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Innovation Water Heaters Installation, Operation & Maintenance Manual

CHAPTER 7 – TROUBLESHOOTING GUIDE

OMM-0078_0M

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

Page

103

216

GF-128

Phone: 800-526-0288

09/11/2015

TABLE 7-1. WATER HEATER TROUBLESHOOTING – Continued

FAULT INDICATION

PROBABLE CAUSES

CORRECTIVE ACTION

HIGH WATER TEMP

SWITCH OPEN

Faulty Water temperature switch.

Incorrect PID settings.

Faulty shell temperature sensor.

Unit in MANUAL mode

Unit setpoint is greater than

Over

Temperature

switch setpoint.

System flow rate changes are

occurring faster than units can

respond.

Test the temperature switch to insure it trips at its actual

water temperature setting.

Check PID settings against Menu Default settings in Chapter

3. If the settings have been changed, record the current

readings then reset them to the default values.

Using the resistance charts in Appendix C, measure the

resistance of Shell sensor and BTU sensor at a known water

temperature.

If unit is in MANUAL mode switch to AUTO mode.

Check setpoint of unit and setpoint of Temperature switch;

Ensure that the temperature switch is set higher than the

unit’s setpoint.

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

See HIGH WATER TEMPERATURE

SWITCH OPEN.

Temp HI Limit setting is too low.

See HIGH WATER TEMPERATURE SWITCH OPEN.

Check Temp HI Limit setting.

IGN BOARD

COMM FAULT

Communication fault has occurred

between the PMC board and

Ignition/Stepper (IGST) board

Press CLEAR button and restart unit. If fault persists,

contact qualified Service Personnel.

IGN SWTCH CLOSED

DURING PURGE

Air/Fuel Valve not rotating

Defective or shorted switch

Start the unit. The Air/Fuel Valve should rotate to the purge

(open) position. If the valve does not rotate at all or does not

rotate fully open, check the Air/Fuel Valve calibration. If

calibration is okay, the problem may be in the Air-Fuel Valve

or the Control Box. Refer to qualified service personnel

If the Air/Fuel Valve does rotate to purge, check the

Ignition

switch for continuity between the N.O. and COM terminals. If

the switch shows continuity when not in contact with the cam

replace the switch.

Summary of Contents for Innovation 1060

Page 1: ...eries Gas Fired Water Heaters Natural Gas or Propane Modulating Condensing Water Heater Models Applicable to Serial Number G 15 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 Gui...

Page 2: ...information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual nor for incidental or consequential damages occurring ...

Page 3: ...URE 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 SENS...

Page 4: ... 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 60 4 5 REASSEMBLY 62 4 6 TEMPERATURE CONTROL...

Page 5: ...LTER REPLACEMENT 92 6 11 LOW WATER CUTOFF LWCO CAPACITOR INTEGRITY TEST 93 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 6 14 SPARK MONITOR AC CURRENT TRANSDUCER 96 CHAPTER 7 TROUBLESHOOTIN...

Page 6: ...29 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 APPENDIX C ...

Page 7: ... Controllers 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 Tra...

Page 8: ...Train 1 095 lbs 496 7 kg INN800SVDBB INN800SVPDBB Innovation Potable Water Heater 800 000 BTU HR 234 5 kW Input Natural Gas or Propane Double Block Bleed Formerly IRI Gas Train with WHM Sequencing Valve 1 115 lbs 505 8 kg INN1060 INN1060P Innovation Potable Water Heater 1 060 000 BTU HR 310 7 kW Input Natural Gas or Propane FM Gas Train 1 100 lbs 499 0 kg INN1060SV INN1060SVP Innovation Potable Wa...

Page 9: ...al to bits per second unless each 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 0 45 kg of water 1 F 0 55 C BTU HR BTUs per Hour 1 BTU hr 0 29 W 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 Mon...

Page 10: ...zation Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 thousandth of an ampere MAX Max Maximum MIN Min Minimum Modbus A serial half duplex data transmission protocol 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 OMM Operation and Maintenance Manual OnAER AERC...

Page 11: ...etpt Setpoint Temperature SHLD Shld Shield SPDT Single Pole Double Throw a type of switch SSD Slave to Slave programming SSOV Safety Shut Off Valve SV Sequencing Valve Used with Water Heater Management WHM system TEMP Temp Temperature 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 communic...

Page 12: ...ter Heaters Installation Operation Maintenance Manual FORWARD Page 12 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 13: ...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 restricti...

Page 14: ...y soaps 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 ...

Page 15: ...ited to 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 installe...

Page 16: ...r of 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 f...

Page 17: ... sign 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 close...

Page 18: ...ons 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 0 61 m Front 24 inches 0 61 m Rear 30 inches 0 76 m Top 18 inches 0 46 m All gas piping water piping and electrical conduit or cable must be arranged so that they do not interfere ...

Page 19: ... 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 to 6 inch 10 2 to 15 2 cm housekeeping concrete pad required in the desired location In multiple u...

Page 20: ...nance 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...

Page 21: ...ctions 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 hot w...

Page 22: ...e 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 temperatur...

Page 23: ... 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 1 034 kPa at 190 F 87 8 C A suitable pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any into the valve body Th...

Page 24: ...ion 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 base of the condensate trap must be supported to ensure...

Page 25: ...TE Two different 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 ...

Page 26: ...rom 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 C 3 49 kPa Leak test all ex...

Page 27: ...rnal 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 1 74 kPa gas pressure a mandatory external gas supply r...

Page 28: ...VED 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 dedicat...

Page 29: ...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 Front ...

Page 30: ...ION 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 connect to the spark monitor P N 61034 also called AC Current transducer which monitors the current going to the ignition transformer P N 650...

Page 31: ... these signals is provided 2 12 6 VALVE FEEDBACK Terminals 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 i...

Page 32: ...he 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 Delayed Inte...

Page 33: ...it 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 watertight ven...

Page 34: ... 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 compoun...

Page 35: ...bustion 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 combu...

Page 36: ...ers Installation Operation Maintenance Manual CHAPTER 2 INSTALLATION Page 36 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 37: ...es CAUTION All of the installation procedures in Chapter 2 must be completed before attempting to start the unit WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS WARNING 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 PER...

Page 38: ...ion Operation Maintenance Manual CHAPTER 3 OPERATION Page 38 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 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: ...ing 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 N ...

Page 40: ...as 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...

Page 41: ...re 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 Th...

Page 42: ...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: ... 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 4 4 C 190 F 87 8 C 2 Inlet Temp 30 F 1 1 C 240 F 115 6 C Calibration Menu 3 Air Temp 70 F 56 7 C 245 F 118 3 C 4 Outdoor Temp 70 F 56 7 C 130 F 54 4 C Configuration Menu 5 Valve Position In 0 100...

Page 44: ...2 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 per...

Page 45: ...0 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 1 1 C 100 F 37 8 C 60 F 15 5 C 9 Setpt Lo Limit 40 F 4 4 C Setpt Hi Limit 60 F 15 5 C 10 Setpt Hi Limit Setpt Lo Limit 190 F 87 8 C 150 F 65 6 C 11 Temp Hi Limit 40 F 4 4 C 200 F 93 3 C 160 F 71 1 C 12 Max Valve Position 40 100 100 13 Pump...

Page 46: ...m 1 Prop Band 1 F 17 2 C 200 F 93 3 C 30 F 1 1 C 2 Integral Gain 0 00 10 00 3 00 3 Derivative Time 0 00 min 2 00 min 0 20 min 4 Warmup Prop Band 1 F 17 2 C 120 F 48 9 C 95 F 35 C 5 Warmup Int Gain 00 2 00 0 50 6 Warmup PID timer 0 sec 240 sec 20 sec 7 Min Load Adj an offset 50 F 27 5 C 50 F 27 5 C 0 F 0 C 8 Max Load Adj an offset 50 F 27 5 C 50 F 27 5 C 0 F 0 C 9 FFWD Temp 30 F 1 1 C 245 F 118 3 C...

Page 47: ...0 30 26 Fdback Value 0 100 Read Only Value 27 Temp Gov Enable or Disable Enable 28 GOV Limit 5 0 100 30 29 GOV Limit 7 0 100 20 30 GOV Limit 10 0 100 15 31 GOV Limit 12 0 100 10 32 GOV Limit 15 0 100 5 33 PID Output 0 100 Read Only Value 34 P Output 0 100 Read Only Value 35 I Output 0 100 Read Only Value 36 D Output 0 100 Read Only Value 37 Reset Defaults Yes No No 3 8 CALIBRATION MENU The Calibra...

Page 48: ... 100 70 14 PWM In Adj 5 0 5 0 0 0 15 Analog In Adj 5 0 5 0 0 0 16 Flow In Adj 5 0 5 0 0 0 17 Supply Gas Pressure In Adj 5 0 5 0 0 0 18 Gas Plate dp In Adj 5 0 5 0 0 0 19 mA Out Adj 1 0 mA 1 0 mA 0 0 mA 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 M...

Page 49: ... switches to ensure they are closed These switches include Safety Shut Off Valve Proof of Closure POC switch Low Water Level switch High 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 switc...

Page 50: ...r 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 i...

Page 51: ...gnition 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 Current to the igniter or igniter injector is monitored by the spa...

Page 52: ...vels are the Air Fuel Valve positions open that start and stop the unit based on load These levels are Factory preset as follows Fuel Model Stop Level Ignition Position Natural Gas All 16 25 Propane INN600 18 26 INN800 18 24 INN1060 18 28 INN1350 18 24 INN1400 18 24 Normally these settings should not require adjustment Note that the energy input is not linearly related to the Air Fuel Valve positi...

Page 53: ...e 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 compl...

Page 54: ...eter 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 SSOV as...

Page 55: ... the 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 ...

Page 56: ... 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 mode ens...

Page 57: ...to AERCO for proper Warranty Validation It is important to perform the calibration procedure as outlined below This will keep readjustments to a minimum and provide optimum performance NATURAL GAS Combustion Calibration 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the NATURAL GAS supply valve s to the unit 3 Set the control panel ON OFF ...

Page 58: ...4 4 SSOV Gas Pressure Adjustment Screw Location 14 If it was removed above replace the brass hex cap on the SSOV 15 Compare the oxygen O2 level carbon monoxide CO nitrogen oxide NOx and flame strength readings with the range shown in step 22 below You may need to adjust O2 above this range to meet ultra low NOx requirements or to avoid combustion tone issues 16 Press the MENU key on the front pane...

Page 59: ...shown in the table Record the increased O2 value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position Oxygen O2 0 25 Nitrogen Oxide NOx Carbon Monoxide CO Flame µA 100 6 0 20 ppm 100 ppm 6 80 6 5 20 ppm 100 ppm 6 60 6 5 20 ppm 100 ppm 6 50 7 0 20 ppm 100 ppm 6 40 7 0 20 ppm 100 ppm 6 30 7 5 20 ppm 100 ppm 5 20 7 0 20 ppm 100 ppm 4 16 6 0 20 ppm 100 ppm 2 23 If the oxy...

Page 60: ...or 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 control panel ON O...

Page 61: ... it was removed above replace the brass hex cap on the SSOV 15 Compare the oxygen O2 level carbon monoxide CO and flame strength readings with the range shown in step 19 below You may need to adjust O2 above this range to avoid combustion tone issues 16 Press the MENU key on the front panel of the C More until COMBUSTION CAL MENU appears on the display 17 Press the arrow key until Set Valve Positi...

Page 62: ...r voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 5 in the previous section Rotate 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 18 after making a change to the idle screw TAC valve This completes the PROPANE gas combus...

Page 63: ...de of operation 2 The Outlet Feedback option in the Tuning Menu must be set to DISABLED while performing calibration 3 Monitor the OUTLET TEMPERATURE display and VALVE POSITION bar graph to set load conditions and observe the effect of adjustments 4 Perform the calibration using the Tuning Menu of the C More Control Box 5 Make small adjustments and allow time between adjustments for the outlet wat...

Page 64: ...nce stabilized the OUTLET TEMPERATURE display should read no more than 2 to 3 degrees F 1 1 to 1 65 degrees C above the unit s setpoint 4 If the outlet temperature is stabilized proceed to the Maximum Load Adjustment procedure in section 4 6 3 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 MIN LOAD ADJ is displa...

Page 65: ...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 value ...

Page 66: ...not adjustable and is permanently fixed at 190 F 87 7 C This switch will shut down and lock out the heater if the water temperature exceeds 190 F 87 7 C 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 Limit switch is adjustable and allows the unit to restart once the temperature d...

Page 67: ...unit to perform the following tests WARNING 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 Te...

Page 68: ...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 1 00 kPa The FAULT indicator should also start flashing 7 Reduce the gas pressure back to 2 ...

Page 69: ...en 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 temperature fault is simulated by ...

Page 70: ...ocks 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 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 Manu...

Page 71: ...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 72: ...s 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 t...

Page 73: ...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 74: ...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 75: ... 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 76: ... 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 FUEL...

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

Page 78: ... 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 assembly from the igniter...

Page 79: ...d 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 20 34 Nm Do not over tighten VIEWED FROM BELOW LOOKING UP Figure 6 2 Igniter In...

Page 80: ...Reinstall 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 o...

Page 81: ...vent connector and 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 Locate the intake manifold at the bottom of the unit s heat exchanger see Figures 6 3 and 6 4 5 Disconnec...

Page 82: ...haust manifold 12 Carefully lower and remove the intake manifold burner assembly the burner gasket P N GP 18899 and the intake manifold flange gasket P N 81198 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 exch...

Page 83: ...ireside 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 FLANGE GASKET P N GP 18899 EXHAUST MANIFOLD 5 16 18 STUDS 6 SIDE NUTS 2 FRONT NUT 1 EXHAUST SENSOR BURNER SHIELD GASKET P N 81197 BURNER FLANGE GASKET P N GP 18899 INTAKE MANIFOLD FLANGE GASK...

Page 84: ... step 15 19 When attaching the intake manifold to the exhaust manifold removed in step 11 torque the six 5 16 hex nuts to 146 in lbs 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 good seal between the manifold and heat exchanger 20 Rei...

Page 85: ... 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 18 4 cm X 10 16 cm replace them as described in...

Page 86: ...rring 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 F...

Page 87: ...xchanger 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...

Page 88: ...of water listed below INN600 24 5 gallons 92 7 L drain at least 12 25 gallons 46 37 L INN800 24 5 gallons 92 7 L drain at least 12 25 gallons 46 37 L INN1060 23 gallons 87 01 L drain at least 11 5 gallons 43 53 L INN1350 20 6 gallons 77 97 L drain at least 10 3 gallons 38 98 L For the Innovation model being cleaned drain at least the amount of eater shown in parentheses 3 Prepare a 50 solution of ...

Page 89: ... 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 n...

Page 90: ...est should be performed near the end of the circulating time If the solution has been expended more HydroSkrub will be required to complete the job If the solution is still active at the end of the time all the scale has been dissolved pH Trend Charting The initial pH of the cleaning solution will measure between 1 3 See pH sheet on HydroSkrub packaging To test the effectiveness of the circulating...

Page 91: ...nnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 6 10 2 Loosen the four 4 thumbscrews securing the trap s cover and then remove the cover and the O ring from under the cover 3 Remove the float and then thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thor...

Page 92: ...anel 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 is equipped with its own clam...

Page 93: ...orm the standard Low Water Cutoff test using the C More controls On the Innovation series the LWCO probe is located on the heat exchanger body on the left side of the unit Refer to Figure 6 12 for an illustration of the LWCO probe assembly and its installation Figure 6 12 LWCO Probe Location INN 1350 Shown 6 11 1 Low Water Cutoff LWCO Capacitor Electrical Short Test This test determines if there i...

Page 94: ...gure 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 Pr...

Page 95: ...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 DOWN...

Page 96: ...onitor P N 61034 evaluates the strength of the current between the ignition transformer and igniter or igniter injector Wire 140 connected to the ignition transformer see Figure 6 15 passes through the monitor s orifice If an adequate AC current is not detected in the wire during ignition the unit automatically shuts down The monitor s wires are connected to the I O board s Spark Signal terminals ...

Page 97: ...o 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 c...

Page 98: ...Installation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 98 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 99: ...he 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 the ...

Page 100: ...p 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 101: ...lled 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 inject...

Page 102: ...ge 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 1 Check c...

Page 103: ...int 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 TEMPE...

Page 104: ...nition 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 th...

Page 105: ...system 2 Defective 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 Mod...

Page 106: ...k 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 Outdoor ...

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: ...ULT 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 Or...

Page 110: ...nstallation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE Page 110 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 111: ... 1 Gas Train Component Locations Figure 7 2 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 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 INLET MANUAL ...

Page 112: ... International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Figure 7 3 SSOV Actuator With Gas Pressure Adjustment Damping Orifice SSOV ACTUATOR COVER ACTUATOR COVER SCREW DAMPING ORIFICE BRASS HEX HEAD CAP Remove to access gas pressure adjustment screw OPEN CLOSED INDICATOR WINDOW ...

Page 113: ...m 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 92123 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 he...

Page 114: ...rating 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 Val...

Page 115: ...ack 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 co...

Page 116: ...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 d...

Page 117: ...n t ignite 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 t...

Page 118: ...130 F 54 4 C 9 Setback 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 se...

Page 119: ...g 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 th...

Page 120: ...reasonable spread between the 2 values 5 Lead Lag Hours This 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 allows for ...

Page 121: ... 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 specif...

Page 122: ...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 d...

Page 123: ...ysically disconnect it from the Modbus network in I O board b Make sure that the Modbus load and bias resistors are properly configured for the system to operate without the ProtoNode installed c Temporarily set the WHM system for Constant Setpoint mode of operation see below d Turn on and completely test the installation to verify that it is operating proper e Once the installation is working pro...

Page 124: ...ector on the sequencing valve to the mating connector on the Innovation harness at the rear of the unit 7 This completes the sequencing valve installation Figure 8 2 Innovation Water Heater Equipped With Sequencing Valve 8 8 3 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 ...

Page 125: ... 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 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 te...

Page 126: ...plished by simply ensuring that the 4 pin Molex connectors on the units are connected to the corresponding connectors on the valves Figure 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...

Page 127: ... 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 des...

Page 128: ...e 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 bac...

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: ...ncing Valve P N 92123 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: ...utch 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 b...

Page 132: ...ed in the Power Box of the Innovation Water 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 ...

Page 133: ...p 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 Pos...

Page 134: ...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 da...

Page 135: ...ove which the unit shuts down 9 Setpoint Lo Limit Used to set the minimum allowable setpoint 40 F 4 4 C to Setpoint Hi Limit 10 Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint Lo Limit to 190 F 87 8 C 11 Temp Hi Limit This is the maximum allowable outlet temperature 40 to 200 F 93 3 C Any temperature above this setting will turn off the unit The temperature must then drop 5 F...

Page 136: ...oes 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 Dea...

Page 137: ... setpoint error This is the time that this action advances the output Warmup The feature embodied in the next three menu items eliminates Temperature Overshoots during the Warmup period of a cold ignition cycle on all boilers by temporarily modifying the PID Gain parameter during warmup and for a period defined in the Tuning Menu 4 Warmup Prop Band Range 1 120 F 17 2 C to 48 9 C Default 95 F 35 C ...

Page 138: ...OV Limit 7 When the Outlet Temperature exceeds the HIGH TEMPERATURE LIMIT 7 the effective Fire Rate will be reduced by the value entered in GOV Limit 7 30 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 31 GOV Limit 12 When the Outlet Temperature exceeds the HIGH TEMPERATURE LIMIT 12 the eff...

Page 139: ...osition 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 adjustm...

Page 140: ... 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 Fire Rate of the skip ...

Page 141: ...n 3 8 for a range of choices and the default values MENU LEVEL OPTION DESCRIPTION 41 Outlet Wtr Offset Range 20ºF to 20ºF 28 9 C to 6 7 C 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 ...

Page 142: ...ation Operation Maintenance Manual APPENDIX A INNOVATION MENU ITEM DESCRIPTIONS Page 142 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 143: ...m 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 purge ...

Page 144: ...URING 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 the ...

Page 145: ...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 purge SSOV FAUL...

Page 146: ...ation Operation Maintenance Manual APPENDIX B STARTUP STATUS AND FAULT MESSAGES Page 146 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 147: ...50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 40 34 4 28 9 23 3 17 2 12 2 6 7 1 1 4 4 10 15 5 21 1 26 7 32 2 37 8 43 3 48 9 54 4 60 65 6 71 1 76 7 82 2 87 8 93 3 98 9 104 4 110 115 6 121 1 779 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 ...

Page 148: ... Operation Maintenance Manual APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART Page 148 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 149: ...l APPENDIX D DIMENSIONAL DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 149 of 216 GF 128 Phone 800 526 0288 09 11 2015 APPENDIX D DIMENSIONAL DRAWINGS Drawing Number AP A 888 rev H 160 PSIG 1103 kPa 210 F 98 9 C 240 PSIG 1655 kPa ...

Page 150: ...aintenance Manual APPENDIX D DIMENSIONAL DRAWINGS Page 150 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number AP A 902 rev C 160 PSIG 1103 kPa 210 F 98 9 C 240 PSIG 1655 kPa ...

Page 151: ...PANE 48 1 65085 TRANSFORMER 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 VALV...

Page 152: ...hown 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 1 122...

Page 153: ...AWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 216 GF 128 Phone 800 526 0288 09 11 2015 INN 1350 PICTURED INN 600 800 1060 PICTURED AERCO International Inc Blauvelt NY 10913 Innovation Parts List 8 28 2015 Top Level Page 3 of 4 RIGHT SIDE VIEW EXPLODED ...

Page 154: ...RAWINGS Page 154 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 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 8 28 2015 Top Level Page 4 of 4 ...

Page 155: ...4 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 5 3 81cm 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 1 123...

Page 156: ... 3 4 NPT 10 1 124862 RESISTOR ASSY 32 1 59053 CHANNEL STRUT 11 1 94028 24 00 NIPPLE 1 NPT TBE X 24 70cm 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 5 6 35cm LG 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 36 1 94028 4 50 NIPPLE 1 NPT TBE X 4 5 11 43cm LG 15 1 93364 TEE 1 X 1 X ...

Page 157: ...ARTS LIST DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 216 GF 128 Phone 800 526 0288 09 11 2015 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: ... 1 NPT TBE X 3 0 7 62cm 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 5 6 34cm 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 6 35cm LG 12 1 124150 ...

Page 159: ...I 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 8 NPT 27...

Page 160: ... 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 WIRING IRI 16 ...

Page 161: ...ARTS LIST DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 216 GF 128 Phone 800 526 0288 09 11 2015 AERCO International Inc Blauvelt NY 10913 Innovation 600PDBB 800PDBB 1 2 1 27 cm Propane DBB Gas Train 09 19 2014 22179 1 rev A Sheet 2 of 2 ...

Page 162: ... 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 REDUCING 3 4 x 1 4 NPT BLK M...

Page 163: ... 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 94061 24 00 NI...

Page 164: ...E PARTS LIST DRAWINGS Page 164 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 AERCO International Inc Blauvelt NY 10913 Innovation 1060PDBB 1350PDBB 3 4 Propane DBB Gas Train 09 19 2014 22180 1 rev A Sheet 2 of 2 ...

Page 165: ...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 5 6 35 cm LG 13 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 36 1 94028 3 50 NIPPLE 1 NPT TBE X 3 5 8 9 cm LG 14 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 37 1 93337 BUSHING REDUCING 1x 15 2 9 22 PIPE PLUG 1 4 NPT STEEL 38 2 9 3...

Page 166: ... E PARTS LIST DRAWINGS Page 166 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 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: ... 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 27 1 61002 ...

Page 168: ...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 SWITCH 4 ...

Page 169: ...11 BLOWER AMETEK 8 9 14 1 61002 5 BLOCKED INLET SWITCH 4 5 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 15 2 cm 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 STREE...

Page 170: ...4028 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 4 5 W C 9 1 24220 4 A F VALVE ASSY 19 1 124979 1 8 C S STREET ELBOW 10...

Page 171: ...LOW NOX BURNER HEAD ASSEMBLY 4 1 66037 FLAME DETECTOR 11 1 49209 CONDENSATE SHIELD 5 1 66026 IGNITER INJECTOR 12 1 81197 BURNER 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 I...

Page 172: ...nstallation Operation Maintenance Manual APPENDIX E PARTS LIST DRAWINGS Page 172 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This page left intentionally blank ...

Page 173: ...on Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 216 GF 128 Phone 800 526 0288 09 11 2015 APPENDIX F PIPING DRAWINGS Drawing Number SD A 829 rev B ...

Page 174: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 174 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 830 rev B ...

Page 175: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 831 rev B ...

Page 176: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 176 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 845 rev B ...

Page 177: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 848 rev C ...

Page 178: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 178 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 849 rev C ...

Page 179: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 850 rev C ...

Page 180: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 180 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 851 rev C ...

Page 181: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 181 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 852 rev C ...

Page 182: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 182 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 853 rev D ...

Page 183: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 183 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 854 rev D ...

Page 184: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 184 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 855 rev D ...

Page 185: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number SD A 856 rev C ...

Page 186: ...rs Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS Page 186 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Drawing Number SD A 939 rev A ...

Page 187: ...EL VIEWS Figure G 1 Control Panel Exploded View ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 FISH PAPER INSULATOR P N 124960 V F D DISPLAY MODULE P N 124527 FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 PUSH BUTTON SWITCHES P N 124954 ROCKER SWITCH P N 124947 GREEN LED P N 124948 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW...

Page 188: ...lauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 Figure G 2 C MORE CONTROL PANEL REAR VIEW SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX GAS TRAIN HARNESS CONNECTOR 9 PIN SHELL HARNESS CONNECTOR 19 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX ...

Page 189: ... Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 189 of 216 GF 128 Phone 800 526 0288 09 11 2015 APPENDIX H C MORE WIRING DIAGRAMS Drawing Number 68056 rev C Sheet 1 of 2 ...

Page 190: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 190 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 191: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68056 rev C Sheet 2 of 2 ...

Page 192: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 192 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 193: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68057 rev C Sheet 1 of 2 ...

Page 194: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 194 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 195: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 195 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68057 rev C Sheet 2 of 2 ...

Page 196: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 196 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 197: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 197 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68058 rev C Sheet 1 of 2 ...

Page 198: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 198 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 199: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 199 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68058 rev C Sheet 2 of 2 ...

Page 200: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 200 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 201: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 201 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68059 rev C Sheet 1 of 2 ...

Page 202: ...stallation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS Page 202 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 203: ...llation Operation Maintenance Manual APPENDIX H C MORE WIRING DIAGRAMS OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 203 of 216 GF 128 Phone 800 526 0288 09 11 2015 Drawing Number 68059 rev C Sheet 2 of 2 ...

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Page 205: ...gulator 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 below 123552 Table I 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit Staged Ignition 58036 01 24 month Waterside Firesid...

Page 206: ...Installation Operation Maintenance Manual APPENDIX I RECOMMENDED SPARES Page 206 of 216 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0078_0M 09 11 2015 Phone 800 526 0288 GF 128 This Page Is Intentionally Blank ...

Page 207: ... Warranty Validation It is important to perform the calibration procedure as outlined below This will keep readjustments to a minimum and provide optimum performance NATURAL GAS Combustion Calibration 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the NATURAL GAS supply valve s to the unit 3 Set the control panel ON OFF switch to the OFF p...

Page 208: ...Pa Figure J 1 SSOV Gas Pressure Adjustment Screw Location 14 If it was removed above replace the brass hex cap on the SSOV 15 Compare the oxygen O2 level carbon monoxide CO nitrogen oxide NOx and flame strength readings with the range shown in step 22 below You may need to adjust O2 above this range to meet ultra low NOx requirements or to avoid combustion tone issues 16 Press the MENU key on the ...

Page 209: ...e increased O2 value on the Combustion Calibration sheet Combustion Calibration Readings Oxygen O2 0 25 Valve Position INN600K INN800K INN1060K INN1400K Nitrogen Oxide NOx Carbon Monoxide CO Flame µA 100 6 0 3 25 20 ppm 100 ppm 6 80 6 5 4 25 20 ppm 100 ppm 6 60 6 5 5 25 20 ppm 100 ppm 6 50 7 0 6 25 20 ppm 100 ppm 6 40 7 0 6 75 20 ppm 100 ppm 6 30 7 5 7 0 20 ppm 100 ppm 5 20 7 0 6 25 20 ppm 100 ppm...

Page 210: ...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 control panel ON OFF switch to the OFF position 4 Turn on external AC power to the unit 5 Enter the password 6817 to continue 6 Se...

Page 211: ...Pa 14 If it was removed above replace the brass hex cap on the SSOV 15 Compare the oxygen O2 level carbon monoxide CO and flame strength readings with the range shown in step 19 below You may need to adjust O2 above this range to avoid combustion tone issues 16 Press the MENU key on the front panel of the C More until COMBUSTION CAL MENU appears on the display 17 Press the arrow key until Set Valv...

Page 212: ... the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure J 2 in the previous section Rotate 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 18 after making a change to the idle screw TAC valve This completes the PROPANE ...

Page 213: ...nst 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 cham...

Page 214: ... 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 shall accept no responsibility if such...

Page 215: ...Innovation Water Heaters Installation Operation Maintenance Manual OMM 0078_0M AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 215 of 216 GF 128 Phone 800 526 0288 09 11 2015 NOTES ...

Page 216: ... defaults now in Chapter 3 1092 Removed Chapter 8 RS232 Communication per Firmware version 4 0 and above 1118 Removed vent gasket 81148 expanded section 2 13 Flue Gas Vent Installation use Red RTV when installing flue vent Chris Blair 09 11 2015 Rev M 992 1 Replaced old style Condensate trap 20460 with new style 24441 in section 6 9 1011 Changed Blocked Inlet switch pressure from 8 0 to 4 5 in App...

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