Aerco G-13-1854 Installation, Operation And Maintenance Manual Download

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Innovation Water Heaters Installation, Operation & Maintenance Manual

OMM-0078_0J

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

Page

196

GF-128

Phone: 800-526-0288

PRI: 11/22/2013

Benchmark 3000

USER MANUAL

Installation, Operation and Maintenance

INNOVATION Series

Gas-Fired Water Heaters

Natural Gas or Propane
Modulating, Condensing
Water Heater Models

Applicable to Serial Numbers:

G-13-1854 and above

Other documents for this product
include:

•

GF-5030

INN Gas Supply Guide

•

GF-5050

INN Venting Guide

•

GF-5060

INN Elect. Power Guide

•

GF-5080

INN Sizing Guide

Latest Update: 11/22/2013

Summary of Contents for G-13-1854

Page 1: ...nchmark 3000 USER MANUAL Installation Operation and Maintenance INNOVATION Series Gas Fired Water Heaters Natural Gas or Propane Modulating Condensing Water Heater Models Applicable to Serial Numbers G 13 1854 and above Other documents for this product include GF 5030 INN Gas Supply Guide GF 5050 INN Venting Guide GF 5060 INN Elect Power Guide GF 5080 INN Sizing Guide Latest Update 11 22 2013 ...

Page 2: ...he 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 occurri...

Page 3: ... VALVE INSTALLATION 24 2 9 CONDENSATE DRAIN PIPING 24 2 10 GAS SUPPLY PIPING 26 2 10 1 Gas Supply Specifications 26 2 10 2 Manual Gas Shutoff Valve 26 2 10 3 External Gas Supply Regulator 27 2 11 AC ELECTRICAL POWER WIRING 28 2 11 1 Electrical Power Requirements 28 2 12 FIELD CONTROL WIRING 29 2 12 1 OUTDOOR AIR IN Terminal 30 2 12 2 COMBUSTION AIR Terminals 30 2 12 3 O2 SENSOR Terminals 31 2 12 4...

Page 4: ...stalling Gas Supply Manometer 50 4 2 3 Accessing the Analyzer Probe Port 50 4 2 4 Connecting Multimeter to Flame Detector 51 4 3 NATURAL GAS COMBUSTION CALIBRATION 52 4 4 PROPANE COMBUSTION CALIBRATION 55 4 5 REASSEMBLY 57 4 6 TEMPERATURE CONTROL CALIBRATION 57 4 6 1 Setting the Outlet Water Temperature Setpoint 58 4 6 2 Minimum Load Adjustment 58 4 6 3 Maximum Load Adjustment 59 4 7 OVER TEMPERAT...

Page 5: ...GED SHUTDOWN 86 CHAPTER 7 TROUBLESHOOTING GUIDE 87 7 1 INTRODUCTION 87 7 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 99 CHAPTER 8 RS232 COMMUNICATION 103 8 1 INTRODUCTION 103 8 1 1 Acquiring the PuTTY Application 103 8 1 2 Logging on to a Remote Machine Using PuTTY 103 8 1 3 Running a Command on a Remote Machine Using PuTTY 104 8 2 RS232 COMMUNICATION SETUP 105 8 3 MENU PROCESSING UTILIZIN...

Page 6: ... 117 9 9 SEQUENCING VALVE DESCRIPTION OPERATION 118 9 9 1 Sequencing Valve Description 118 9 9 2 Sequencing Valve Operating Characteristics 120 APPENDIX A INNOVATION MENU ITEM DESCRIPTIONS 121 APPENDIX B STARTUP STATUS AND FAULT MESSAGES 127 APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART 131 APPENDIX D INNOVATION DEFAULT SETTINGS 133 APPENDIX E DIMENSIONAL DRAWINGS 135 APPENDIX F PARTS LIS...

Page 7: ...rs furnished with each unit When the heater is ordered with a Sequencing Valve SV up to eight 8 Innovation Water Heaters can be controlled by the WHM system utilizing RS485 Modbus protocol All available Innovation Water Heater models are listed in the table on the following page As this table shows units can be ordered with Factory Mutual FM or Double Block and Bleed formerly IRI Gas Trains with o...

Page 8: ...Block Bleed Formerly IRI Gas Train 1 095 lbs INN800SVDBB INN800SVPDBB Innovation Potable Water Heater 800 000 BTU HR Input Natural Gas or Propane Double Block Bleed Formerly IRI Gas Train with WHM Sequencing Valve 1 115 lbs INN1060 INN1060P Innovation Potable Water Heater 1 060 000 BTU HR Input Natural Gas or Propane FM Gas Train 1 100 lbs INN1060SV INN1060SVP Innovation Potable Water Heater 1 060...

Page 9: ... symbol is 1 bit long BLDG Bldg Building BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound of water 1 F CCP Combustion Control Panel C More Controller or Control Box A control system developed by AERCO and currently used in all Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide COMM Comm Communication Cal Calibration CNTL Contr...

Page 10: ...tocol developed by AEG Modicon NC N C Normally Closed NO N O Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen O D Outside Diameter PMC Board A Primary Micro Controller PMC board is contained in the C More Control Box used on all Benchmark units PPM Parts Per Million PTP Point to Point usually over RS232 networks REF Ref Reference RES Resistive RS232 or EIA 232 A standard for ser...

Page 11: ...BBREVIATIONS AND ACRONYMS Continued Terminating Resistor A resistor placed at each end of a daisy chain or multi drop network in order to prevent reflections that may cause invalid data in the communication VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column WHM Water Heater Management µA Micro amp 1 millionth of...

Page 12: ...r Heaters Installation Operation Maintenance Manual FORWARD Page 12 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 13: ...g jurisdiction should be consulted before installations are made See pages 15 and 16 for information on installations within the Commonwealth of Massachusetts IMPORTANT This Instruction Manual is an integral part of the product and must be maintained in legible condition It must be given to the user by the installer and kept in a safe place for future reference IMPORTANT Read the following restric...

Page 14: ...s used for gas pipe leak testing are corrosive to metals The piping must be rinsed thoroughly with clean water after leak checks have been completed CAUTION DO NOT use this heater if any part has been under water Call a qualified service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the ma...

Page 15: ...o decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In a...

Page 16: ...f Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for ...

Page 17: ...hipment Note the information on the carrier s paperwork and request a freight claim and inspection by a claims adjuster before proceeding Any other visual damage to the packaging materials should also be made clear to the delivering carrier 2 3 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials After unpacking closely inspect the ...

Page 18: ... in Figure 2 1 shown with optional Sequencing Valve The minimum clearance dimensions required by AERCO are listed below However if Local Building Codes require additional clearances these codes shall supersede AERCO s requirements Minimum acceptable clearances required are as follows Sides 24 inches Front 24 inches Rear 30 inches Top 18 inches All gas piping water piping and electrical conduit or ...

Page 19: ...as shown in Figure 2 2 USE THESE TWO LUGS TO LIFT AND MOVE THE UNIT Remove the top panel from the unit to provide access to the lifting lugs Remove the four 4 lag screws securing the unit to the shipping skid Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad required in the desired location In multiple unit installations it is important to plan t...

Page 20: ...erfere with removal of any covers inhibit service or maintenance or prevent access between the unit and walls or another unit Figure 2 3a Water Inlet Outlet Locations 2 5 1 WHM Actuator Controlled Ball Valve Installation If the Innovation Water Heater was ordered for use with the C More Water Heater Management WHM system and the actuator controlled ball valve is not already installed on the unit F...

Page 21: ...he cold water supply piping 5 Tighten all pipe connections after the valve is properly positioned 6 Connect the 3 pin Molex connector on the valve to the mating connector on the Innovation harness at the rear of the unit 7 This completes the actuator controlled ball valve installation Figure 2 3b Innovation Water Heater Equipped With Sequencing Valve 2 6 TEST HOSE BIB CONNECTION A Test Hose Bib co...

Page 22: ... 2 5 This assembly contains a recirculator pump which connects between the upper hot water outlet and lower cold water inlet of the unit s heat exchanger The purpose of this loop is to provide feed forward FFWD temperature control by mixing a portion of the hot water outlet with the cold water inlet of the unit Temperature sensors located in the hot water outlet and cold water inlet provide temper...

Page 23: ...6 0288 PRI 11 22 2013 REAR VIEW WITH CENTER PANEL REMOVED Figure 2 5 Recirculation Loop NOTE The maximum working pressure for installations within the Province of Alberta is 87 psig Therefore a pressure temperature relief valve with a setting of 75 psig 210 F is supplied with Alberta shipments RECIRCULATION LOOP PIPING HOT WATER OUTLET P T VALVE RECIRCULATION PUMP COLD WATER INLET DRAIN VALVE ...

Page 24: ...anifolded together Each must be individually run to a suitable discharge location 2 9 CONDENSATE DRAIN PIPING The Innovation Water Heater is designed to condense water vapor from the flue products Therefore the installation must have provisions for suitable condensate drainage or collection The condensate drain port is located on the exhaust manifold at the rear of the unit Figure 2 6 This drain p...

Page 25: ...r the heater installation site 2 At the condensate trap outlet install a 3 4 NPT nipple 3 Connect a length of 1 I D polypropylene hose to the trap outlet and secure with a hose clamp 4 Route the hose on the trap outlet to a nearby floor drain If a floor drain is not available a condensate pump can be used to remove the condensate to drain The maximum condensate flow rate is 20 GPH The condensate d...

Page 26: ... or other foreign particles Do Not install any flexible connectors or unapproved gas fittings Piping must be supported from the floor ceiling or walls only and must not be supported by the unit A suitable piping compound approved for use with natural gas should be used Any excess must be wiped off to prevent clogging of components To avoid unit damage when pressure testing gas piping isolate the u...

Page 27: ...stallations a mandatory external gas supply regulator must be positioned as shown in Figure 2 8 The gas supply regulator must be properly vented to outdoors Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator 2 10 3 2 All Installations Except Massachusetts For all installations other than Massachusetts that EXCEED 7 W C gas pressure a mandatory ex...

Page 28: ...n the unit and walls or another unit POWER BOX WITH COVER POWER BOX WITH COVER REMOVED Figure 2 9 Power Box Location Partial Front View Front Panel Removed 2 11 1 Electrical Power Requirements The AERCO Innovation Heater accepts 120 VAC single phase 60 Hz 20A The Power Box contains a terminal block as shown in Figure 2 10 In addition a wiring diagram showing the required AC power connections is pr...

Page 29: ...nal operating control system No field control wiring is required for normal operation However the C More control system used with all Innovation Heaters does allow for some control and monitoring features Wiring connections for these features are made in the Input Output I O Box The I O Box is located on the upper left portion of the unit front panel Figure 2 11 behind the removable front panel do...

Page 30: ...d heaters These I O Box connections are noted in the sections below NOTE Use Figure 2 12 to determine the functions of the I O PCB connections Do not use the silkscreened labels on the PCB itself as these may not match DO NOT make any connections to the I O Box terminals labeled NOT USED Attempting to do so may cause equipment damage Figure 2 12 I O Box Terminal Strips 2 12 1 OUTDOOR AIR IN Termin...

Page 31: ...ns between the source and the Heater s I O Box must be made using twisted shielded pair of 18 22 AWG wire such as Belden 9841 Polarity must be maintained and the shield must be connected only at the source end and must be left floating not connected at the Heater s I O Box Whether using voltage or current for the drive signal they are linearly mapped to a 40 F to 240 F setpoint or a 0 to 100 air f...

Page 32: ...nals The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers or other accessories These interlocks are called the Remote Interlock and Delayed Interlock REMOTE INTL K IN and DELAYED INTL K IN in Figure 2 12 Both interlocks described below are factory wired in the closed position NOTE Both the Remote Interlock and Delaye...

Page 33: ... designed or installed Suitable U L approved positive pressure watertight vent materials MUST be used for safety and UL certification Because the unit is capable of discharging low temperature exhaust gases the flue must be pitched back towards the unit a minimum of 1 4 per foot to avoid any condensate pooling and to allow for proper drainage While there is a positive flue pressure during operatio...

Page 34: ... Outside the Building Air supplied from outside the building must be provided through two permanent openings For each unit these two openings must have a free area of not less than one square inch for each 4000 BTUs input of the equipment or 250 square inches of free area The free area must take into account restrictions such as louvers and bird screens For Canada installations refer to the requir...

Page 35: ...imes All of the installation procedures in Chapter 2 must be completed before attempting to start the unit ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS DO NOT ATTEMPT TO DRY FIRE THE UNIT STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAM...

Page 36: ...e 3 1 Control Panel Front View NOTE If there is a requirement to use the RS232 port Item 4 on the C More controller front panel contact AERCO to purchase the RS232 Adaptor Cable P N 124675 which is designed for this purpose This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports 3 2 1 4...

Page 37: ...ng up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection 4 RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel AERCO offers for purchase the RS232 Adaptor Cable P N 124675 which is designed to work with this port This cable features a DB9 connector for connect...

Page 38: ... pressed and the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE k...

Page 39: ...gure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures Menu Processing Procedure 1 The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status Pressing the or arrow key will display the other available data items in the Operating Menu 2 Press the MENU key ...

Page 40: ...6 0288 GF 128 Figure 3 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages NOTE THE WHM MENU IS ONLY DISPLAYED WHEN THE UNIT TYPE IN THE CONFIGURATION MENU IS SET TO INNOVATION WH...

Page 41: ...t Temp 40 F 140 F Air Temp 70 F 245 F Outdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Out 0 100 FFWD Temp 80 F 160 F Flame Strength 0 100 Run Cycles 0 999 999 999 Run Hours 0 999 999 999 Fault Log 0 19 0 NOTE The Outdoor Temp display item shown with an asterisk in Table 3 2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu Table 3 4 ...

Page 42: ... The remaining options in this menu require the valid password to be entered prior to changing existing entries This menu contains a number of other configuration settings which may or may not be displayed depending on the current operating mode setting NOTE The Configuration Menu settings shown in Table 3 4 are Factory Set in accordance with the requirements specified for each individual order Th...

Page 43: ...Hi Limit 40 F 240 F 160 F Max Valve Position 40 100 100 Pump Delay Timer 0 min 30 min 0 min Aux Start On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown Low Fire Timer 2 sec 600 sec 2 sec Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0 F 10 F 0 Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt EN 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband L...

Page 44: ...tback Start 12 00am 11 59pm 12 00am Setback End 12 00am 11 59pm 12 00am WHM Auto Mstr Yes or No No WHM Auto Timer 10 sec 120 sec 30 sec NOTE The Level 2 Password 6817 in the Setup Menu must be entered to view or change the WHM Auto Mstr and WHM Auto Timer options 3 8 TUNING MENU The Tuning Menu items in Table 3 6 are Factory set for each individual unit Do not change these menu entries unless spec...

Page 45: ... is not checked prior to starting the pre purge If all of the above switches are closed the READY light above the ON OFF switch will light and the unit will be in the Standby mode When there is a demand for hot water the following events will occur NOTE If any of the Pre Purge safety device switches are open the appropriate fault message will be displayed Also if the required conditions are not ob...

Page 46: ... The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 c The VALVE POSITION bargraph will show 100 Figure 3 4 Air Fuel Valve In Purge Position 4 Next the blower proof switch on the Air Fuel Valve Figure 3 5 closes The display will show Purging and indicate the elapsed ...

Page 47: ... gas to flow into the Air Fuel Valve Figure 3 6 Air Fuel Valve In Ignition Position 6 Up to 7 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 7 After 2 seconds of continuous flame Flame Proven will be displayed and the flame strength will be indicated After 5 seconds the current date and time will be displayed in place of ...

Page 48: ...ergy input is not linearly related to the Air Fuel Valve position Refer to Table 3 7 for the relationship between the energy input and Air Fuel Valve position for a unit running on natural gas Table 3 7 Relationship Between Air Fuel Valve Position and Energy Input For Units Running Natural Gas Air Fuel Valve Position Open Innovation Water Heater Model Energy Input BTU Hr INN600 INN800 INN1060 INN1...

Page 49: ...lue gas emissions Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this Chapter it will be necessary to perform the Safety Device Testing procedures specified in Chapter 5 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Innovation Heater must be com...

Page 50: ...l gas supply shut off valve upstream of the unit 2 Remove the front door and left side panels from the heater to access the gas train components 3 Remove the 1 4 inch NPT pipe plug from the leak detection ball valve on the downstream side of the Safety Shut Off Valve SSOV as shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to th...

Page 51: ...flow DO NOT install the probe at this time Figure 4 2 Analyzer Probe Hole Location IMPORTANT For Innovation Water Heater installations in Korea refer to the Natural Gas Combustion Calibration procedures in Appendix K 4 2 4 Connecting Multimeter to Flame Detector During Combustion Calibration the flame strength generated by the flame detector is measured using a multimeter set to the µA scale The f...

Page 52: ...t up for either Natural Gas or Propane as specified by the Style Number on the Sales Order Perform the appropriate Combustion Calibration procedures in section 4 3 for Natural Gas or section 4 4 for Propane 4 3 NATURAL GAS COMBUSTION CALIBRATION The Innovation Heater is combustion calibrated at the factory prior to shipping However recalibration is necessary as part of initial start up due to chan...

Page 53: ...e air fuel valve position to 0 by pressing the arrow key 7 Ensure that the leak detection ball valve downstream of the SSOV is open 8 Set the ON OFF switch to the ON position 9 Change the valve position to 29 using the arrow key The unit should begin its start sequence and fire 10 Next verify that the gas pressure downstream of the SSOV is within the appropriate range shown below for the Innovatio...

Page 54: ...lowly rotate the gas pressure adjustment approximately 1 4 turn increments Allow the combustion analyzer to stabilize following each adjustment Clockwise rotation reduces the oxygen level while counterclockwise rotation increases the oxygen level 15 Once the oxygen level is within the required range listed in step 13 the gas pressure on the downstream side of the SSOV should be within the appropri...

Page 55: ...urned to AERCO for proper Warranty Validation It is important to perform the calibration procedure as outlined in the following steps This will keep readjustments to a minimum and provide optimum performance Propane Combustion Calibration 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the propane gas supply valve s to the unit 3 Set the co...

Page 56: ...at the rear of the exhaust manifold Allow enough time for the combustion analyzer to settle 13 Verify that the oxygen O2 level is within the range shown below Also ensure that the carbon monoxide CO nitrogen oxide NOx and flame strength readings are within the values shown Combustion Oxygen Level at 16 Valve Position Oxygen 0 5 Carbon Monoxide NOx Flame Strength 6 0 50 ppm 15 ppm 2 0 µA 14 If the ...

Page 57: ...ervice operation Reassembly 1 Set the ON OFF switch in the OFF position 2 Disconnect AC power from the unit 3 Shut off the gas supply to the unit 4 Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound 5 Remove the combustion analyzer probe from the 1 8 vent hole in the exhaust manifold Replace the 1 8 NPT plug in the manifold 6 Replace the unit ...

Page 58: ...et Feedback back to ENABLE Temperature control calibration is accomplished by performing the Minimum and Maximum Load Adjustment procedures in sections 4 6 2 and 4 6 3 respectively 4 6 1 Setting the Outlet Water Temperature Setpoint The setpoint temperature of the unit may be changed using the following steps However once a setpoint has been changed recalibration may be necessary The temperature c...

Page 59: ... arrow key Increasing this value will increase outlet water temperature while decreasing it will decrease outlet water temperature 9 Press ENTER to save the change Allow time for the system to stabilize between adjustments 10 Repeat steps 5 through 9 as needed until the temperature is stabilized at no more than 2 to 3 degrees above the unit s setpoint 4 6 3 Maximum Load Adjustment Check the temper...

Page 60: ...tative NOTE After performing Temperature Calibration and prior to placing the water heater into service be sure to set the Outlet Feedback option in the Tuning Menu back to ON 4 7 OVER TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over temperature limit switches These switches are mounted on a plate as shown in Figure 4 5 The switches can be accessed by opening the f...

Page 61: ...om the unit to perform the following tests ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 5 2 LOW GAS PRESSURE FAULT TEST Refer to Figure 5 1 and ensure that the leak detection ball valve located at the high gas pressure switch is closed Low Gas Pressure Fault Tes...

Page 62: ... removed 3 Slowly open the leak detection ball valve 4 Start the unit in Manual mode at a valve position firing rate of 25 5 Slowly increase the gas pressure using the adjustment screw on the SSOV 6 The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 4 0 W C The FAULT indicator should also start flashing 7 Reduce the gas pressure back to 2 8 W C 8 ...

Page 63: ...turn piping to the unit 9 Open the water supply shut off valve to the unit to refill 10 After the shell is full press the LOW WATER LEVEL RESET button to reset the low water cutoff 11 Press the CLEAR button to reset the FAULT LED and clear the displayed error message 12 Set the ON OFF switch to the ON position The unit is now ready for operation 5 5 WATER TEMPERATURE FAULT TEST A high water temper...

Page 64: ...these circuits are located in the I O Box Figure 2 12 and are labeled REMOTE INTL K IN and DELAYED INTL K IN These circuits can shut down the unit in the event that an interlock is opened These interlocks are shipped from the factory jumpered closed However each of these interlocks may be utilized in the field as a remote stop and start an emergency cut off or to prove that a device such as a pump...

Page 65: ...ccur during ignition or while the unit is already running To simulate each of these fault conditions proceed as follows Flame Fault Tests 1 Set the ON OFF switch to the OFF position 2 Place the unit in the Manual Mode and set the valve position between 25 and 30 3 Close the manual gas shutoff valve located between the Safety Shut Off Valve SSOV and the Air Fuel Valve see Figure 5 3 4 Set the ON OF...

Page 66: ...ck the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 5 4 Air Flow Fault Tests 1 Disable the blower output drive voltage as follows a Press the MENU key until CONFIGURATION MENU is displayed b Press the arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the arrow key until OFF is displayed then press the ENTER key 2 Start the un...

Page 67: ...me turn off the blower by going to the Configuration Menu Analog Output menu item and select OFF 7 The Blower Proof Switch will open and the blower should stop The unit should shut down and display AIRFLOW FAULT DURING RUN 8 Go to the Configuration Menu Analog Output item and select VALVE POSITION 0 10v 9 Press the CLEAR button The unit should restart 10 Next check the operation of the Blocked Inl...

Page 68: ...n Manual Mode and set the valve position between 25 and 30 3 Refer to Figure 5 1 and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 5 6 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 6 The unit should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press ...

Page 69: ... 5 7 3 Remove one of the two wires 171 or 172 from the Purge Switch Figure 5 8 4 Initiate a unit start sequence 5 The unit should begin its start sequence then shut down and display PRG SWITCH OPEN DURING PURGE 6 Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart 5 11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch and the Purge Switch is located on ...

Page 70: ...n and display IGN SWITCH OPEN DURING IGNITION 7 Replace the wire on the Ignition Switch and press the CLEAR button The unit should restart Figure 5 7 Typical Air Fuel Valve Cover Location Figure 5 8 Air Fuel Valve Purge and Ignition Switch Locations 5 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code Section VI AIR FUEL VALVE CO...

Page 71: ...URE 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 Table 6 1 Maintenance Schedule Section Item 6 Mos 12 Mos 24 Mos Labor Time 6 2 Igniter 66023 Insp...

Page 72: ...tector To inspect replace the Igniter Igniter Inspection Replacement 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remove the side and rear panels from the unit 3 Disconnect the ignition cable and ground wire from the Igniter 4 Next loosen and remove the igniter from the intake manifold flange using a 1 open end wrench 5 Check the igniter for ...

Page 73: ... tab of the igniter to ensure that it is pointing outward toward the perimeter of the intake manifold flange 7 Refer to Figure 6 2 and reinstall the igniter on the intake manifold flange Install clocking washers as needed to ensure that the igniter ground tab is pointing outward toward the perimeter of the intake manifold flange Torque to 15 ft lbs Do not over tighten 8 Figure 6 2 Igniter Flame De...

Page 74: ...einstall the flame detector and flame detector gasket 8 Reconnect the flame detector lead wire 9 Reinstall the side and rear panels on the unit 6 4 COMBUSTION CALIBRATION Combustion settings must be checked at the intervals shown in Table 6 1 as part of the maintenance requirements Refer to Chapter 4 for combustion calibration instructions 6 5 SAFETY DEVICE TESTING Systematic and thorough tests of...

Page 75: ...he side and rear panels from the unit Also remove the bottom panel of the cabinet to expose the mechanical room floor beneath the burner This is need to provide clearance for pulling the burner 3 Refer to Figures 6 3 and 6 4 to locate the blower side intake manifold part no 44106 at the bottom of the unit s heat exchanger 4 Disconnect the lead wire from the flame detector installed on the intake m...

Page 76: ... burner assembly 46023 burner gasket 18899 and fiber frax gasket 124749 from the unit See Figures 6 3 and 6 4 12 Disconnect the exhaust temperature sensor Figure 6 3 by unscrewing it from the exhaust manifold 13 While supporting the exhaust manifold remove the two 2 side nuts Figure 6 5 securing the manifold to the heat exchanger Loosen but do not remove the third nut nearest to the front of the u...

Page 77: ...00 526 0288 PRI 11 22 2013 Fireside Inspection Continued Figure 6 4 Innovation Heater Partial Left Side View PARTIAL RIGHT SIDE VIEW WITH SUPPORT REMOVED Figure 6 5 Innovation Heater Partial Cut Away View BURNER ASSEMBLY 46023 INTAKE MANIFOLD 44106 CONDENSATE SHIELD 49209 BURNER GASKET 18899 FIBER FRAX GASKET 124749 EXHAUST MANIFOLD 5 16 18 STUDS 6 SIDE NUTS 2 FRONT NUT 1 EXHAUST SENSOR ...

Page 78: ...iner is installed before reinstalling the exhaust manifold During reassembly apply high temperature anti seize lubricant to the threads of the igniter and grounding screw Also ensure that the igniter are properly positioned and are not contacting other components Torque the igniter to 15 ft lbs 18 Beginning with the exhaust manifold assembly removed in step 14 reinstall all the components in the r...

Page 79: ...e pressure and allow air into the shell 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 Figure 6 7 6 Inspect and 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 ...

Page 80: ...m for additional information or call technical service at 800 526 0288 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 6 8 1 Pumping System Set Up Instructions A sample pumping set up diagram is shown in Figure 6 8 for an Innovation Water Heater As this diagram shows heat exchanger cleaning is accomplis...

Page 81: ... 23 gallons drain at least 11 5 gallons INN1350 20 6 gallons drain at least 10 3 gallons For the Innovation model being cleaned drain at least the amount of eater shown in parentheses 3 Prepare a 50 solution of HydroSkrub and clean water The amount of the solution should be approximately equal to the full volume of water that the heat exchanger holds 4 Mix 11 gallons of HydroSkrub with 11 gallons ...

Page 82: ...is depleted two pounds of deposits removed per gallon used or the equipment is free from calcium and other water formed mineral deposits 7 Periodically test the solution for effectiveness to determine if more HydroSkrub is needed Refer to Testing HydroSkrub Effectiveness in the next section for details If the cleaning solution is expended before circulation time is up additional HydroSkrub will be...

Page 83: ...ENSATE DRAIN TRAP The Innovation Water Heater contains a condensate trap as shown in Chapter 2 Figure 2 7 The 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 Currently two styles of the condensate traps are in use Both styles perform the same functions and contain i...

Page 84: ...FF position Disconnect AC power from the unit 2 Remove the side panels from the unit 3 Refer to Figure 6 10 and locate the air filter attached to the air fuel valve inlet 4 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 5 Each replacement air filter is equipped with its own clamp Therefore s...

Page 85: ... TIME If the heater is to be taken out of service for an extended period of time one year or more complete the following instructions Extended Period Shut Down 1 Set ON OFF switch on the front panel to the OFF position to shut down the heater s operating controls 2 Disconnect AC power from the unit 3 Close the water inlet and outlet valves to isolate unit 4 Close external gas supply valve 5 Open r...

Page 86: ... A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing Heater Back In Service After Prolonged Shutdown 1 Review installation requirements included in Chapter 2 2 Inspect all piping and connections to the unit 3 Inspect exhaust vent air duct if applicable 4 Perform initial startup per Chapter 4 5 Perform safety device testing and schedule...

Page 87: ...is RS232 communication feature permits service personnel to view menu items and data logs which can be useful in isolating faults Refer to Chapter 7 of this manual for detailed RS232 communication set up and procedures When a fault occurs in the unit proceed as follows to isolate and correct the fault General Troubleshooting Instructions 1 Observe the fault messages displayed in the Control Box di...

Page 88: ...stallation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 88 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 89: ... the Blower proof switch and inspect for signs of blockage clean or replace as necessary 4 Remove the blocked air inlet switch and inspect for signs of blockage clean or replace as necessary 5 Measure the Blower proof switch for continuity with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Measure th...

Page 90: ...up to the combustion blower for signs of blockage 5 Measure for 24 VAC during start sequence from each side of the switch to ground If 24VAC is not present refer to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 2 Blocked Blower inlet or inlet ductwork 3 Blocked...

Page 91: ... not installed or loose 2 Worn flame detector 3 No spark from Spark Plug 4 Defective Ignition Transformer 5 Defective Ignition Stepper IGST Board 6 Defective SSOV 7 Carbon or other debris on Burner 1 Inspect and install retighten Burner Ground Screw 2 Remove and inspect the flame detector for signs of wear Replace if necessary 3 Close the internal gas valve in the unit Install and arc a spark igni...

Page 92: ...ove blockage in condensate drain HEAT DEMAND FAILURE 1 The Heat Demand Relays on the Ignition Stepper board failed to activate when commanded 2 Relay is activated when not in Demand 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Poor combustion calibration 2 Heat exchanger has scale...

Page 93: ...setpoint of unit and setpoint of Temperature Switch Ensure that the temperature switch is set higher than the unit s setpoint 6 If the system is a variable flow system monitor system flow changes to ensure that the rate of flow change is not faster than what the units can respond to HIGH WATER TEMPERATURE 1 See HIGH WATER TEMPERATURE SWITCH OPEN 2 Temp HI Limit setting is too low 1 See HIGH WATER ...

Page 94: ...gnition position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Control Box Refer fault to qualified service personnel 2 If the Air Fuel Valve does rotate to the ignition position check the ignition position switch for continuity between t...

Page 95: ...efective water level circuitry 3 Defective water level probe 1 Check system for sufficient water level 2 Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons Replace water level circuitry if it does not respond 3 Check continuity of probe end to the shell change probe if there is no continuity MODBUS COMM FAULT Unit not seeing information from Modbus networ...

Page 96: ...eck to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST Board OUTDOOR TEMP SENSOR FAULT 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect Outdoo...

Page 97: ... fault persists replace actuator SSOV RELAY FAILURE 1 SSOV relay failed on IGST board 2 Floating Neutral 3 Hot and Neutral reversed at SSOV 1 Press CLEAR button and restart unit If fault persists replace Ignition Stepper IGST Board 2 The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two This measurement should be near zero or no more...

Page 98: ...ed to 100 fully open positions Verify VALVE POSITION bargraph and dial on the Air Fuel Valve track each other to indicate proper operation If operation is not correct perform the Stepper Feedback Calibration GF 112 section 6 2 1 2 Check that the Air Fuel Valve is connected to the Control Box 3 Inspect for loose connections between the Air Fuel Valve motor and the wiring harness 4 Replace stepper m...

Page 99: ...AULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Fluctuating Gas Pressure 1 Gas pressure going into unit is fluctuating 2 Damping Orifice not installed 1 Stabilize gas pressure going into unit If necessary troubleshoot Building Supply Regulator 2 Check to ensure that the Damping Orifice is installed in the SSOV Actuator shown in Figure 7 3 For DBB Gas Trains the Damping O...

Page 100: ...13 Phone 800 526 0288 GF 128 Figure 7 1 Gas Train Component Locations Figure 7 2 Blower Side Intake Manifold Shown removed from Heater MANUAL SHUTOFF VALVE SSOV LEAK DETECTION BALL VALVE TO AIR FUEL VALVE LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWITCH GAS INLET FLAME DETECTOR BLOWER SIDE INTAKE MANIFOLD IGNITOR FLAME DETECTOR FLAME DETECTOR GASKET BURNER FLANGE GASKET OBSERVATION PORT IGNITOR ...

Page 101: ...national Inc 100 Oritani Dr Blauvelt NY 10913 Page 101 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Figure 7 3 SSOV Actuator With Gas Pressure Adjustment Damping Orifice SSOV ACTUATOR COVER ACTUATOR COVER SCREW DAMPING ORFICE BRASS HEX HEAD CAP Remove to access gas pressure adjustment screw OPEN CLOSED INDICATOR WINDOW ...

Page 102: ...allation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 102 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 103: ...d the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it 8 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote machine bring up the PuTT...

Page 104: ...guration 8 1 3 Running a Command on a Remote Machine Using PuTTY PuTTY may also be used to run some command residing on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open depending on how...

Page 105: ...TILIZING RS232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS232 communication is accomplished as follows RS232 Menu Processing 1 Start the emulator software program and ensure that the specified baud rate and data formats have been entered 2 Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS232 passwor...

Page 106: ...ill be stored in non volatile memory 9 To redisplay the menu and view the option which was just changed in step 5 enter D and press Rtn 10 To display the Fault F Log Sensor S Log or Time T Line Log press F S or T followed by Rtn Refer to section 8 4 for descriptions and samples of these data logs 11 To log off and terminate the RS232 communication link press L followed by Rtn 8 4 DATA LOGGING Duri...

Page 107: ...Time Log for a unit Table 8 2 Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time Off Direct Drive 0 0 8 1 15 02 2 35pm Run Direct Drive 38 100 34 1 15 02 2 27pm Run Direct Drive 31 100 30 1 15 02 1 53am Run Direct Drive 35 100 2 1 15 02 1 23pm Run Direct Drive 29 100 0 1 15 02 1 21pm Ignition 0 0 0 1 15 02 1 20pm Off Switch 0 0 35 1 15 02 12 30pm Run Manual 40 100 0 1 15...

Page 108: ...FWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 ...

Page 109: ...em The WHM can control up to eight 8 water heaters in parallel Each water heater controlled by the WHM must be equipped with an Actuator Controlled Sequencing Valve Part No 92093 These valves are installed on the cold water inlet of each water heater being controlled by the WHM 9 2 GENERAL DESCRIPTION The C More Water Heater Management System WHM is designed to ensure that all water heaters in the...

Page 110: ...ill close the sequencing valve on a unit The philosophy behind this approach is to maintain the fire rates Air Fuel Valve open at a level that maximizes heater efficiency In addition to collecting Air Fuel Valve position data the controlling Master also monitors the total accumulated operating time for each unit on the system and attempts to balance the system so that all units operate for approxi...

Page 111: ... an actuator controlled sequencing valve part no 92093 If this valve is not already installed on the cold water inlet proceed as follows WHM Hardware Installation 1 Remove the sequencing valve from its stowed location 2 Refer to Figure 9 2 and attach the valve to the cold water inlet of the unit using the pipe union and nipple provided 3 Ensure that the valve is positioned with the actuator enclos...

Page 112: ...st be made using shielded twisted pair wiring 18 24 AWG such as Belden 9841 3105A 8760 or equivalent The Modbus wiring connections are made at the RS485 COMM terminals on the I O board included with each C more Control System Connect the Modbus wiring as follows Modbus Network Wiring 1 Starting at the first unit connect the twisted shielded pair cable to the RS485 Comm plus and minus terminals on ...

Page 113: ...onnected to the corresponding connectors on the valves Figure 9 4 WHMS Network Wiring Diagram NOTES 1 Wiring to be shielded twisted pair cable Belden 9841 or equivalent 2 Activate DIP 1 Modbus TERM on the first and last units in the daisy chain 3 Tie incoming outgoing shields together and terminate at the shield terminal of the LAST WHMS slave in the chain 4 On the CPU board inside the C More Cont...

Page 114: ... WHM Setpoint The default setpoint for the WHM is 130 F If a different setting is desired the setpoint can be varied from 40 F to 240 F 9 6 4 WHM Nxt On VP This is the Next On Air Fuel Valve Position VP open for the system The default value for this option is 75 When all enabled water heaters have a valve position VP greater than this value the WHM Master will enable another water heater if one is...

Page 115: ...HM Master and Slaves all required hardware installation and network wiring must be completed In addition the required menu entries to be entered must be determined based on the descriptions in the previous sections AERCO recommends that the WHM Master be set up first By doing so the Master will push most of the required menu entries to each WHM Slave as each unit is brought on line The following s...

Page 116: ... store each entry 19 This completes the required entries for the WHM Master All but two of the required menu setting will be automatically be pushed to the WHM Slaves as they are brought on line The options which are not pushed to each WHM Slave are Comm Address in Setup menu WHM Mode 20 Enter the desired Comm Address and WHM Mode WHM Slave at the C More Control Panel for each of the WHM Slaves on...

Page 117: ...TLET TEMPERATURE display is flashing on 2 C More Control Panels 1 Two C Mores have their WHM Mode menu option set to WHM Master 1 Check the WHM Mode entries in the units which have their displays flashing Change one of the WHM Mode settings to WHM Slave REMOTE LED on one or more WHM units is Off 1 Improperly connected or faulty RS485 Modbus wiring 2 Improper Comm address 3 Unit Comm address is not...

Page 118: ...e Actuator Controlled Sequencing Valve shown in Figure 9 5 is comprised of the following main components 2 Brass Ball Valve Actuator Linkage Actuator Housing Valve Shaft Handle Figure 9 5 Actuator Controlled Sequencing Valve 92093 The Actuator Housing contains a cover which is removed by simply loosening a single captive screw Removing the cover provides access to a PC Board containing wiring conn...

Page 119: ...h Failure to observe this precaution may damage the Actuator The PC board also contains a brass button which is used to disengage the clutch and permit the ball valve to be manually rotated To disengage the clutch proceed as follows Actuator Clutch Disengagement 1 Disconnect the 3 pin connector on the Actuator to ensure that 24 VAC power is not being supplied 2 Press and hold the brass CLUTCH butt...

Page 120: ...m a step down transformer located in the Power Box of the Innovation Water Heater The 24 VAC power output and a 0 to 20 mA control signal from the I O Box of the Water Heater are routed to the Sequencing Valve via a 3 pin Molex connector During normal Water Heater Management WHM a control signal of less than 4 mA will rotate the valve to the fully open 0 position Conversely a control signal above ...

Page 121: ...t valve position This would normally be the same as the valve position shown on the bargraph when the heater is operating Flame Strength Displays flame strength from 0 to 100 Run Cycles Displays the total number of run cycles from 0 to 999 999 Run Hours Displays total run time of unit in hours from 0 to 9 999 999 Fault Log Displays information on the last 20 faults 0 19 SETUP MENU Password Allows ...

Page 122: ...t Setpoint Lo Limit to 240 F Default 200 F Temp Hi Limit This is the maximum allowable outlet temperature 40 to 240 F Any temperature above this setting will turn off the unit The temperature must then drop 5 F below this setting to allow the unit to run Default 160 F Max Valve Position Sets the maximum allowable valve position for the unit 40 to 100 Default 100 Pump Delay Timer Specifies the amou...

Page 123: ... Start Level value There will not be a one minute delay when firing at the 29 Valve Position level Setting range is 0 to 25 Default 0 Deadband High Deadband Low Deadband High and Deadband Low settings create an Outlet Temperature Zone In which no Valve Position corrections will be attempted The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint Deadband High a...

Page 124: ...onable spread between the 2 values Default 35 Lead Lag Hours The Lead Lag Hours menu option is basically designed to spread the total number of run hours accumulated on all units in the system so that each of the units have approximately the same number of run hours The default value for this option is 72 hours Setback Setpoint This is the setpoint temperature F that each unit in the WHM system is...

Page 125: ... an offset to the breakpoint chart at minimum flow This is used to fine tune Feed Forward FFWD output at low flow levels Default zero Max Load Adj Setting is adjustable from 50 F to 50 F It adjusts the output by changing the scaling of the breakpoint chart at maximum flow Default zero FFWD Temp Displays the Feed Forward temperature Outlet Feedback Used to Enable or Disable feedback Disable this fu...

Page 126: ...on Operation Maintenance Manual APPENDIX A INNOVATION MENU ITEM DESCRIPTIONS Page 126 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 127: ... pm and date that the unit was disabled FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during the purg...

Page 128: ... DURING RUN The Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switch is closed GAS PRESSURE FAULT The High Gas Pressure Limit Switch OR Low Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded th...

Page 129: ...ition Limit Switch on the Air Fuel Valve opened during purge RECIRC PUMP FAILURE Internal Recirculation Pump has failed REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during pur...

Page 130: ...ion Operation Maintenance Manual APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 130 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 131: ... VOLTAGE CHART BALCO TEMP F RES OHMS VOLTS 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 1364 2 1391 0 1418 2 1445 7 1 93 1 96 1 99 2 02 2 05 2 07 2 10 2 12 2 15 2 17 2 2...

Page 132: ...peration Maintenance Manual APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART Page 132 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 133: ... Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type Innovation WH Unit Size 600 MBH 800 MBH 1060 MBH 1350 MBH Fuel Type Natural Gas Heater Mode Constant Setpoint Remote Signal If Heater Mode Remote Setpoint 4 20 mA 1 5V Outdoor Sensor Disabled Setpt Lo Limit 60 F Setpt Hi Limit 200 F Temp Hi Limit 160 F Max Valve Position 100 Aux Start On Dly 0 sec Failsafe Mode Shutdown mA...

Page 134: ...S Continued MENU OPTION FACTORY DEFAULT Tuning Menu Prop Band 8 F Integral Gain 1 60 Derivative Time 0 10 min Min Load Adj 0 F Max Load Adj 0 F FFWD Temp N A Outlet Feedback On Feedback Gain 0 05 Breakpoint At 100 85 F Breakpoint At 90 86 F Breakpoint At 80 87 F Breakpoint At 70 88 F Breakpoint At 60 89 F Breakpoint At 50 90 F Breakpoint At 40 94 F Breakpoint At 30 103 F Breakpoint At 20 118 F Bre...

Page 135: ...ation Maintenance Manual APPENDIX E DIMENSIONAL DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 135 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 APPENDIX E DIMENSIONAL DRAWINGS Drawing Number AP A 888 rev H ...

Page 136: ...nstallation Operation Maintenance Manual APPENDIX E DIMENSIONAL DRAWINGS Page 136 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number AP A 902 rev C ...

Page 137: ...3 HARNESS SHELL WIRING AIR FUEL DELIVERY SYSTEM BLOWER A F VALVE ACCEESS 51 1 63079 HARNESS INNOVATION CONTROL 10 1 24111 BLOWER AMETEK 8 9 52 1 69158 I O BOX WITH ONAER SEQ VALVE 11 1 24220 3 A F VALVE ASSY INN 600 800 1060 1 69153 I O BOX WITH ONAER w o SEQ VALVE 1 24220 4 A F VALVE ASSY INN 1350 ONLY 53 1 123552 switch over temp manual 12 1 59138 AIR FILTER 6 54 1 123966 SWITCH OVER TEMP AUTO R...

Page 138: ...E 98 1 93100 UNION 2 NPT 304 STAINLESS 99 1 90046 3 NIPPLE 2 NPT 304 SS 100 1 92093 VALVE 2 DOMESTIC WATER MTRZD SEQ BALL NOTES Not shown in drawings below For pictorial purposes only See below for full gas train full diagrams and part lists See drawing PL A 164 below for exploded diagram and full part list 24311 3 A F VALVE FRU KIT 1 81057 GASKET BLOWER 1 88003 O RING 2 339 1 24220 3 A F VALVE AS...

Page 139: ...078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 AERCO International Inc Blauvelt NY 10913 Innovation Parts List 09 15 2013 29184 TAB rev G 29293 rev D Page 3 of 4 INN 1350 PICTURED RIGHT SIDE VIEW EXPLODED INN 600 800 1060 PICTURED ...

Page 140: ...e 140 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation Parts List 09 15 2013 29184 TAB rev G 29293 rev D Page 4 of 4 LEFT REAR VIEW RIGHT FRONT VIEW LEFT SIDE VIEW PARTIAL FRONT VIEW ...

Page 141: ...N O 19 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 6 2 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 20 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 7 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 21 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 8 1 61002 4 HIGH GAS PRESSURE SWITCH 4 0 W C 22 2 9 22 PIPE PLUG 1 4 NPT STEEL 9 1 123542 FLANGE 2 125 2 NPT 23 1 93315 TEE RDCG 1 x x 1 M I 10 1 93035 ELBOW STREET 1 4 NPT 24 1 9 43 BUSHI...

Page 142: ...3315 TEE RDCG 1 x x 1 M I 22 1 124862 RESISTOR ASSY 8 1 69005 ACTUATOR SSOV W REGULATOR 23 2 8 22 BUSHING REDUCING 1 1 2 F NPT X 1 M NPT 9 1 124150 VALVE SSOV 1 1 2 NPT 24 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 10 1 123771 UNION MA x FEM 1 NPT 150 M I 25 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 11 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 26 1 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 12 1 9 222 EL...

Page 143: ...S TRAIN 30 1 94061 3 00 NIPPLE 3 4 NPT X 3 00 LG 10 1 124862 RESISTOR ASSY 31 1 94061 19 00 NIPPLE 3 4 NPT 11 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 32 1 59053 CHANNEL STRUT 12 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 33 1 124024 HARNESS WIRING IRI 13 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 34 1 9 465 TEE 1 NPT 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 35 1 94028 2 50 NIPPLE 1 NPT TBE X 2 50 LG 15 2 93181 E...

Page 144: ...ST DRAWINGS Page 144 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation 600 800 1060 DBB Gas Train 08 12 2013 22122 1 rev F AP A 897 Sheet 2 of 2 INSTALL MONOMETER HERE ...

Page 145: ...417 FEM x MA 90 STREET ELBOW BLK MI 21 1 90102 NIPPLE x 6 00 SCH 40 BLK STL 7 2 93418 TEE NPT BLACK MI 22 2 92006 3 VALVE FULL PORT BALL 1 2 NPT BRASS 8 1 93419 ELBOW 90 FEMALE NPT BLACK MI 23 2 92077 1 4 NPT MXF BRASS BALL VALVE CLOSED 9 1 93420 UNION NPT FEMALE BLACK MI 24 2 12951 2 BUSHING CONTROL BOX 10 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 25 1 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 11 1 9342...

Page 146: ...TUATOR SSOV W REGULATOR 7 1 93398 TEE INLINE REDUCING 3 4 X 3 4 X 1 2 BLK MI 23 2 92006 4 VALVE FULL PORT BAL 3 4 NPT 8 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 24 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 9 1 93405 TEE 1 4 NPT BLK M I 25 2 12951 2 BUSHING CONTROL BOX 10 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 26 1 161450 HARNESS WIRING GAS TRAIN 11 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 27 1 124862 RE...

Page 147: ...S TRAIN 30 1 94061 3 00 NIPPLE 3 4 NPT X 3 00 LG 10 1 124862 RESISTOR ASSY 31 1 94061 19 00 NIPPLE 3 4 NPT 11 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 32 1 59053 CHANNEL STRUT 12 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 33 1 124024 HARNESS WIRING IRI 13 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 34 1 9 465 TEE 1 NPT 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 35 1 94028 2 50 NIPPLE 1 NPT TBE X 2 50 LG 15 2 93181 E...

Page 148: ...ENDIX F PARTS LIST DRAWINGS Page 148 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation 1350 DBB Gas Train 08 12 2013 22168 1 rev A AP A 906 Sheet 2 of 2 ...

Page 149: ...PT 4 1 24111 BLOWER AMETEK 8 9 14 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 5 1 88004 O RING 2 244 BUNA N 15 1 60011 4 SWITCH ASSY BLOWER PROOF 6 4 54028 SCREW HEX HD SERRATED 5 16 18 16 1 59138 FILTER AIR 6 7 6 55071 SCREW SOC HD M8 x 1 25 x 30mm LG 17 1 61024 AIR INLET TEMPERATURE SENSOR 8 1 81057 GASKET BLOWER 18 1 93367 SNUBBER FAN PROVING SWITCH 9 1 24220 3 A F VALVE ASSY 19 1 124979 1 8 C S STR...

Page 150: ...T X 2 00 4 4 54028 SCREW HEX HD SERRATED 5 16 18 14 2 123535 TEE 1 8 NPT 5 1 88004 O RING 2 244 BUNA N 15 1 93367 SNUBBER FAN PROVING SWITCH 6 1 44108 BLOWER A F VALVE ADAPTER 16 1 60011 3 SWITCH ASSY BLOWER PROOF 7 6 55071 SCREW SOC HD M8 x 1 25 x 30mm LG 17 3 123534 PLUG HEX 1 8 NPT 8 1 81057 GASKET BLOWER 18 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 9 1 24220 4 A F VALVE ASSY 19 1 124979 1 8 C S S...

Page 151: ... MTG PLATE 4 1 66018 FLAME DETECTOR 12 1 46023 LOW NOX BURNER HEAD ASSEMBLY 5 1 52036 STUD 8 32 x 1 LG STL ZINC PLATED 13 8 123948 10 32 x 3 8 LG SET SCREW 6 1 59206 STANDOFF FEM THREADED 8 32 x 5 8 x 1 4 HEX 14 1 49209 CONDENSATE SHIELD 7 1 66023 IGNITOR w HOOKED GROUND ROD 15 1 52037 STUD 10 32 x 1 LG STL ZINC PLATED 8 2 93358 PLUG 1 4 NPT HEX HD PIPE 304 STAINLESS 16 1 59207 STANDOFF FEM THREAD...

Page 152: ...tallation Operation Maintenance Manual APPENDIX F PARTS LIST DRAWINGS Page 152 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 153: ... Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 APPENDIX G PIPING DRAWINGS Drawing Number SD A 829 rev B ...

Page 154: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 154 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 830 rev B ...

Page 155: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 155 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 831 rev B ...

Page 156: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 156 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 832 rev B ...

Page 157: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 833 rev B ...

Page 158: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 158 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 836 rev B ...

Page 159: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 837 rev B ...

Page 160: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 160 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 838 rev B ...

Page 161: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 841 rev B ...

Page 162: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 162 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 842 rev C ...

Page 163: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 843 rev C ...

Page 164: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 164 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 844 rev C ...

Page 165: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 845 rev B ...

Page 166: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 166 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 848 rev C ...

Page 167: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 167 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 849 rev C ...

Page 168: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 168 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 850 rev C ...

Page 169: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 851 rev C ...

Page 170: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 170 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 852 rev C ...

Page 171: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 853 rev D ...

Page 172: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 172 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 854 rev D ...

Page 173: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 855 rev D ...

Page 174: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 174 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 Drawing Number SD A 856 rev C ...

Page 175: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number SD A 939 rev A ...

Page 176: ...nstallation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 176 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 177: ...ntenance Manual APPENDIX H C MORE CONTROL PANEL VIEWS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 APPENDIX H C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL EXPLODED VIEW ...

Page 178: ...tion Maintenance Manual APPENDIX H C MORE CONTROL PANEL VIEWS Page 178 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL REAR VIEW ...

Page 179: ...aintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 APPENDIX I C MORE WIRING DIAGRAMS Drawing Number 68039 rev D Sheet 1 of 2 ...

Page 180: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 180 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 181: ...ation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 181 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number 68039 rev D Sheet 2 of 2 ...

Page 182: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 182 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 183: ...ation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 183 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number 68042 rev D Sheet 1 of 2 ...

Page 184: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 184 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 185: ...ation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 Drawing Number 68042 rev D Sheet 2 of 2 ...

Page 186: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 186 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 187: ...111 SSOV Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of DBB IRI gas train models 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of DBB IRI gas train models 69038 Temperature Switch Manual Reset SEE NOTE 1 123552 Table J 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58036 01 24 month Waterside Firesid...

Page 188: ...stallation Operation Maintenance Manual APPENDIX J RECOMMENDED SPARES Page 188 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 189: ...e s to the unit 3 Set the control panel ON OFF switch to the OFF position 4 Turn on external AC power to the unit The display will show LOSS OF POWER and the time and date 5 Set the unit to the Manual Mode by pressing the AUTO MAN key A flashing Manual Valve Position message will be displayed with the present position in Also the MANUAL LED will light 6 Adjust the air fuel valve position to 0 by p...

Page 190: ... of the exhaust manifold Allow enough time for the combustion analyzer to settle 13 Verify that the oxygen O2 level is within the range shown below Also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown Combustion Oxygen Level at 16 Valve Position Oxygen 0 5 Carbon Monoxide NOx 6 5 50 ppm 15 ppm 14 If the oxygen level is not within the required toler...

Page 191: ...Once the oxygen level is within the required range listed in step 13 the gas pressure on the downstream side of the SSOV should be within the appropriate range shown below for the Innovation Model being tested INNOVATION MODEL GAS PRESSURE RANGE DOWNSTREAM OF SSOV INN1350 2 8 3 0 W C INN1060 2 4 2 6 W C INN800 1 3 1 5 W C INN600 0 7 0 9 W C 16 Replace the brass cap on the SSOV gas pressure adjustm...

Page 192: ...ion Operation Maintenance Manual APPENDIX K COMBUSTION CALIBRATION KOREA ONLY Page 192 of 196 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0J PRI 11 22 2013 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 193: ...n Operation Maintenance Manual APPENDIX L WARRANTY OMM 0078_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 196 GF 128 Phone 800 526 0288 PRI 11 22 2013 APPENDIX L WARRANTY INNOVATION WATER HEATER LIMITED WARRANTY ...

Page 194: ...trol panels are conditionally warranted against failure for 2 two years from shipment OTHER COMPONENTS 18 MONTHS FROM SHIPMENT All other components with the exception of the igniter and flame detector are conditionally guaranteed against any failure for 18 months from shipment The warranty as set forth on the back page of the Operations Maintenance Manual is in lieu of and not in addition to any o...

Page 195: ...nt and or repairs to the item The use of replacement parts not manufactured or sold by AERCO will void any warranty express or limited AERCO shall accept no responsibility if such item has been damaged due to contaminated combustion air containing but not limited to sheetrock particles plaster board particles dirt dust lint and corrosive chemicals such as chlorine gas halogenated hydrocarbons and ...

Page 196: ... Replaced p n 93367 in gas train drawings PIR 890 Replaced wiring harness 63072 with 63143 in Part List drawing item 50 PIR 855 Added Snubber to A F assy per PIR 890 Changed wiring harness PIR 855 Replaced exhaust manifold with 44085 1 PIR 926 1 Added new gas pressure regulator info PIR 934 5 Changed sealed combustion air to ducted combustion air section 2 14 PIR 934 3 Added info about RS 232 cabl...

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