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Innovation Water Heaters Installation, Operation & Maintenance Manual

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8

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206

AERCO International, Inc.

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100 Oritani Dr.

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Blauvelt, NY 10913

OMM-0078_0L

PRI: 11/25/2014

Phone: 800-526-0288

GF-128

INNOVATION POTABLE WATER HEATER MODELS

Part Number

Description

Shipping

Weight

INN600
INN600P

Innovation Potable Water Heater, 600,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train

1,060 lbs.

INN600SV
INN600SVP

Innovation Potable Water Heater, 600,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve

1,080 lbs.

INN600DBB
INN600PDBB

Innovation Potable Water Heater, 600,000 BTU/HR
Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train

1,085 lbs.

INN600SVDBB
INN600SVPDBB

Innovation Potable Water Heater, 600,000 BTU/HR
Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve

1,105 lbs.

INN800
INN800P

Innovation Potable Water Heater, 800,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train

1,080 lbs.

INN800SV
INN800SVP

Innovation Potable Water Heater, 800,000 BTU/HR
Input, Natural Gas, or Propane FM Gas Train with WHM
Sequencing Valve

1,100 lbs.

INN800DBB
INN800PDBB

Innovation Potable Water Heater, 800,000 BTU/HR
Input, Natural Gas or Propane, Double 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, 1,060,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve

1,120 lbs.

INN1060DBB
INN1060PDBB

Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas, or Propane Double Block & Bleed
(Formerly IRI) Gas Train

1,115 lbs.

INN1060SVDBB
INN1060SVPDBB

Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve

1,135 lbs.

INN1350
INN1350P

Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train

1,150 lbs.

INN1350SV
INN1350SVP

Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve

1,170 lbs.

INN1350DBB
INN1350PDBB

Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train

1,165 lbs.

INN1350SVDBB
INN1350SVPDBB

Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve

1,205 lbs.

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Summary of Contents for INN1350

Page 1: ... Series Gas Fired Water Heaters Natural Gas or Propane Modulating Condensing Water Heater Models Applicable to Serial Number G 14 2265 and above This guide applies to the following Innovation models Innovation 600 Innovation 800 Innovation 1060 Innovation 1350 Other documents for this product include GF 5030 INN Recon Gas Supply Guide GF 5050 INN Recon Venting Guide GF 5060 INN Recon Elect Power G...

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: ...SSURE TEMPERATURE RELIEF VALVE INSTALLATION 23 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 SE...

Page 4: ...ed Tools Instrumentation 53 4 2 2 Installing Gas Supply Manometer 54 4 2 3 Accessing the Analyzer Probe Port 55 4 2 4 Connecting Multimeter to Flame Detector 55 4 2 5 Recommendations for Temperature Calibration 56 4 2 6 Recommendations for WHM Water Heater Management Operation 56 4 3 NATURAL GAS COMBUSTION CALIBRATION 57 4 4 PROPANE COMBUSTION CALIBRATION 59 4 5 REASSEMBLY 61 4 6 TEMPERATURE CONTR...

Page 5: ...R FILTER REPLACEMENT 91 6 11 LOW WATER CUTOFF LWCO CAPACITOR INTEGRITY TEST 92 6 11 1 Low Water Cutoff LWCO Capacitor Electrical Short Test 93 6 11 2 Low Water Cutoff LWCO Standard C More Test 95 6 12 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME 95 6 13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN 96 CHAPTER 7 TROUBLESHOOTING GUIDE 97 7 1 INTRODUCTION 97 7 2 ADDIT...

Page 6: ...on 129 8 11 2 Sequencing Valve Operating Characteristics 132 APPENDIX A INNOVATION MENU ITEM DESCRIPTIONS 133 Table A 1 Operating Menu Item Descriptions 133 Table A 2 Setup Menu Item Descriptions 134 Table A 3 Configuration Menu Item Descriptions 135 Table A 4 Tuning Menu Item Descriptions 137 Table A 5 Calibration Menu Item Descriptions 139 APPENDIX B STARTUP STATUS AND FAULT MESSAGES 143 APPENDI...

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: ...itish 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 Control DBB Double Block Bleed Used to define gas tr...

Page 10: ...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 serial full duplex FDX transmission of data based on the RS232 Standard RS422 or EIA 422 A standard for serial full duplex FDX transmiss...

Page 11: ... Page 11 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 PHRASES ABBREVIATIONS AND ACRONYMS Continued Phrase Abbreviation or Acronym Meaning 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 an ampere ...

Page 12: ...r Heaters Installation Operation Maintenance Manual FORWARD Page 12 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 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: ...ign for the shipment 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...

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: ...he lifting lugs must be installed 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 insta...

Page 20: ...ce 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 Figure 2 3b it will be packed separately within the shipping co...

Page 21: ... connections after the valve is properly positioned 6 Connect the 4 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 connection upstream of the shut off valve on the...

Page 22: ...ure 2 5 This assembly contains a recirculation pump that connects the upper hot water outlet to the 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 temperat...

Page 23: ...e Temperature P T Relief Valve is factory installed on each Innovation water heater on the hot water outlet at the top of the Recirculation Loop Assembly as shown in Figure 2 5 With the exception of Alberta installations see above Note the valve setpoint is 150 psig 190 F A suitable pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any i...

Page 24: ... is shown in Figure 2 7 However the actual installation details for the trap will vary depending on the available clearances housekeeping pad height dimensions and other prevailing conditions at the site The following general guidelines must be observed to ensure proper condensate drainage The condensate trap inlet Figure 2 7 must be level with or lower than the exhaust manifold drain port The bas...

Page 25: ...ifferent styles of condensate traps are currently in use The functions and connections provided are nearly identical however they look slightly different LEFT SIDE VIEW Figure 2 7 Sample Condensate Trap Installation NOTE As a general guideline AERCO recommends use of its Condensate Neutralizer Kit to raise the pH level of the condensate prior to drainage At a minimum the installation must be desig...

Page 26: ... 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 unit from the gas supply piping The gas pressure applied to the unit should never exceed 14 W ...

Page 27: ...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 external gas supply regulator must be p...

Page 28: ...MOVED 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 provided on the front cover of the Power Box Each unit must be connected to a dedic...

Page 29: ...O Box is located on the upper left portion of the unit front panel Figure 2 11 behind the removable front panel door To access the I O Box terminal strips shown in Figure 2 11 loosen the four cover screws and remove the cover All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided Figure 2 11 Input Output I O Box Location Partial Fron...

Page 30: ...are not applicable to this unit 2 12 2 COMBUSTION AIR Terminals The COMBUSTION AIR and AIR SENSOR COMMON terminals are not applicable to this unit 2 12 3 O2 SENSOR Terminals The O2 SENSOR and O2 SENSOR terminals are not currently used in this unit 2 12 4 SPARK SIGNAL Terminals The SPARK SIGNAL terminals permit an external current sensor to be connected for ignition spark monitoring purposes If no ...

Page 31: ...erminals The Valve Feedback terminals are used when the Sequencing Isolation Valve Feedback option is selected The Valve Feedback signal is connected to the Valve Fdbk terminals and is used to confirm that the valve has properly opened or closed If the Valve Feedback signal does not match the Valve Open or Valve Close command for the time defined in the Valve Fdbk timer entry the controller will p...

Page 32: ...terfacing 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 Delayed Interlock must be in the closed position for the...

Page 33: ... as a unit status indictor firing or not firing Its contacts are rated for 120 VAC 5 amps Refer to Figure 2 12 to locate the AUX RELAY terminals N C COM N O for wiring connections 2 13 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide GF 5050 must be consulted before any flue or combustion air venting is designed or installed Suitable U L approved positive pressure watert...

Page 34: ...nting is designed or installed Air supply is a direct requirement of ANSI 223 1 NFPA 54 CSA B149 1 and local codes These codes should be consulted before a permanent design is determined The combustion air must be free of chlorine halogenated hydrocarbons or other chemicals that can become hazardous when used in gas fired equipment Common sources of these compounds are swimming pools degreasing co...

Page 35: ...ed combustion For ducted combustion installations the screen inlet air ductwork must then be attached directly to the unit s air inlet In a ducted combustion air application the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run See the AERCO Innovation Venting and Combustion Air Guide GF 5050 When using the heater in a ducted...

Page 36: ...s Installation Operation Maintenance Manual CHAPTER 2 INSTALLATION Page 36 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 37: ...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 38: ...n Operation Maintenance Manual CHAPTER 3 OPERATION Page 38 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Figure 3 1 Control Panel Front View 3 2 1 4 5 7 8 9 10 11 12 6 ...

Page 39: ...ating in the Deadband Mode 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection 4 RS232 Port This port is used only factory trained personnel to monitor OnAER communications in combination with the RS232 Adaptor Cable P ...

Page 40: ... was 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 CHAN...

Page 41: ...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 42: ...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 43: ...escription of each item appears in Table A 1 of Appendix A Innovation Menu Item Descriptions Table 3 2 Operating Menu Menu Item Display Available Choices or Limits Appears only if enabled in the following menu Minimum Maximum 1 Active Setpoint 40 F 190 F 2 Inlet Temp 30 F 240 F Calibration Menu 3 Air Temp 70 F 245 F 4 Outdoor Temp 70 F 130 F Configuration Menu 5 Valve Position In 0 100 6 Exhaust T...

Page 44: ... 12 00 am 11 59 pm 4 Date 01 01 00 12 31 99 5 Unit of Temp Fahrenheit or Celsius Fahrenheit 6 Comm Address 0 127 0 7 Baud Rate 2400 4800 9600 19 2K 9600 8 OnAER Mode Ethernet or SD Card Ethernet 9 Upload Timer 0 9999 Sec 0 10 Unit Alpha E G H R N or A A 11 Unit Year 0 99 0 12 Unit Serial 0 9999 0 13 Software Ver 0 00 Ver 9 99 Current software version 3 6 CONFIGURATION MENU The Configuration Menu p...

Page 45: ...irect Drive or Combination 4 20 mA 1 5V 0 20 mA 0 5V PWM Input Legacy BMS Network 4 20 mA 1 5V 7 Outdoor Sensor Enabled or Disabled Disabled 8 System Start Tmp If Outdoor Sensor Enabled 30 F 100 F 60 F 9 Setpt Lo Limit 40 F Setpt Hi Limit 60 F 10 Setpt Hi Limit Setpt Lo Limit 190 F 150 F 11 Temp Hi Limit 40 F 200 F 160 F 12 Max Valve Position 40 100 100 13 Pump Delay Timer 0 min 30 min 0 min 14 Au...

Page 46: ...Item Descriptions Table 3 5 Tuning Menu Menu Item Display Available Choices or Limits Default Minimum Maximum 1 Prop Band 1 F 200 F 30 F 2 Integral Gain 0 00 10 00 3 00 3 Derivative Time 0 00 min 2 00 min 0 20 min 4 Min Load Adj 50 F 50 F 0 F 5 Max Load Adj 50 F 50 F 0 F 6 FFWD Temp 30 F 245 F Read Only Value 7 Outlet Feedback Yes On or No Off Yes On 8 Feedback Gain 0 01 1 00 0 10 Breakpoints show...

Page 47: ... Output 0 100 Read Only Value 31 P Output 0 100 Read Only Value 32 I Output 0 100 Read Only Value 33 D Output 0 100 Read Only Value 34 Reset Defaults Yes No No 3 8 CALIBRATION MENU The Calibration Menu is used by Factory Trained Service personnel to adjust or reset the parameters listed below A full description of each item appears in Table A 5 of Appendix A Innovation Menu Item Descriptions Table...

Page 48: ... 20 A F Sensitivity 1 5 2 21 Power Reset Automatic or Manual Automatic 22 Water Temp Reset Automatic or Manual Automatic 23 Gas Press Reset Automatic or Manual Manual 24 Min Off Time 0 Min 15 Min 0 Min 25 Heatr Tuning Dsp Enabled or Disabled Disabled 26 Heatr Bkpt Dsp Enabled or Disabled Disabled 27 Stop Level 0 Start Level 16 28 Start Level Stop Level 40 20 29 Skip Range Cntr 10 95 40 30 Skip Ran...

Page 49: ... Water Temperature switch High Gas Pressure switch Low Gas Pressure switch Blower Proof switch NOTE The downstream Low Gas Pressure switch 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 o...

Page 50: ...for SSOV location Figure 3 3 SSOV Location INN1060 Gas Train shown 3 With all required safety device switches closed a purge cycle will be initiated and the following events will occur a The Blower relay energizes and turns on blower b 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...

Page 51: ...the purge cycle the Control Box initiates an ignition cycle and the following events occur a The Air Fuel Valve rotates to the low fire ignition position and closes the ignition switch The dial on the Air Fuel Valve Figure 3 6 will read between 25 and 35 to indicate that the valve is in the low fire position b The igniter injector relay is activated and provides ignition spark c The gas Safety Shu...

Page 52: ...e The blower relay will be deactivated and the Air Fuel Valve will be closed Standby will be displayed 3 10 START STOP LEVELS The start and stop levels are the Air Fuel Valve positions open that start and stop the unit based on load These levels are Factory preset as follows Start Level 25 Stop Level 16 Normally these settings should not require adjustment Note that the energy input is not linearl...

Page 53: ...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 54: ... Manometer The gas supply manometer is installed in the gas train as follows Installing Gas Supply Manometer 1 Close the main manual 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 S...

Page 55: ...e exhaust manifold 2 If necessary adjust the stop on the combustion analyzer probe so it will extend mid way into the flue gas 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 J 4 2 4 Connecting Multimeter to Flame Detector During Com...

Page 56: ...ntrol Calibration below to properly set up the temperature control for the heater Ignoring this commissioning step may cause water temperature faults poor water temperature control and rapid cycling of the heater 4 2 6 Recommendations for WHM Water Heater Management Operation In case of multiple Innovation units it is highly recommended to ALWAYS operate the system in WHM mode Operation in WHM mod...

Page 57: ... and the time and date 5 Enter the password 6817 to continue 6 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 7 Adjust the air fuel valve position to 0 by pressing the arrow key 8 Ensure that the leak detection ball valve downstream of the SSOV is open 9 Set the ON O...

Page 58: ... Voltage 100 is flashing 19 The oxygen level at the 100 valve position should be as shown below Also ensure that the nitrogen oxide NOx carbon monoxide CO and flame strength readings match the following values Combustion Calibration Readings at 100 Valve Position Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO Flame µA 100 6 0 0 25 20 ppm 100 ppm 6 µA 20 If the oxygen level is not w...

Page 59: ...tate the screw 1 2 turn clockwise CW to add fuel and reduce the O2 to the specified level Recalibration MUST be performed again from 60 down to 16 after making a change to the idle screw TAC valve Figure 4 5 TAC Valve Adjust Idle Screw This completes the NATURAL GAS combustion calibration procedure 4 4 PROPANE COMBUSTION CALIBRATION IMPORTANT The unit is shipped from the factory set up for either ...

Page 60: ... 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 Innovation Model being tested If gas pressure adjustment is required remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 4 Make gas pressure adjustments using a fla...

Page 61: ... range shown below for the Innovation Model being tested PROPANE Gas Pressure Range Downstream Of SSOV Model Gas Pressure Range Innovation 1350 2 0 2 2 W C Innovation 1060 1 8 2 0 W C Innovation 800 2 8 3 0 W C Innovation 600 1 6 1 8 W C 16 Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed 17 Following combustion calibration at the 16 valve position check the c...

Page 62: ...ibration There are two primary adjustments for performing temperature calibration Min Load Adj and Max Load Adj minimum and maximum load adjustment Adjustments to these settings are made at minimum and maximum load conditions and should be made in small increments from 1 to 3 degrees After making an adjustment the outlet water temperature must be allowed to settle for several minutes prior to maki...

Page 63: ...um Load Adjustment 1 While monitoring the VALVE POSITION bar graph create a minimum load on the system that will yield a steady valve position between 25 and 35 NOTE It may be desirable to shut off the outlet valve and use the hose bib see Figure 2 4 to simulate a minimum flow load condition 2 Wait several minutes to allow the outlet temperature to stabilize under load conditions 3 Once stabilized...

Page 64: ...s below the unit s setpoint 4 If the outlet temperature is stabilized no adjustment is necessary If the temperature is not stabilized proceed to step 5 5 Press the MENU key and select the Tuning Menu 6 Press the or arrow key until Max Load Adj is displayed 7 Press the CHANGE key The display will begin to flash 8 Raise or lower the maximum load adjustment using the or arrow key Increasing this valu...

Page 65: ...is not adjustable and is permanently fixed at 190 F This switch will shut down and lock out the heater if the water temperature exceeds 190 F Following an over temperature condition it must be manually reset by pressing the RESET button before the heater can be restarted The automatic reset over temperature switch is adjustable and allows the unit to restart once the temperature drops below its te...

Page 66: ...Installation Operation Maintenance Manual CHAPTER 4 INITIAL START UP Page 66 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 67: ...s from 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...

Page 68: ... was 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 ...

Page 69: ...return 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 temp...

Page 70: ...hipped 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 gas booster or louver is operational 5 6 1 Remote Interlock Remote Interlock 1 Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals see Figure 2 12 2 Start the unit in the Manual Mode an...

Page 71: ... occur 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 ...

Page 72: ...sts check 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...

Page 73: ...lame 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 I...

Page 74: ... in 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 pres...

Page 75: ...re 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 o...

Page 76: ...en shut down 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 FU...

Page 77: ... 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 Injector Kit 58023 Inspect Inspect Replace 15 mins 6 3 Flame Detector Kit P N 24...

Page 78: ...ent 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 injector 4 Refer to Figure 6 1 Disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the ignition assembly Disconnect the ignition assem...

Page 79: ... outward toward the intake manifold perimeter 8 Refer to Figure 6 2 and reinstall the igniter injector on the intake manifold flange Install one to three clocking washers as needed to position the igniter injector s gas tube so that it is pointing outward toward the outer edge of the intake manifold flange Torque to 15 ft lbs Do not over tighten VIEWED FROM BELOW LOOKING UP Figure 6 2 Igniter Inje...

Page 80: ...nstall 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 t...

Page 81: ...d remove all sealant from both surfaces in preparation for reassembly 3 Remove the 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 needed to provide clearance for pulling the burner 4 Refer to Figures 6 3 and 6 4 to locate the blower side intake manifold at the bottom of the unit s heat exchanger 5 Discon...

Page 82: ...otruding from the exhaust manifold 12 Carefully lower and remove the blower side intake manifold burner assembly and both burner gaskets P N GP 18899 See Figures 6 3 and 6 4 13 Disconnect the exhaust temperature sensor Figure 6 3 by unscrewing it from the exhaust manifold 14 While supporting the exhaust manifold remove the two 2 side nuts Figure 6 5 securing the manifold to the heat exchanger Loos...

Page 83: ...one 800 526 0288 PRI 11 25 2014 Fireside Inspection Continued Figure 6 4 Intake Manifold and Burner PARTIAL RIGHT SIDE VIEW WITH SUPPORT REMOVED Figure 6 5 Intake and Exhaust Manifolds BURNER ASSEMBLY INTAKE MANIFOLD CONDENSATE SHIELD BURNER GASKET P N GP 18899 EXHAUST MANIFOLD 5 16 18 STUDS 6 SIDE NUTS 2 FRONT NUT 1 EXHAUST SENSOR SHIELD GASKET P N 81197 BURNER GASKET P N GP 18899 ...

Page 84: ...onents Torque the igniter injector to 15 ft lbs 18 Reinstall all components in the reverse order in which they were removed beginning with the exhaust manifold assembly removed in step 15 WARNING The manifold to heat exchanger gasket must be held in place with High Temp RTV Silicone sealant The exhaust manifold must be carefully raised into place centered and leveled to insure the gasket makes a g...

Page 85: ...mbly out of the chamber exposing the heat exchanger tubes 6 Inspect and clean the heat exchanger tubes of scale and clean all gasket surfaces thoroughly before reassembling the upper head AERCO recommends that NEW gaskets be used when reassembling 7 Inspect the anode blocks for corrosion If they have corroded by more than 40 original dimensions are 7 1 4 X 4 replace them as described in the next s...

Page 86: ...g to Figure 6 8 remove the four 4 1 4 20 hex bolts holding the anode blocks to the anode mounting bracket and then remove both old anode blocks 3 Position the four 4 O rings P N 88019 in the circular recesses around the threaded holes in the new anode blocks P N 44174 The O rings keep water from entering the threaded holes preventing them from corroding which would shorten the anode s life 4 Faste...

Page 87: ...anger overheating and lets the water heater continue to perform at its peak efficiency low water heating cost In addition to reduced inspection frequency the periodic maintenance to remove and flush the water heater for scale deposits is no longer necessary Alternatively AERCO recommends that the heat exchanger of the unit be cleaned annually to maintain maximum heat transfer efficiencies using a ...

Page 88: ...n models hold approximately the gallons of water listed below INN600 24 5 gallons drain at least 12 25 gallons INN800 24 5 gallons drain at least 12 25 gallons INN1060 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 w...

Page 89: ...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 90: ...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 91: ...N OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remove the side panels from the unit 3 Refer to Figure 6 11 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 ...

Page 92: ...uctions The LWCO capacitor should be tested for electrical shorts every 12 months and replaced then tested every 24 months The LWCO capacitor integrity test consists of two parts as described in the next two sections The first procedure explains how to test for electrical shorting of the LWCO probe capacitor while the second procedure instructs how to perform the standard Low Water Cutoff test usi...

Page 93: ...the LWCO capacitor and the heat exchanger Perform the capacitor electrical short test as described below LWCO Capacitor Electrical Short Test 1 Turn OFF AC power to the unit 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 oc...

Page 94: ...Figure 6 13 Figure 6 13 Removing Shell Harness Cable from P5 Conn 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 6 14 4 Connect the second ohmmeter probe to Pin 6 of Shell Harness Connector removed from the C More controller as shown on right in Figure 6 14 Figure 6 14 Connecting Ohmmeter between LWCO ...

Page 95: ...e C More controls as described below Standard Low Water Cutoff C More Test 1 Turn on the AC power to the unit 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 Water Level message is cleared 6 12 SHUTTING THE WATER HEATER DO...

Page 96: ... 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 97: ... to isolate and correct the fault General Troubleshooting Instructions 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 7 1 which follows and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication 4 Perform the...

Page 98: ...stallation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 98 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 99: ... 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 100: ... 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 Blocke...

Page 101: ...talled 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 igniter inje...

Page 102: ...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 103: ...point 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 TEM...

Page 104: ...ignition 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 ...

Page 105: ...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 106: ...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 107: ... 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 108: ...properly from 0 fully closed 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 h...

Page 109: ...FAULT 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 ...

Page 110: ...tallation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 110 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 111: ...in Component Locations Figure 7 2 Blower Side Intake Manifold Shown removed from Heater SSOV LEAK DETECTION BALL VALVE TO AIR FUEL VALVE LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWITCH FLAME DETECTOR BLOWER SIDE INTAKE MANIFOLD IGNITER INJECTOR Kit P N 58023 FLAME DETECTOR Kit P N 24356 2 FLAME DETECTOR GASKET Kit P N 24356 2 BURNER FLANGE GASKET P N GP 18899 OBSERVATION PORT IGNITER INJECTOR GAS...

Page 112: ...nternational Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 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 113: ...tem The WHMII 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 P N 92093 These valves are installed on the cold water inlet on each water heater being controlled by the WHM see Figure 8 2 8 1 GENERAL DESCRIPTION The C More Water Heater Management System WHM is designed to ensure that all water ...

Page 114: ...perating time for each unit on the system and attempts to balance the system so that all units operate for approximately the same number of hours 8 3 NEW AERCO WHM FEATURES 8 3 1 Valve Feedback The Valve Feedback feature is designed to confirm that the Neptronic Valve has successfully executed either a Valve Open or Valve Close command from the C More The Valve Feedback signal from the Neptronic V...

Page 115: ... back of the CMORE box and insert the dongle in its place 3 In the Cal Temp Sensor item of the calibration menu change the menu entry to Start and hit the Enter Key 4 This feature will only calibrate Inlet water Temp FFWD Water Temp Exhaust Air temp and Outlet Water Temp 5 In this version this feature will not calibrate the Inlet Air temp and Outdoor Air temp sensors Once the calibration has been ...

Page 116: ...y prevents the Outlet Temperature from exceeding the High Temp Limit The High Temperature Governor is independent of the system PID and Feed forward control methodology and independently modulates the Valve Position Fire Rate if the Outlet Temperature dangerously approaches the High Temp Limit setting This feature has 5 separate temperature bands for more precise control This feature is enabled or...

Page 117: ...te Wtr Heatr Active This Slave unit is active its valve is opened and it can ignite REMOTE SIG FAULT Remote signal fault WHMS FAILSAFE WHMS is in Failsafe Mode Example If all available heaters are turned off the C More display will alternate the display above MASTER STANDBY with the All Heaters Off status message as follows 8 6 WHM MENU The WHM Menu in each C More can only be viewed when the Unit ...

Page 118: ...back Start 12 00am 11 59pm 12 00am 10 Setback End 12 00am 11 59pm 12 00am 11 WHM Auto Mstr Yes or No No 12 WHM Auto Timer 10 sec 120 sec 30 sec 13 WHM min addr 1 8 1 14 WHM max addr 1 8 8 15 SSD address 0 250 0 16 SSD Temp Format Degrees or Points Degrees 17 1 Valve Status 8 0 0 0 18 1 Comm Errors 8 0 0 0 19 WHM On Delay 30 sec 300 sec 60 sec 20 WHM Off Delay 30 sec 300 sec 60 sec 21 Over WHM Unde...

Page 119: ...ing character for each unit Default 0 0 Off 1 On Off Line Not available fault etc A Lead On B Lag On a Lead Off b Lag Off 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 items 11 and 12 above 8 7 WHM MENU ITEM DESCRIPTIONS The required settings for WHM Menu items will vary depending on the number of units connected to ...

Page 120: ...onable spread between the 2 values 5 Lead Lag Hours The Lead Lag Hours menu option is designed to spread the total number of run hours accumulated on all units in the system so that each unit has approximately the same number of run hours 6 WHM Upld Timer Sets the time between successive WHM Heartbeat OnAER data transmissions 7 Setpoint Setback Enables Disables the Setpoint Setback feature which a...

Page 121: ...ve Status 8 Displays the valve status of all the units 0 valve closed 1 valve open 2 valve stuck closed 3 valve stuck open 18 1 Comm Errors 8 Display Comm Errors of all the units 19 20 WHM On Delay WHM off Delay Specifies the WHM On and Off time delays associated with the Next ON VP and Next OFF VP menu options Therefore if the Next ON VP or Next OFF VP is at its preset Valve Position for the spec...

Page 122: ...e status of the unit 0 valve closed 1 valve open 2 valve stuck closed 3 valve stuck open 30 MB Head Temp En Enable or disable the Modbus Header Temp sensor 31 WHM Header Temp Display the Header Sensor 32 Mdbus Temp Units Modbus temp unit format F or C 33 Header Temp Addr Modbus header Temp address 34 Header Tmp Point Modbus point to read the header temp register point 35 MB Outdr Sens En Enable or...

Page 123: ... here to avoid unnecessary referencing 8 8 1 Hardware Installation All Innovation Water Heaters which will be controlled by a WHM master must be equipped with 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 8 2 an...

Page 124: ... WHM Modbus Network Wiring As previously mentioned all units being controlled by the WHM will be connected to a RS485 Modbus Network All Modbus networks are wired in a daisy chain configuration using a Master Slave scenario as shown in Figure 8 3 NOTE The WHMS Master does not necessarily have to be on either end of the Daisy Chain loop Figure 8 3 Typical Daisy Chain Modbus RS485 Network WHM MASTER...

Page 125: ... the left side I O board as shown in Figure 8 4 2 At the I O board of the first unit in the daisy chain not necessarily Master activate the DIP switch labeled MODBUS TERM by placing it in the up position This will connect a termination resistor across the terminals at the source end 3 Refer to Figure 8 4 and run the shielded cable to the next unit in the daisy chain and connect the and wire leads ...

Page 126: ...igure 8 4 WHMS Network Wiring Diagram NOTES Wiring to be shielded twisted pair cable Belden 9841 or equivalent Complete the following instructions 1 Activate DIP 1 Modbus TERM on the first and last units in the daisy chain 2 Tie incoming outgoing shields together and terminate at the shield terminal of the LAST WHMS slave in the chain 3 On the CPU board inside the C More Control Panel of the last ...

Page 127: ...he entry Note that the Outlet Temperature display on the WHM Master will begin flashing every two seconds 6 Select the WHM Setpoint option If you want to change the current setpoint for WHM press the CHANGE key 7 Enter the desired WHM Setpoint temperature and then press ENTER to store the selection 8 Scroll to the WHM Nxt On option If you want to change the value press the CHANGE key 9 Enter the d...

Page 128: ...ese options are WHM Auto Mstr and WHM Auto Timer In order to view or change these two options the Level 2 Password 6817 must be entered as follows a Press the MENU key on the front panel of the C More and access the Setup Menu b Scroll to the Password menu option and press the CHANGE key c Enter 6817 and then press the ENTER key to store the password d Press the MENU key on the C More and scroll b...

Page 129: ...cure 2 Verify that the address of the affected unit is within the allowable range 1 thru 8 3 Check to ensure that none of the units have the same Comm address Actuator controlled sequencing valve does not open 1 Control cable not connected to valve actuator 2 24 VAC power not being supplied to valve actuator 3 Defective valve actuator 1 Ensure that the control cable from the unit s I O Box is conn...

Page 130: ...equencing 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 connections and control circuitry components as shown in Figure 8 6 The components on the PC board include DIP switches which are preset at the factory and should not be changed unless instructed to do so 4 PIN CO...

Page 131: ...ch 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 4 pin connector on the Actuator to ensure that 24 VAC power is not being supplied 2 Press and hold the brass CLUTCH but...

Page 132: ...ater Heater The 24 VAC power output and a 2 to 10Vdc control signal from the I O Box of the Water Heater are routed to the Sequencing Valve via a 4 pin Molex connector During normal Water Heater Management WHM a control signal of less than 2Vdc will rotate the valve to the fully open 90 position Conversely a control signal above 8Vdc will rotate the valve to the fully closed 0 position The sequenc...

Page 133: ...emp Displays Inlet Water Temperature 3 Air Temp For monitoring purposes only 4 Outdoor Temp Displayed only if outdoor sensor is installed and enabled 5 Valve Position In Desired input valve position This is normally the same as the valve position shown on the bargraph when the heater is operating 6 Exhaust Temp Displays Exhaust Gas Temperature 7 Valve Position Out Displays actual real time Valve P...

Page 134: ...2 00 am to 11 59 pm 4 Date Displays dates from 01 01 00 to 12 31 99 5 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C 6 Comm Address For RS 485 communications 0 to 127 Default address is 0 RS232 should have its own programmable password 7 Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K 8 OnAER Mode Allows the selection of OnAER ...

Page 135: ... which the unit shuts down 9 Setpoint Lo Limit Used to set the minimum allowable setpoint 40 F to Setpoint Hi Limit 10 Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint Lo Limit to 190 F 11 Temp Hi Limit This is the maximum allowable outlet temperature 40 to 200 F Any temperature above this setting will turn off the unit The temperature must then drop 5 F below this setting to ...

Page 136: ... goes below the Active Setpoint Demand Offset In addition the heater will fire at the 29 Valve Position level or below for a period of one minute When this entry is set to zero the unit will turn on again as soon as the Valve Position in reaches the Start Level value There will not be a one minute delay when firing at the 29 Valve Position level 23 24 Deadband High Deadband Low Deadband High and D...

Page 137: ...to move towards the setpoint Gain is adjustable from 0 00 to 10 00 3 Derivative Time This value 0 0 to 20 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output 4 Min Load Adj Setting is adjustable from 50 F to 50 F It adjusts the output by adding an offset to the breakpoint chart at minimum flow This is used to fine tune Feed Forward FFWD ...

Page 138: ...he effective Fire Rate will be reduced by the value entered in GOV Limit 7 27 GOV Limit 10 When the Outlet Temperature exceeds the HIGH TEMPERATURE LIMIT 10 the effective Fire Rate will be reduced by the value entered in GOV Limit 10 28 GOV Limit 12 When the Outlet Temperature exceeds the HIGH TEMPERATURE LIMIT 12 the effective Fire Rate will be reduced by the value entered in GOV Limit 12 29 GOV ...

Page 139: ... Position Fire Rate increase rate when raising the Valve Position VP Up Rate is defined as Seconds per Step 11 VP Down Rate Allows adjustment of the Valve Position Fire Rate decrease rate when lowering the Valve Position VP Down Rate is defined as Seconds per Step 12 Purge Blwr Offst Allows adjustment of the blower speed Blower Output Voltage during the Purge cycle 13 4 20mA Purge Pct Allows adjus...

Page 140: ...ly set Stop Level to a maximum of 40 SKIP FEATURE Items 29 31 embody a feature that allows the user to define a Fire Zone the C More will avoid In the rare instance when a unit emits an objectionable noise at a certain Fire Rate and no other remedy solves the problem a Fire Rate skip zone may be defined to command the C More to Skip Over the defined Fire Rate 29 Skip Range CNTR Defines the Center ...

Page 141: ...U ITEM DESCRIPTIONS See section 3 8 for a range of choices and the default values MENU LEVEL OPTION DESCRIPTION 42 Spark Monitor Enables or disables the Spark Monitor function which displays the AC current on the input of the Ignition Transformer 43 Min Spark Amps Allows the adjustment of the minimum spark current required at the spark transformer input 44 Max Spark Amps Allows the adjustment of t...

Page 142: ...ion Operation Maintenance Manual APPENDIX A INNOVATION MENU ITEM DESCRIPTIONS Page 142 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 143: ... 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 144: ... 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 145: ...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 146: ...ion Operation Maintenance Manual APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 146 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 147: ... 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 148: ...peration Maintenance Manual APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART Page 148 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 149: ...ation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 149 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 APPENDIX D DIMENSIONAL DRAWINGS Drawing Number AP A 888 rev H ...

Page 150: ...nstallation Operation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS Page 150 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number AP A 902 rev C ...

Page 151: ...ER IGNITION EXHAUST MANIFOLD 49 1 65146 IGNITION CABLE ASSEMBLY 8 1 44085 1 6 EXHAUST MANIFOLD INNOVATION 9 1 123449 SENSOR EXHAUST TEMPERATURE 50 1 63072 HARNESS SHELL WIRING AIR FUEL DELIVERY SYSTEM BLOWER A F VALVE ACCEESS 51 1 63079 HARNESS INNOVATION CONTROL 10 1 58039 BLOWER REPLACEMENT KIT AMETEK 8 9 52 1 69158 I O BOX WITH ONAER with SEQ VALVE 11 1 24311 3 A F VALVE ASSY INN 600 800 1060 1...

Page 152: ...Not shown in drawings below For pictorial purposes only See below for full gas train diagrams and part lists 24311 3 A F VALVE FRU KIT 1 81057 GASKET BLOWER 1 88003 O RING 2 339 1 24220 3 A F VALVE ASSY 58039 BLOWER FRU KIT 1 24111 BLOWER AMETEK 8 9 1 81064 GASKET BLOWER 1 81057 GASKET BLOWER 1 88004 O RING 69126 LWCO CAPACITOR ASSEMBLY KIT 1 122843 LOW WATER CUT OFF 1 63070 47 MCF CAPACITOR ASSY ...

Page 153: ...NGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 INN 1350 PICTURED RIGHT SIDE VIEW EXPLODED INN 600 800 1060 PICTURED AERCO International Inc Blauvelt NY 10913 Innovation Parts List 10 30 2014 Top Level Page 3 of 4 ...

Page 154: ...WINGS Page 154 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 LEFT REAR VIEW RIGHT FRONT VIEW LEFT SIDE VIEW PARTIAL FRONT VIEW AERCO International Inc Blauvelt NY 10913 Innovation Parts List 10 30 2014 Top Level Page 4 of 4 ...

Page 155: ... 6 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 22 2 9 22 PIPE PLUG 1 4 NPT STEEL 7 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 23 1 93364 TEE 1 X 1 X 1 2 NPT 8 1 61002 4 HIGH GAS PRESSURE SWITCH 4 0 W C 24 1 9 331 NIPPLE 1 NPT TBE X 1 50 LG 9 1 123542 FLANGE 2 125 2 NPT 25 1 93315 TEE RDCG 1 x x 1 M I 10 1 93035 ELBOW STREET 1 4 NPT 26 2 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 11 2 92006 5 VALVE BALL 1 NPT 27 1 ...

Page 156: ...061 19 00 NIPPLE 3 4 NPT 10 1 124862 RESISTOR ASSY 32 1 59053 CHANNEL STRUT 11 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 33 1 124024 HARNESS WIRING IRI 12 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 34 1 9 465 TEE 1 NPT 13 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 35 1 94028 2 50 NIPPLE 1 NPT TBE X 2 50 LG 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 36 1 94028 4 50 NIPPLE 1 NPT TBE X 4 50 LG 15 1 93364 TEE 1 X 1 X 1 ...

Page 157: ...TS LIST DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 AERCO International Inc Blauvelt NY 10913 Innovation 600 800 1060 DBB Gas Train 10 23 2014 22122 1 rev J Sheet 2 of 2 INSTALL MANOMETER HERE ...

Page 158: ...GN 7 1 94028 3 00 NIPPLE 1 NPT TBE X 3 00 LG 24 1 124862 RESISTOR ASSY 8 2 92006 5 VALVE BALL 1 NPT 25 2 8 22 BUSHING REDUCING 1 1 2 F NPT X 1 M NPT 9 2 94028 2 50 NIPPLE 1 NPT TBE X 2 50 LG 26 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 10 1 93315 TEE RDCG 1 x x 1 M I 27 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 11 1 69005 ACTUATOR SSOV W REGULATOR 28 1 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 12 1 ...

Page 159: ... BLACK MI 22 2 92077 1 4 NPT MXF BRASS BALL VALVE CLOSED 7 2 93419 ELBOW 90 FEMALE NPT BLACK MI 23 2 12951 2 BUSHING CONTROL BOX 8 1 93420 UNION NPT FEMALE BLACK MI 24 1 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 9 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 25 1 61002 4 HIGH GAS PRESSURE SWITCH 4 0 W C 10 2 15950 BUSHING REDUCING 1 2 X 1 4 NPT 26 1 124862 RESISTOR ASSY 11 2 123536 BUSHING REDUCING 1 4 X 1 ...

Page 160: ...1 2 BUSHING CONTROL BOX 11 1 93405 TEE 1 4 NPT BLK M I 35 1 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 12 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 36 1 61002 4 HIGH GAS PRESSURE SWITCH 4 0 W C 13 1 93420 UNION NPT FEMALE BLACK MI 37 1 124862 RESISTOR ASSY 14 1 5016 UNION 3 4 NPT MALE FEMALE 150 38 1 63147 HARNESS GAS TRAIN WIRING 4 SEC IGN 15 1 93439 COUPLING REDUCING x NPT BLK MI 39 1 124024 HARNESS WIR...

Page 161: ... PARTS LIST DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 AERCO International Inc Blauvelt NY 10913 Innovation 600PDBB 800PDBB 1 2 Propane DBB Gas Train 09 19 2014 22179 1 rev A Sheet 2 of 2 ...

Page 162: ...3 4 X 3 4 X 1 2 BLK MI 24 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 8 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 25 2 12951 2 BUSHING CONTROL BOX 9 1 93405 TEE 1 4 NPT BLK M I 26 1 63147 HARNESS GAS TRAIN WIRING 4 SEC IGN 10 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 27 1 124862 RESISTOR ASSY 11 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 28 1 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 12 1 12609 6 2 BUSHING REDUCI...

Page 163: ...BOW 90 3 4 NPT 28 1 122774 VALVE VENT 3 4 NPT 9 2 93035 ELBOW STREET 1 4 NPT 29 4 12951 2 BUSHING CONTROL BOX 10 2 5016 UNION 3 4 NPT MALE FEMALE 150 30 1 63147 HARNESS GAS TRAIN WIRING 4 SEC IGN 11 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 31 1 124862 RESISTOR ASSY 12 3 9 467 TEE NPT BLK MI 32 1 124024 HARNESS WIRING IRI 13 1 93405 TEE 1 4 NPT BLK M I 33 1 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 14 1 ...

Page 164: ...TS LIST DRAWINGS Page 164 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation 1060PDBB 1350PDBB 3 4 Inch Propane DBB Gas Train 09 19 2014 22180 1 rev A Sheet 2 of 2 ...

Page 165: ...HARNESS GAS TRAIN WIRING 4 SEC IGN 33 1 124024 HARNESS WIRING IRI 11 1 124862 RESISTOR ASSY 34 1 9 465 TEE 1 NPT 12 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 35 1 94028 2 50 NIPPLE 1 NPT TBE X 2 50 LG 13 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 36 1 94028 3 50 NIPPLE 1 NPT TBE X 3 50 LG 14 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 37 1 93337 BUSHING REDUCING 1x 1 4 15 2 9 22 PIPE PLUG 1 4 NPT STEEL 38 2 ...

Page 166: ... PARTS LIST DRAWINGS Page 166 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation 1350 DBB Gas Train 11 17 2014 22168 1 rev D Sheet 2 of 2 INSTALL MANOMETER HERE ...

Page 167: ... 1 80087 2 INNOVATION ENCLOSURE PIPE SEAL 4 1 69005 ACTUATOR SSOV W REGULATOR 40 1 63063 RELAY 5 1 124138 ACTUATOR SSOV 41 1 124933 UNION 1 4 NPT 24 1 123771 UNION MA x FEM 1 NPT 150 M I 42 1 64083 REGULATOR GAS PRESSURE WITH VENT LIMITING ORIFICE 25 1 67007 GAGE LOW PRESSURE 0 15 in H2O 43 1 124866 SOLENOID VALVE 1 4 NPT 26 1 67006 GAGE LOW PRESSURE 0 10 in H2O 44 2 9 22 PIPE PLUG 1 4 NPT STEEL 2...

Page 168: ...OR SSOV W REGULATOR 39 1 80087 1 INNOVATION ENCLOSURE PIPE SEAL 4 1 124138 ACTUATOR SSOV 40 1 124933 UNION 1 4 NPT 12 1 5016 UNION 3 4 NPT MALE FEMALE 150 42 1 64083 REGULATOR GAS PRESSURE WITH VENT LIMITING ORIFICE 24 2 92006 4 VALVE FULL PORT BAL 3 4 NPT 43 1 9 22 PIPE PLUG 1 4 NPT STEEL 25 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 44 1 124866 SOLENOID VALVE 1 4 NPT 33 1 61002 8 LOW GAS PRESSURE...

Page 169: ...4111 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 STREET ELBO...

Page 170: ... 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 STREET EL...

Page 171: ...46023 LOW NOX BURNER HEAD ASSEMBLY 4 1 66037 FLAME DETECTOR 11 1 49209 CONDENSATE SHIELD 5 1 66026 IGNITER INJECTOR 12 1 81197 SHIELD GASKET 6 4 53033 WASHER CLOCKING 13 1 24247 IGNITION SOLENOID 7 1 93288 ELBOW COMPRESSION 81048 66037 are supplied as kit 24356 2 66026 53033 are supplied as kit 58023 GP 18899 46023 are supplied as kit 24335 1 AERCO International Inc Blauvelt NY 10913 Innovation In...

Page 172: ...tallation Operation Maintenance Manual APPENDIX E PARTS LIST DRAWINGS Page 172 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 173: ... Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 APPENDIX F PIPING DRAWINGS Drawing Number SD A 829 rev B ...

Page 174: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 174 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 830 rev B ...

Page 175: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 831 rev B ...

Page 176: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 176 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 845 rev B ...

Page 177: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 848 rev C ...

Page 178: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 178 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 849 rev C ...

Page 179: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 850 rev C ...

Page 180: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 180 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 851 rev C ...

Page 181: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 181 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 852 rev C ...

Page 182: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 182 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 853 rev D ...

Page 183: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 183 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 854 rev D ...

Page 184: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 184 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 855 rev D ...

Page 185: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number SD A 856 rev C ...

Page 186: ... Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 186 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 Drawing Number SD A 939 rev A ...

Page 187: ...ntenance Manual APPENDIX G C MORE CONTROL PANEL VIEWS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 187 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 APPENDIX G C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL EXPLODED VIEW ...

Page 188: ...tion Maintenance Manual APPENDIX G C MORE CONTROL PANEL VIEWS Page 188 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL REAR VIEW ...

Page 189: ...aintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 189 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 APPENDIX H C MORE WIRING DIAGRAMS Drawing Number 68039 rev D Sheet 1 of 2 ...

Page 190: ...allation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 190 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 191: ...ation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number 68039 rev D Sheet 2 of 2 ...

Page 192: ...allation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 192 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 193: ...ation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number 68042 rev D Sheet 1 of 2 ...

Page 194: ...allation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 194 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 195: ...ation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 195 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 Drawing Number 68042 rev D Sheet 2 of 2 ...

Page 196: ...allation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 196 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 197: ...r 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 I 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit Staged Ignition 58036 01 24 month Waterside Firesid...

Page 198: ...stallation Operation Maintenance Manual APPENDIX I RECOMMENDED SPARES Page 198 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 199: ...et 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 pressing the arrow k...

Page 200: ... 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 201: ...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 202: ...ion Operation Maintenance Manual APPENDIX J COMBUSTION CALIBRATION KOREA ONLY Page 202 of 206 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0L PRI 11 25 2014 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 203: ...ainst any condensate corrosion thermal stress failure mechanical defects or workmanship Operation of the heater using contaminated air will void the warranty The heat exchangers combustion chamber shall not be warranted from failure due to scaling liming corrosion or erosion due to water or installation conditions AERCO will repair rebuild or exchange at its option the heat exchanger combustion ch...

Page 204: ...he above reasons within the specified time period from the date of original shipment s AERCO shall at its option modify repair or exchange the defective item AERCO shall have the option of having the item returned FOB its factory or to make field replacements at the point of installation In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges AERCO s...

Page 205: ...Innovation Water Heaters Installation Operation Maintenance Manual OMM 0078_0L AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 205 of 206 GF 128 Phone 800 526 0288 PRI 11 25 2014 NOTES ...

Page 206: ...9 2 10 2 to related to the pressure relief and manual shutoff valves 1034 Updated graphic instructions in section 2 10 updated tables 3 2 3 3 and 3 4 added removed WHM menu options to Appendix A added new options to Chapter 9 Water Heater Management Chris Blair 11 25 2014 Rev L PIRs 979 Updated gas train 22168 1 1018 This PIR not implemented returned 22151 in place of 22225 in Appendix F 1074 Igni...

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