes replacement of the parts shown in Table 2-2. Table 2-2: Waterside Inspection Replacement Parts PART# DESCRIPTION GP Head Gasket GP Head Release Gasket Baffle Seal Waterside Inspection Procedure 1. Ensure that electrical power to the unit is turned OFF. 2. Ensure that water inlet, outlet, and recirculation shut-off valves are turned OFF. 3. Vent the shell by carefully opening the drain valve while opening the P&T relief valve (see Figure 2-7) 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 head liner causing serious damage not covered by warranty. 4. Referring to see Figure 2-7, below, remove the sixteen 5/8-11 hex nuts and washers from the upper head, and then remove the upper head, upper head-liner and gaskets. 5/8-11 HEX NUT (x16) LIFTING RING (x2) WASHER (x16) UPPER HEAD UPPER HEAD LINER (COPPER) HEAD RELEASE GASKET (P/N GP-18556) 5/8-11 X 3-3/4 STUD (x16) HEAD GASKET (P/N GP-18532) P&T RELIEF VALVE Figure 2-7: Heat Exchanger Head Configuration 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 11 of 20

12 Waterside Inspection Procedure - Continued 5. If the unit contains a baffle assembly (Figure 2-8), remove it, exposing the heat exchanger tubes. 6. Replace the baffle seal (P/N 89037) around the edge of the baffle plate with a NEW one from the kit. Refer to the inset of Figure 2-8 for a profile as to how the baffle plate outer edge should be positioned within the inner lips of the baffle seal. PLASTIC CAP (x3) THREADED ROD (x3) HEX NUTS (x3) BAFFLE PLATE BAFFLE PLATE BAFFLE SEAL Showing Top Head Removed Baffle Seal Edge Profile BAFFLE SEAL Transparent - Showing Baffle Assembly Inside Figure 2-8: Heat Exchanger Baffle Assembly Location and Components 7. Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembly. 8. While they are exposed, the anode blocks should be inspected for corrosion (Figure 2-8). If they have corroded by more than 50% (original dimensions are approximately 7-1/4" X 4 ), then they should be replaced. If the anode blocks need to be replaced, order the Anode Block Replacement Kit from AERCO, P/N Even if the anodes themselves do not need replacement, check the integrity of the entire anode assembly, including the anode mounting bracket, ensuring there are no loose bolts or corroded supporting structures. ANODE BLOCKS COMBUSTION CHAMBER HEAD SUPPORTING STRUCTURES ANODE MOUNTING BRACKET Figure 2-9: Anode Assembly and Combustion Chamber Head 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 12 of 20

13 Waterside Inspection Procedure - Continued 10. Place the head gasket (P/N GP-18532) on top of the heat exchanger shell flange, aligning the gasket holes with the bolts in the shell flange. 11. Lower the baffle assembly (with NEW baffle seal P/N 89037) into the heat exchanger until there is gap between the bottom surface of the baffle and the top of the heat exchanger tubes of 1/4 inch maximum to 1/16 inch minimum. See Figure 2-9 for a cut-away profile of how the baffle assembly should be installed. 12. Rotate the threaded studs until the top part of all three spindle caps are flush with the top surface of the heat exchanger shell flange. If the caps protrude above the top edge of the heat exchanger, they may damage the copper head liner when the head is assembled. TOP OF SHELL FLANGE ROD TOPS ROTATE THREADED RODS (x3) UNTIL TOPS ARE FLUSH WITH TOP SURFACE OF THE HEAT EXCHANGER SHELL FLANGE). COMBUSTION CHAMBER HEAD THREADED BAFFLE RODS BAFFLE PLATE BAFFLE SEAL HEAT EXCHANGER CASING (CUT-AWAY) HEAT EXCHANGER TUBES 1/16 MIN. TO 1/4 MAXIMUM BETWEEN TOP OF TUBES AND BOTTOM OF BAFFLE Figure 2-10: Baffle Assembly Positioning Side View 13. Place the head release gasket (P/N GP-18556) on top of the head gasket, aligning the gasket holes with the bolts in the shell flange. 14. Place the copper upper head liner on, aligning the holes with the 5/8-11 X 3-3/4 studs. 15. Place upper head onto the 5/8-11 X 3-3/4 studs, and install the washers and nuts. 16. Cross tighten the nuts to approximately 75 ft.-lb. torque to obtain a uniform seating, then progressively tighten the nuts to 200 ft.-lb. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 13 of 20

14 2.4 Condensate Drain Trap Inspection The RECON Water Heater condensate trap is located external to the unit and attached to the drain connection from the exhaust manifold. This trap should be inspected and, if necessary, cleaned to ensure proper operation. Condensate drain trap maintenance includes replacement of the parts shown in Table 2-3. Table 2-3: Condensate Trap Replacement Parts PART# DESCRIPTION Condensate Drain Trap Cover O-Ring To inspect and clean the trap, proceed as follows: Condensate Drain Trap Inspection and Cleaning 1. Loosen the four (4) thumbscrews securing the trap s cover, and then remove the cover and the O-ring from under the cover. Discard the O-ring as it will be replaced at reassembly. 2. Remove the float from the condensate trap. 3. Thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap (P/N 24441). 4. Replace the float and install the new condensate trap O-ring from the kit (P/N 84017). 5. Secure the trap cover in place with four (4) thumb screws. 6. Reassemble all piping and hose connections to the trap s inlet and outlet. 3/4" NPT Port Thumb Screws (4) Thumb Screw INLET Condensate Trap O-Ring (P/N 84017) Float O-Rings (2) 3/4" NPT Port OUTLET CROSS-SECTION EXPLODED VIEW Figure 2-11: External Condensate Trap Cross-Section and Exploded Views 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 14 of 20

15 2.5 Air Filter Replacement Air filter maintenance includes replacement of the parts shown in Table 2-4. Table 2-4: Air Filer Replacement Parts PART# DESCRIPTION or Air Filter or Air Filter Cleaning kit To replace the air filter, proceed as follows: NOTE: If you are using the kit with air filter cleaning kit instead of a new filter, disregard the instructions below and refer instead to the manufacturer s instructions in the cleaning kit. Air Filter Replacement 1. Ensure the power switch on the control panel is set to OFF and AC power is disconnected. 2. Refer to Figure 2-12 and locate the air filter attached to the air/fuel valve inlet. 3. Using a flat-tip screwdriver or 5/16 nut driver, loosen the clamp securing the filter to the inlet flange of the air/fuel valve. Remove the filter and clamp. 4. Each replacement air filter is equipped with its own clamp, therefore, simply install the replacement air filter (P/N 59139) on the inlet flange of the air fuel valve and tighten the clamp with a flat-tip screwdriver or 5/16 nut driver. BLOWER AIR FILTER CLAMP AIR/FUEL VALVE AIR FILTER (P/N 59139) Figure 2-12: Air Filter Mounting Location 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 15 of 20

16 2.6 Gas Train Gasket Replacement NOTE Replacing the gas train gasket will normally be necessary only if the gas train must be disconnected from the air/fuel valve for some reason (such as performing maintenance in zero side clearance situations), or if a leak is suspected at the connection. In case it is needed, the gasket (P/N 81155) is provided in the kit, with generic instructions given below for its replacement. The RECON gas train gasket (P/N 81155) is located at gas inlet into the air/fuel valve, as shown in Figure To replace the gas train O-ring, proceed as follows: Gas Train Gasket Replacement 1. Ensure the power switch on the control panel is set to OFF, AC power is disconnected from the unit, and check that the external gas valve is turned to OFF. 2. Locate the gas train assembly per Figure The entire assembly will be moved slightly downward when disconnected from the air/fuel valve to provide access to the gas train gasket (P/N 81155). The gas train assembly is colored gold in Figure Loosen the two nuts on the U-bolt at the gas train bracket (Figure 2-13) to allow the gas train assembly to be lowered when removed from the air filter valve. 4. Remove the four 5/8-11 bolts affixing the gas train to the air/fuel valve (Figure 2-13). 5. Remove the old gasket and discard, then replace with new one (P/N 81155) from the kit. 6. Affix gas train to air/fuel valve using the 5/8-11 bolts, gradually tightening in a criss-cross pattern. Tighten bolts to torque value of 2.3 to 2.6 foot/lbs. of pressure (27 to 31 inch/lbs.). 7. Adjust the U-bolt and gas train on the gas train bracket and then tighten the two nuts (Figure 2-13). AIR/FUEL VALVE STEPS 5: REPLACE OLD GAS TRAIN FILTER WITH NEW ONE (P/N 81155) STEPS 4 / 6: 5/8-11 BOLTS (4 EA) GAS TRAIN SUPPORT BRACKET GAS TRAIN INLET CONNECTION U-BOLT STEP 3 / 7: TWO NUTS ON U- BOLT AT GAS TRAIN BRACKET Figure 2-13: Diassembly of Gas Train from A/F Valve 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 16 of 20

17 2.7 LWCO (Low Water Cut Off) Probe Assembly Replacement The LWCO (Low Water Cut Off) probe is comprised of the sensor with a capacitor assembly attached. LWCO Probe maintenance includes replacement of the parts shown in Table 2-5, then testing. Table 2-5: LWCO Probe Replacement Parts PART# DESCRIPTION LWCO Probe assembly LWCO Probe Assembly Replacement 1. Ensure that water valves in and out of the boiler are closed and the heater is properly drained. 2. Find the existing LWCO probe, located high on the left side of the heat exchanger shell as you are facing the unit front (Figure 2-14). 3. Cut the shell harness wire just below the female spade connector (Figure 2-14). The new LWCO assembly includes a new female connector to crimp onto the shell harness wire. LWCO PROBE PLASTIC NUT CAPACITOR ASSEMBLY (COVERED BY LARGE SHRINK TUBING) CUT HERE FRONT VIEW - TOP COVERS REMOVED CONNECTOR (TO SHELL HARNESS) Figure 2-14: LWCO Probe Assembly Replacement SHELL HARNESS WIRE (CRIMP TO NEW ASSY) 4. Remove the old LWCO probe assembly from the recess well on the hot water outlet piping by unscrewing the brass coupling to which it is attached. 5. Retrieve the new LWCO probe (P/N 69126) from the kit and sparingly apply an NSF approved pipe dope to the threads of the brass coupling (Do NOT use Teflon tape) and install into the probe well vacated by the old LWCO probe. 6. The new LWCO assembly comes with a spare female connector already inserted into the male connector, and this should be crimped onto the stripped end of the shell harness wire. 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 17 of 20

18 2.8 LWCO (Low Water Cutoff) Testing After replacement, the LWCO (Low Water Cut Off) capacitor should be tested by checking for electrical shorts and performing a Low Water Cutoff test using the C-More controller LWCO Capacitor Electrical Short Test This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger. Perform the capacitor electrical short test as described below. LWCO Capacitor Electrical Short Test 1. Ensure AC power to the unit is turned OFF. WARNING! High voltages are used to power these units and so it is required that power applied to these units is removed first before performing the procedure described in this instruction. Serious personal injury or death may occur if this warning is not observed. 2. Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the rear panel of the C-More controller (see gold connector in Figure 2-15). C-MORE REAR PANEL UNPLUG SHELL HARNESS CABLE FROM P5 CONNECTOR (2 nd FROM RIGHT, FACING REAR) Figure 2-15: Removing Shell Harness Cable Connector (P5) on C-More Rear Panel 3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure Connect the second ohmmeter probe to Pin #6 of Shell Harness Cable Connector (removed from the C-More controller) as shown on right in Figure CONNECT 1 st LEAD TO LWCO T i l CONNECT 2 nd LEAD TO PIN #6 19-PIN SHELL HARNESS CABLE CONNECTOR Ohmmeter Figure 2-16: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 18 of 20

19 LWCO Capacitor Electrical Short Test - Continued 5. Confirm that the ohmmeter does NOT read a short. 6. Remove both ohmmeter probes and reconnect the Shell Harness connector to the P5 connector on the rear of the C-More controller Standard C-More LWCO Test Perform the standard Low Water Cutoff test using the C-More controls as described below. Standard C-More LWCO Test NOTE The unit shell must first be filled, drain valves closed, water lines opened, and AC power applied before performing this test. See Section After ensuring the shell is filled with water, drain valves are OFF, water lines are OPEN, and AC power is applied, turn on the C-More controller power switch. 2. Press the TEST switch on the C-More controller and confirm that the blinking "Low Water Level" message appears on the C-More display within 4 seconds. 3. Press the RESET key, followed by the Clear button, and confirm that the "Low W ater Level" message is cleared. 3. END OF MAINTENANCE RETURN TO SERVICE 1. Assemble all panels onto unit. 2. Ensure: a) drain valve is closed, End of Maintenance Return to Service b) all water supply and return valves are OPEN, c) gas supply valve is OPEN, d) External AC power to the unit is ON. 3. Turn the C-More controller power switch to ON, and operate per instructions in the RECON installation, operation, and maintenance manual (GF-147). 09/28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 19 of 20

20 Change Log: Date Description Changed By 09/28/2015 Rev-A: 1 st Release Curtis Harvey AERCO International, Inc., /28/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 20 of 20