Aerco INNOVATION INN1060 User Manual Download Page 85

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Chapter 7

Innovation Series Water Heaters

GF-128

Troubleshooting Guide

USER MANUAL

OMM-0079_0B

07/21/11 AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

•

Ph: 800-526-0288

Page

200

Figure 7-1. Gas Train Component Locations

Figure 7-2. Blower-Side Intake Manifold (Shown removed from Heater)

Summary of Contents for INNOVATION INN1060

Page 1: ...sing Water Heater Models INN600 INN800 INN1060 Applicable to Serial Numbers G 10 1350 to G 11 0563 Other documents for this product include GF 5030 INN Gas Supply Guide GF 5050 INN Venting Guide GF 5060 INN Elect Power Guide GF 5080 INN Sizing Guide Copies of these documents are included in Appendices J thru M of this Manual Released 07 21 2011 Installation Operation and Maintenance ...

Page 2: ...RCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Technical ...

Page 3: ...16 2 7 PRESSURE TEMPERATURE RELIEF VALVE INSTALLATION 17 2 8 SYSTEM RECIRCULATION LOOP 17 2 9 CONDENSATE DRAIN PIPING 17 2 10 GAS SUPPLY PIPING 19 2 10 1 Gas Supply Specifications 20 2 10 2 Manual Gas Shutoff Valve 20 2 10 3 External Gas Supply Regulator 20 2 11 AC ELECTRICAL POWER WIRING 21 2 11 1 Electrical Power Requirements 21 2 12 FIELD CONTROL WIRING 22 2 12 1 Outdoor Air Sensor 23 2 12 2 AU...

Page 4: ...STRUMENTATION FOR COMBUSTION CALIBRATION 41 4 2 1 Required Tools Instrumentation 41 4 2 2 Installing Gas Supply Manometer 42 4 2 3 Accessing the Analyzer Probe Port 42 4 3 NATURAL GAS COMBUSTION CALIBRATION 43 4 4 REASSEMBLY 45 4 5 TEMPERATURE CONTROL CALIBRATION 45 4 5 1 Setting the Outlet Water Temperature Setpoint 45 4 5 2 Minimum Load Adjustment 46 4 5 3 Maximum Load Adjustment 46 4 6 OVER TEM...

Page 5: ...TION 62 6 7 WATERSIDE INSPECTION 65 6 8 HEAT EXCHANGER CLEANING 67 6 8 1 Pumping System Set Up Instructions 67 6 8 2 Cleaning Procedure 68 6 8 3 Testing HydroSkrub Effectiveness 69 6 9 CONDENSATE DRAIN TRAP 69 6 10 AIR FILTER REPLACEMENT 70 6 11 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME 71 6 12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN 71 CHAPTER 7 TROUBLESH...

Page 6: ...SENSOR RESISTANCE VOLTAGE CHART 99 APPENDIX D WATER HEATER DEFAULT SETTINGS 101 APPENDIX E PARTS LIST DRAWINGS 103 APPENDIX F PIPING DRAWINGS 113 APPENDIX G C MORE CONTROL PANEL VIEWS 127 APPENDIX H C MORE WIRING DIAGRAMS 129 APPENDIX I RECOMMENDED SPARES 137 APPENDIX J GF 5030 GAS COMPONENTS SUPPLY DESIGN GUIDE 139 APPENDIX K GF 5050 VENTING COMBUSTION AIR GUIDE 151 APPENDIX L GF 5060 ELECTRICAL ...

Page 7: ...s modulate over a 20 1 turn down ratio to match the system demand and yield high thermal efficiencies When installed and operated on natural gas in accordance with this Instruction Manual the Innovation Series Models covered herein comply with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Texas Commission on Environmental Quality TCEQ Title 3...

Page 8: ...GF 128 Innovation Series Water Heaters OMM 0079_0B USER MANUAL Foreword Page 8 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 9: ...mmonwealth 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 restrictions prior to installing the water heater 1 The water heater can only be used for applications where the chlorine concentrations D...

Page 10: ...ter 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the manual gas shutoff valve Figure 1 1 located external to the unit IMPORTANT The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the startup procedures in Chapter 4 and...

Page 11: ...red carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontall...

Page 12: ...uctions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies...

Page 13: ...on 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 a close inspection of the unit should be made to ensure that there is no evidence of damage not indicated by the Tip...

Page 14: ...d are as follows Sides 24 inches Front 24 inches Rear 30 inches Top 18 inches All gas piping water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels or inhibit service or maintenance of the unit Figure 2 1 Innovation Water Heater Clearances WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPOR...

Page 15: ...inch housekeeping concrete pad required in the desired location Figure 2 2 Partial Top View Showing Lifting Tab Location In multiple unit installations it is important to plan the position of each unit in advance Sufficient space for piping connections and future service maintenance requirements must also be taken into consideration All piping must include ample provisions for expansion 2 5 WATER ...

Page 16: ...t NY 10913 Ph 800 526 0288 07 21 11 Figure 2 3 Water Inlet Outlet Locations 2 6 TEST HOSE BIB CONNECTION A Test Hose Bib connection upstream of the shut off valve on the hot water outlet is required for startup and testing Figure 2 4 The pipe diameter should be a minimum of 3 4 The Test Hose Bib cannot be omitted Figure 2 4 Test Hose Bib Location ...

Page 17: ...scharge lines must not be manifolded together Each must be individually run to a suitable discharge location Figure 2 5 P T Relief Valve Location 2 8 SYSTEM RECIRCULATION LOOP The System Recirculation Loop Assembly is located at the rear of the unit as shown in Figure 2 5 This assembly contains a recirculator pump which connects between the upper hot water outlet and lower cold water inlet of the ...

Page 18: ...o ensure that it is level horizontal The trap must be removable for routine maintenance AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port While observing the above guidelines install the condensate trap as follows 1 Connect the condensate trap inlet to the exhaust manifold drain connection using the appropriate piping components ni...

Page 19: ...of any covers inhibit service maintenance or restrict access between the unit and walls or another unit Innovation units contain a 1 inch NPT gas inlet connection on the rear of the unit as shown in Figure 2 3 Prior to installation all pipes should be de burred and internally cleared of any scale metal chips or other foreign particles Do Not install any flexible connectors or unapproved gas fittin...

Page 20: ...stream of the Heater as shown in Figure 2 8 Maximum allowable gas pressure to the Heater is 14 W C NOTE Paragraph 2 10 3 applies only to water heater installations within the Commonwealth of Massachusetts 2 10 3 External Gas Supply Regulator For Massachusetts installations a mandatory external gas supply regulator must be positioned as shown in Figure 2 6 The gas supply regulator must be properly ...

Page 21: ...r 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 8 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 dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE HEATER A ...

Page 22: ...t I O Box The I O Box is located on the upper left portion of the unit front panel Figure 2 11 behind the removable front panel 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 Refer to the wiring diagram provided o...

Page 23: ...enu The sensor must be wired to the AUX SENSOR IN and SENSOR COMMON and must be similar to AERCO BALCO wire sensor P N 12449 A resistance chart for this sensor is located in APPENDIX C 2 12 3 ANALOG IN The ANALOG IN and terminals are used when an external signal is used to change the setpoint Remote Setpoint Mode of the heater Either a 4 to 20 mA 1 to 5 VDC or a 0 to 20 mA 0 to 5 VDC signal may be...

Page 24: ... accessories These interlocks are called the Remote Interlock and Delayed Interlock Figure 2 12 The wiring terminals for these interlocks are located inside the I O Box on the left side of the unit The I O Box cover contains a wiring diagram which shows the terminal strip locations for these interlocks REMOTE INTL K IN and DELAYED INTL K IN Both interlocks described below are factory wired in the ...

Page 25: ...during operation the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet of 1 9 W C Fittings as well as pipe lengths must be calculated as part of the equivalent length For a natural draft installation the draft must not exceed 0 10 W C These factors must be planned into the vent installation If the maximum allowable equivalent lengths of piping are exceed...

Page 26: ...n combustion air is provided from within the building it must be supplied through two permanent openings in an interior wall Each opening must have a free area of not less than one square inch per 1000 BTUH of total input or 1000 square inches of free area The free area must take into account any restrictions such as louvers 2 15 SEALED COMBUSTION The AERCO Innovation Water Heater is UL listed for...

Page 27: ... 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 PERSONNEL OR PROP...

Page 28: ...Innovation Series Water Heaters Chapter 3 OMM 0079_0B USER MANUAL Operation Page 28 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 Figure 3 1 Control Panel Front View ...

Page 29: ...play 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 RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel 5 FAULT Indicator Red FAULT LED indicator lights when a heater alarm ...

Page 30: ...ANGE key 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 ...

Page 31: ...re it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures 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 The display will show the Setup Menu which...

Page 32: ... descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages 3 4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3 2 This menu is Read Only and does not allow personnel to change or adjust any displayed items Since this menu is Read Only it can be viewed at any time...

Page 33: ... provided to indicate the current Control Box software version NOTE The Outdoor Temp display item shown with an asterisk in Table 3 2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu Table 3 4 Table 3 2 Operating Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Status Message Active Setpoint 40 F 240 F Inlet Temp 40 F 140...

Page 34: ...et in accordance with the requirements specified for each individual order Therefore under normal operating conditions no changes will be required Table 3 4 Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Internal Setpt Lo Temp Limit Hi Temp Limit 130 F Unit Type KC Boiler KC Boiler LN BMK Boiler BMK Boiler LN BMK Boiler Dual KC Water Heater KC Water Heater...

Page 35: ...tlet Temp Valve Position 4 20 mA Valve Position 0 10V Valve Position 0 10V Low Fire Timer 2 sec 600 sec 2 sec Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0 F 10 F 0 Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt EN 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 CAUTION DO NOT CHANGE the Analog Output Menu Item from its Default setting Valve Position 0 10...

Page 36: ...ter the following events will occur NOTE If any of the Pre Purge safety device switches are open the appropriate fault message will be displayed Also the appropriate messages will be displayed throughout the start sequence if the required conditions are not observed 1 The DEMAND LED status indicator will light 2 The unit checks to ensure that the Proof of Closure POC switch in the downstream Safet...

Page 37: ... of the purge cycle in seconds Figure 3 5 Blower Proof Switch 5 Upon completion of 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 i...

Page 38: ...rolled by the temperature controller circuitry The heater s VALVE POSITION will be continuously displayed on the front panel bargraph Once the demand for hot water has been satisfied the Control Box will turn off the SSOV gas valve The blower relay will be deactivated and the Air Fuel Valve will be closed Standby will be displayed 3 9 START STOP LEVELS The start and stop levels are the Air Fuel Va...

Page 39: ...ge 39 of 200 Table 3 6 Relationship Between Air Fuel Valve Position and Energy Input For Unit Running On Natural Gas Air Fuel Valve Position Open Energy Input BTU Hr Heater Energy Input of Full Capacity 0 0 0 10 0 0 16 Stop Level 45 000 4 2 20 97 000 10 30 222 000 22 40 416 000 42 50 520 000 52 60 645 000 65 70 715 000 72 80 845 000 85 90 930 000 93 100 1 060 000 100 ...

Page 40: ...novation Series Water Heaters Chapter 4 OMM 0079_0B USER MANUAL Initial Start Up Page 40 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 41: ...apter 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 completed for each unit for warranty validation and a copy must be returned promptly to AERCO at AERCO International Inc 100 Oritani Drive Blauvelt New York 10913 WARNING DO...

Page 42: ...of the Safety Shut Off Valve SSOV as shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch W C manometer Figure 4 1 1 8 Inch Gas Plug Location 4 2 3 Accessing the Analyzer Probe Port The unit contains a 1 8 NPT port at the rear of the exhaust manifold This port is located above t...

Page 43: ...wing procedure as outlined This will keep readjustments to a minimum and provide optimum performance 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 position 4 Turn on external AC power to the unit The display will show LOSS OF POWER and the time and...

Page 44: ... rear of the exhaust manifold Allow enough time for the combustion analyzer to settle 14 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 15 If the oxygen level is not within the required ...

Page 45: ...wed to settle for several minutes prior to making any further adjustments When calibrating temperature control observe the following 1 The unit must be in the Auto mode of operation 2 The Outlet Feedback option in the Tuning Menu must be set to OFF while performing calibration 3 Monitor the OUTLET TEMPERATURE display and VALVE POSITION bar graph to set load conditions and observe the effect of adj...

Page 46: ...ter temperature while decreasing it will decrease outlet water temperature 9 Press ENTER to save the change Allow time for the system to stabilize between adjustments 10 Repeat steps 5 through 9 as needed until the temperature is stabilized at no more than 2 to 3 degrees above the unit s setpoint 4 5 3 Maximum Load Adjustment Check the temperature control at maximum load as follows 1 While monitor...

Page 47: ...ON 4 6 OVER TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over temperature limit switches These switches are mounted on a plate as shown in Figure 4 4 The switches can be accessed by opening the front panel door of the unit The manual reset switch is not adjustable and is permanently fixed at 200 F This switch will shut down and lock out the heater if the water tempe...

Page 48: ...novation Series Water Heaters Chapter 4 OMM 0079_0B USER MANUAL Initial Start Up Page 48 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 49: ...NING 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 1 Remove the 1 8 plug from the ball valve at the low gas pressur...

Page 50: ...HIGH GAS PRESSURE fault message when the gas pressure exceeds 4 0 W C The FAULT indicator should also start flashing 7 Reduce the gas pressure back to 2 8 W C 8 Press the CLEAR button on the Control Box to clear the fault 9 The fault message should clear and the FAULT indicator should go off The unit should restart 10 Upon test completion close the ball valve and remove the manometer Replace the 1...

Page 51: ...ront of the unit as shown in Figure 5 2 1 Start the unit in the normal operating mode Allow the unit to stabilize at its setpoint 2 Lower the adjustable over temperature switch setting to match the displayed OUTLET TEMPERATURE 3 Once the adjustable over temperature switch setting is approximately at or just below the actual outlet water temperature the unit should shut down The FAULT indicator sho...

Page 52: ... 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 1 Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals 2 Start the unit in the Manual Mode and set the valve position between 25 and 30 3 If there is a jumper...

Page 53: ...o 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 OFF switch to the ON position to start the unit 5 The unit should shut down after reaching the Ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve prev...

Page 54: ...execute a 30 second re ignition delay and display WAIT RETRY PAUSE b The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY 4 The unit should perform two IGNITION RETRY cycles and then shut down on the third successive ignition attempt The unit will display AIRFLOW FAULT DURING PURGE 5 Re enable the blower output drive voltage by performing the following steps a Pr...

Page 55: ...lve Figure 5 4 11 Ensure that the sheet metal panels are securely installed on the water heater and the unit is running 12 At the rear of the unit partially block the air inlet Figure 5 5 with a plywood sheet or metal plate 13 The unit should shut down and again display AIRFLOW FAULT DURING RUN 14 Unblock the air inlet and press the CLEAR button The unit should restart Figure 5 4 Blower Proof Bloc...

Page 56: ...ress the CLEAR button 8 Set the ON OFF switch to ON to start the unit 9 Remove the wire again when the unit reaches the purge cycle and PURGING is displayed 10 The unit should shut down and display SSOV FAULT DURING PURGE 11 Replace the wire on the SSOV and press the CLEAR button The unit should restart Figure 5 6 SSOV Actuator Cover Location 5 10 PURGE SWITCH OPEN DURING PURGE The Purge Switch an...

Page 57: ... the unit in Manual Mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 5 5 by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove one of the two wires 169 or 170 from the Ignition Switch Figure 5 8 5 Initiate a unit start sequence 6 The unit should begin it s start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITI...

Page 58: ...USER MANUAL Safety Device Testing Page 58 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 5 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code Section VI ...

Page 59: ...G ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF VALVE PROVIDED WITH THE UNIT ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING TABLE 6 1 MAINTENANCE SCHEDULE PARAGRAPH ITEM 6 Mos 12 Mos 24 Mos Labor Time 6 2 Igniter Inj...

Page 60: ...e intake Manifold Shown Removed from Heater To inspect replace the Igniter Injector 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 cable from the igniter injector Figure 6 1 4 Refer to the partial exploded view in Figure 6 1 and Figure 6 2 Using a 7 16 open end wrench disconnect the...

Page 61: ... contact other components or assemblies of the unit 8 Reinstall the igniter injector on the intake manifold flange Torque to 15 ft lbs Do not over tighten 9 Connect the staged ignition assembly to the gas injector tube of the igniter injector by securing the compression nut to the elbow of the staged ignition assembly 10 Reconnect the igniter injector cable 11 Reinstall the side and rear panels on...

Page 62: ...ion Water Heater will include removal of the exhaust manifold Blower side intake manifold and the burner assembly from the Innovation Water Heater The purpose of this inspection is to check for the formation of deposits on the inside of the heat exchanger tubes exhaust manifold and or the burner assembly These deposits can be caused by the presence of even trace amounts of chlorides and or sulfur ...

Page 63: ... 2 Disconnect the staged ignition assembly from the igniter injector 9 Next loosen and remove the igniter injector from the intake manifold flange using a 1 open end wrench 10 Refer to Figure 6 3 Loosen and remove the four 4 1 4 20 cap screws securing the blower side of the intake manifold 44106 DO NOT REMOVE the two 1 4 20 screws and nuts securing the manifold support bracket Figure 6 3 Blower Si...

Page 64: ...curing the manifold to the heat exchanger Loosen but DO NOT REMOVE the third nut nearest to the front of the unit 15 Remove the exhaust manifold 44085 from the unit 16 Inspect the exhaust manifold and burner assemblies for debris Clean out debris as necessary 17 Using a flashlight inspect the combustion chamber liner 161151 shown in Figure 6 5 Replace the liner if there is evidence of cracking or ...

Page 65: ...nd grounding screw Also ensure that the igniter injector and staged ignition assembly are properly positioned and are not contacting other components Torque the igniter injector to 15 ft lbs 19 Beginning with the exhaust manifold assembly removed in step 15 reinstall all the components in the reverse order that they were removed 6 7 WATERSIDE INSPECTION The waterside of the heating surfaces may be...

Page 66: ...e Figure 6 7 6 Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head AERCO recommends that NEW gaskets be used when reassembling 7 Place a shell head gasket on top of the shell ring first then place the release gasket on top of the shell head gasket Align the gasket holes with those in the shell ring 8 Place the upper head liner o...

Page 67: ...stem Set Up Instructions A sample pumping set up diagram is shown in Figure 6 8 for an Innovation Water Heater As this diagram shows heat exchanger cleaning is accomplished by pumping the HydroSkrub solution from a large circulating bucket to the heat exchanger drain valve through the heat exchanger and then out through the output connection of the heater Set up the pumping system as follows 1 Tur...

Page 68: ...or water may be required to maintain circulation and to prevent the pump from cavitating 6 Circulate the cleaning solution through the heat exchanger and piping for 1 to 3 hours Estimate the circulation period based on the time in service and water hardness When the foaming action stops HydroSkrub strength is depleted two pounds of deposits removed per gallon used or the equipment is free from cal...

Page 69: ...ill measure between 1 3 See pH sheet on HydroSkrub packaging To test the effectiveness of the circulating solution as a function of pH take readings at regular intervals and chart as a trend Note that the deposits can cause a premature jump in the pH After circulating for approximately 75 of the cycle time begin testing the pH at 10 15 minute intervals Once the solution s pH reads 6 0 7 0 on three...

Page 70: ...t replace the Igniter Injector 1 Set the ON 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 10 and locate the air filter attached to the air fuel valve inlet 4 Using a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the inlet flange of the air fuel valve Remove the filte...

Page 71: ...F position to shut down the heater s operating controls 2 Disconnect AC power from the unit 3 Close the water inlet and outlet valves to isolate unit 4 Close external gas supply valve 5 Open relief valve to vent water pressure 6 12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed 1 Review installatio...

Page 72: ...vation Series Water Heaters Chapter 7 OMM 0079_0B USER MANUAL Troubleshooting Guide Page 72 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 73: ...This RS232 communication feature permits service personnel to view menu items and data logs which can be useful in isolating faults Refer to Chapter 7 of this manual for detailed RS232 communication set up and procedures When a fault occurs in the unit proceed as follows to isolate and correct the fault 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indicati...

Page 74: ...vation Series Water Heaters Chapter 7 OMM 0079_0B USER MANUAL Troubleshooting Guide Page 74 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 75: ...oof 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 blocked air ...

Page 76: ...mbustion 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 airflow swi...

Page 77: ...ook up if not installed If installed check polarity Measure signal level Check continuity of wiring between source and unit 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration Menu FLAME LOSS DURING IGN 1 Burner Ground Screw not installed or loose 2 Worn flam...

Page 78: ...mic 2 Defective Regulator 3 Poor combustion calibration 4 Debris on burner 5 Blocked condensate drain 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Check combustion calibration Adjust a...

Page 79: ...greater than Over Temperature Switch setpoint 6 System flow rate changes are occurring faster than units can respond 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against Menu Default settings in the Appendix If the settings have been changed record the current readings then reset them to the default values 3 Using the resistance char...

Page 80: ...red correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 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 IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 2 Defe...

Page 81: ... supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is between 4 0 W C and 2 psig For IRI gas trains ensure it is between 4 2 W C and 2 psig see para 2 7 1 2 Measure gas pressure at the low gas pressure switch If it is greater than 2 6 W C measure continuity across the switch and replace if...

Page 82: ...ty does not exist 2 Measure for 24 VAC from each side of the switch to ground If 24VAC is not present refer fault to qualified service personnel 3 Check 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...

Page 83: ...n 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 Normally this measurement should be near zero or no more than a few millivolts 3 Check SSOV power wiring SSOV SWITCH OPEN 1 Actuator not allowing for full closure of gas valve 2 SSOV powered when it should not be 3 Defective Switch or Actuator 4 Incorrectly ...

Page 84: ...BABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Staged Ignition Ball Valve closed 2 Clogged damaged Gas Injector on Igniter Injector Figure 7 2 3 Defective Staged Ignition Solenoid Figure 7 2 1 Open the 1 4 Staged Ignition Ball Valve on the downstream side of the SSOV Figure 7 1 2 Disconnect the Staged Ignition Assembly from the Igniter Injector and inspect Gas Injector to ensure it is not clogged...

Page 85: ... Troubleshooting Guide USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 85 of 200 Figure 7 1 Gas Train Component Locations Figure 7 2 Blower Side Intake Manifold Shown removed from Heater ...

Page 86: ... Heaters Chapter 7 OMM 0079_0B USER MANUAL Troubleshooting Guide Page 86 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 Figure 7 3 SSOV Actuator With Gas Pressure Adjustment Damping Orifice ...

Page 87: ...elines must be adhered to when setting up the RS232 communication link Baud Rate The baud rates which can be used with the C More Control Panel are 2400 4800 9600 Default 19 2K Data Format The program must be set for 8 data bits 1 stop bit no parity and either Xon Xoff or No flow control 8 3 MENU PROCESSING UTILIZING RS232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu ...

Page 88: ... or setting for the option and press Rtn Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning Menus The Calibration and Diagnostic Menus should only be used by Factory Trained service personnel Menu changes will be stored in non volatile memory 9 To redisplay the menu and view the option which was just changed in step 5 ...

Page 89: ...ing a laptop or other terminal device Ten operation time records are displayed for each T command entry The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu NOTE The Sensor S Log can store up to 1200 records Therefore to view the most recently logged record enter S followed by 0 zero and then press Enter i e S0 Enter To view earl...

Page 90: ...EN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 ...

Page 91: ...uld normally be the same as the valve position shown on the bargraph when the heater is operating Flame Strength Displays flame strength from 0 to 100 Run Cycles Displays the total number of run cycles from 0 to 999 999 Run Hours Displays total run time of unit in hours from 0 to 9 999 999 Fault Log Displays information on the last 20 faults 0 19 SETUP MENU Password Allows password to be entered O...

Page 92: ...tpoint 40 F to Setpoint Hi Limit Default is 60 F Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint Lo Limit to 240 F Default is 200 F Temp Hi Limit This is the maximum allowable outlet temperature 40 to 240 F Any temperature above this setting will turn off the unit The temperature must then drop 5 F below this setting to allow the unit to run Default Hi Limit is 160 F Max Valv...

Page 93: ...e 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 Setting range is 0 to 25 Default is 0 Deadband High Deadband Low Deadband High and Deadband Low settings create an Outlet Temperature Zone In which no Valve Position corrections will be attempted ...

Page 94: ...s 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 Min Load Adj Setting is adjustable from 50 F to 50 F Default is zero It adjusts the output by adding an offset to the breakpoint chart at minimum flow This is used to fine tune Feed Forward FFWD output at low flow levels Max Load Adj Setting is adjustable from 50 F to ...

Page 95: ...t 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 cycle during startup Th...

Page 96: ...t 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 HIGH GAS PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP SWITCH OPEN The High Water Tem...

Page 97: ...ge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge 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 ...

Page 98: ...vation Series Water Heaters Appendix B OMM 0079_0B USER MANUAL Display Messages Page 98 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 99: ...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 20 2 23 2 25 2 27 2 30 2 32 2 34 2 36 2 39 2 41 2 ...

Page 100: ...ion Series Water Heaters Appendix C OMM 0079_0B USER MANUAL Sensor Res Volt Chart Page 100 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 06 10 11 This Page Is Intentionally Blank ...

Page 101: ...aud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type Innovation WH Unit Size 600 800 1060 MBH Fuel Type Natural Gas Heater Mode Constant Setpoint Remote Signal If Heater Mode Remote Setpoint 4 20 mA 1 5V Outdoor Sensor Disabled Setpt Lo Limit 60 F Setpt Hi Limit 200 F Temp Hi Limit 160 F Max Valve Position 100 Aux Start On Dly 0 sec Failsafe Mode Shutdown mA Output Off Lo Fire Timer 2 s...

Page 102: ...TION FACTORY DEFAULT Tuning Menu Prop Band 8 F Integral Gain 1 60 Derivative Time 0 10 min Min Load Adj 0 F Max Load Adj 0 F FFWD Temp N A Outlet Feedback On Feedback Gain 0 05 Breakpoint At 100 83 F Breakpoint At 90 84 F Breakpoint At 80 85 F Breakpoint At 70 86 F Breakpoint At 60 87 F Breakpoint At 50 88 F Breakpoint At 40 92 F Breakpoint At 30 105 F Breakpoint At 20 124 F Breakpoint At 10 136 F...

Page 103: ...B PV CODE SECTION IV STAMP HLW MATERIALS OF CONSTRUCTION PRESSURE VESSEL SHELL 3 16 THK STAINLESS 304L SA 312 ELECTROLESS NICKEL PLATED COMBUSTION CHAMBER 316L STAINLESS HELICAL TUBES SA 249 DOMED HEAD 316 STAINLESS SA 240 TUBESHEET STAINLESS 316 SA 240 1 4 WALL WELDED TUBE SA 312 TP316 ALL ELECTROLESS NICKEL PLATED 79 25 in 2013 0 mm 28 00 in 711 2 mm CONTROL PANEL 14 23 in 361 4 mm 2 NPT HOT WAT...

Page 104: ...GF 128 INNOVATION SERIES HEATER Appendix E OMM 0079_0B USER MANUAL Parts Lists Drawings Page 104 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 ...

Page 105: ...Appendix E Innovation Series Water Heaters GF 128 Parts Lists Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 105 of 200 ...

Page 106: ...GF 128 INNOVATION SERIES HEATER Appendix E OMM 0079_0B USER MANUAL Parts Lists Drawings Page 106 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 ...

Page 107: ...Appendix E Innovation Series Water Heaters GF 128 Parts Lists Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 107 of 200 ...

Page 108: ...GF 128 INNOVATION SERIES HEATER Appendix E OMM 0079_0B USER MANUAL Parts Lists Drawings Page 108 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 ...

Page 109: ...Appendix E Innovation Series Water Heaters GF 128 Parts Lists Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 109 of 200 ...

Page 110: ...GF 128 INNOVATION SERIES HEATER Appendix E OMM 0079_0B USER MANUAL Parts Lists Drawings Page 110 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 ...

Page 111: ...Appendix E Innovation Series Water Heaters GF 128 Parts Lists Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 111 of 200 ...

Page 112: ...OVATION SERIES HEATER Appendix E OMM 0079_0B USER MANUAL Parts Lists Drawings Page 112 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 113: ...ix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 113 of 200 APPENDIX F PIPING DRAWINGS ...

Page 114: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 114 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 115: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 115 of 200 PIPING DRAWINGS ...

Page 116: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 116 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 117: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 117 of 200 PIPING DRAWINGS ...

Page 118: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 118 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 119: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 119 of 200 PIPING DRAWINGS ...

Page 120: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 120 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 121: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 121 of 200 PIPING DRAWINGS ...

Page 122: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 122 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 123: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 123 of 200 PIPING DRAWINGS ...

Page 124: ... 128 Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 124 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 PIPING DRAWINGS ...

Page 125: ...ppendix F Innovation Series Water Heaters GF 128 Piping Drawings USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 125 of 200 PIPING DRAWINGS ...

Page 126: ... Innovation Series Water Heaters Appendix F OMM 0079_0B USER MANUAL PipingDrawings Page 126 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 This Page Is Intentionally Blank ...

Page 127: ...ter Heaters GF 128 Control Panel Views USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 127 of 200 APPENDIX G C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL EXPLODED VIEW ...

Page 128: ...ies Water Heaters Appendix G OMM 0079_0B USER MANUAL Control Panel Views Page 128 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 C MORE CONTROL PANEL VIEWS C MORE CONTROL PANEL REAR VIEW ...

Page 129: ...Appendix H C More Wiring Diagrams Innovation Series Water Heaters USER MANUAL APPENDIX H C MORE WIRING DIAGRAMS ...

Page 130: ...GF 128 Innovation Series Water Heaters OMM 0079_0B USER MANUAL This Page Is Intentionally Blank ...

Page 131: ...Appendix H C More Wiring Diagrams Innovation Series Water Heaters USER MANUAL ...

Page 132: ...GF 128 Innovation Series Water Heaters OMM 0079_0B USER MANUAL This Page Is Intentionally Blank ...

Page 133: ...Appendix H C More Wiring Diagrams Innovation Series Water Heaters USER MANUAL ...

Page 134: ...GF 128 Innovation Series Water Heaters OMM 0079_0B USER MANUAL This Page Is Intentionally Blank ...

Page 135: ...Appendix H C More Wiring Diagrams Innovation Series Water Heaters USER MANUAL ...

Page 136: ...GF 128 Innovation Series Water Heaters OMM 0079_0B USER MANUAL This Page Is Intentionally Blank ...

Page 137: ...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 58036 TAB 24 month Waterside Fireside Inspection Kit ...

Page 138: ...ation Series Water Heaters Appendix J OMM 0079_0B USER MANUAL Recommended Spares Page 138 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Phone 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 139: ...r Heaters GF 128 GF 5030 Gas Guide USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 139 of 200 APPENDIX J GF 5030 INNOVATION WATER HEATER GAS COMPONENTS SUPPLY DESIGN GUIDE ...

Page 140: ...ovation Series Water Heaters Appendix J OMM 0079_0B USER MANUAL GF 5030 Gas Guide Page 140 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 141: ...uvelt NY 10913 Ph 800 526 0288 Page 141 of 200 GF 5030 Gas Supply Design Guide TAG 0044_0A GAS SUPPLY DESIGN GUIDE Natural Gas Modulating Condensing Water Heater Models INN600 INN800 INN1060 Released 05 26 2011 INNOVATION Series Gas Fired Water Heaters ...

Page 142: ...nal Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Pg 2 of 10 Technical Sup...

Page 143: ...n characteristics The air side uses a butterfly type valve for adjusting the air volume The driver of the valve shaft is a precision stepping motor which provides continuous positioning from full input to minimum fire The air fuel valve also contains two proof of position switches CAST ALUMINUM BLOWER ASSEMBLY A cast aluminum pre mix blower ensures the precise mixing of air and fuel prior to enter...

Page 144: ...he drip leg s should not be used to support any or part of the gas piping Diagram 1 Single Heater Pipe Connections Custom Gas Trains Some utilities insurance carriers and industrial customers have special requirement gas components on high input devices beyond that which are normally supplied with AERCO heaters Secondary shutoffs high or low pressure operators and external regulators are typical o...

Page 145: ...ures vary between devices gas pressure regulators at each unit should be installed to allow regulation at any individual unit Gas pressure must never exceed the maximum allowable rating of any connected device The total length of gas piping as well as fitting pressure drop must be considered when sizing the gas piping Total equivalent length should be calculated from the meter or source location t...

Page 146: ...c Gravity Pipe Size of Schedule 40 Standard Pipe Inches Internal Diameter Inches Total Equivalent Length of Pipe Feet 50 100 150 200 250 300 400 500 2 00 2 067 6589 4528 3636 3112 2758 2499 2139 1896 2 50 2 469 10501 7217 5796 4961 4396 3983 3409 3022 3 00 3 068 18564 12759 10246 8769 7772 7042 6027 5342 3 50 3 548 27181 18681 15002 12840 11379 10311 8825 7821 4 00 4 026 37865 26025 20899 17887 15...

Page 147: ...elines for venting of gas regulators are listed below AERCO recommends that these guidelines be followed to ensure the most reliable and proper operation of AERCO gas fired equipment It is also recommended that you consult local codes and the gas regulator manufacturer for additional details Always follow the most stringent guidelines available including those listed below When venting a gas suppl...

Page 148: ...Page 148 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 GF 5030 TAG 0044_0A Gas Supply Design Guide This Page Is Intentionally Blank Pg 8 of 10 ...

Page 149: ..._____ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________...

Page 150: ...CO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 GF 5030 TAG 0044_0A Gas Supply Design Guide AERCO INTERNATIONAL INC 100 ORITANI DRIVE BLAUVELT NY 10913 Visit Us at www aerco com Pg 10 of 10 ...

Page 151: ...er Heaters GF 128 GF 5050 Venting Guide USER MANUAL OMM 0078_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 151 of 200 APPENDIX K GF 5050 INNOVATION WATER HEATER VENTING COMBUSTION AIR GUIDE ...

Page 152: ...ation Series Water Heaters Appendix K OMM 0078_0A USER MANUAL GF 5050 Venting Guide Page 152 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 153: ...nal Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 153 of 200 GF 5050 TAG 0043_0C VENTING COMBUSTION AIR GUIDE Natural Gas Modulating Condensing Water Heater Models INN600 INN800 INN1060 Released 07 21 2011 INNOVATION Series Gas Fired Water Heaters ...

Page 154: ...ational Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Pg 2 of 22 Technical...

Page 155: ...OUS GASES CARBON MONOXIDE IS ODORLESS AND INVISIBLE FOR CORRECT INSTALLATION OF VENT SYSTEM READ ALL OF THESE INSTRUCTIONS AND REFER TO THE VENT PIPE MANUFACTURER S INSTRUCTIONS FAILURE TO USE THE VENTING SYSTEM DESCRIBED IN THIS DOCUMENT WILL VOID THE MANUFACTURER S WARRANTY AND MAY RESULT IN RAPID DETERIORATION OF THE VENTING SYSTEM CREATING A POTENTIAL HEALTH HAZARD FAULTY VENT INSTALLATION CAN...

Page 156: ...re discharged to the outdoors 1 3 CERTIFIED VENTING MATERIALS FOR FLUE PIPE SYSTYEMS Acceptable materials and manufacturers for flue vent pipe systems are listed below in Option 1 and Option 2 The Vent Pipe Systems below are used for venting gas burning Category IV appliances Do not use these vent pipe systems for venting appliances burning fuels such as wood coal oil or kerosene Maintain clearanc...

Page 157: ...llowing tabular listing shows the components and part numbers for connecting the air inlet and the exhaust vents for each Innovation model Basic drawings of the connection components are shown in Figures 1 COMPONENT INN600 4 inch Part Numbers INN800 INN1060 6 inch Part Numbers Exhaust PVC 24287 24286 6 EXHAUST CONNECTION KIT 24286 FOR INN800 INN1060 4 EXHAUST CONNECTION KIT 24287 FOR INN600 Figure...

Page 158: ...egreasing compounds plastic processing and refrigerants Whenever the environment contains these types of chemicals combustion air MUST be supplied from a clean area outdoors for the protection and longevity of the equipment and warranty validation 2 Ventilation of the boiler heater room must be adequate enough to provide sufficient air to properly support combustion 3 When combustion air is brough...

Page 159: ...national Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 159 of 200 GF 5050 TAG 0043_0C Figure 2 Combustion Air From Outside the building COMBUSTION AIR FROM EQUIPMENT ROOM Figure 3 Combustion Air From Inside and Outside the Building Pg 7 of 22 ...

Page 160: ...bustion air inlet must be 3 ft below any vent outlet within 10 ft See Figure 4 b Combustion air inlet must also face away from the vent outlet See Figure 4 6 All inlet air ducts must be sealed air tight 7 When using sealed combustion the combustion air inlet and vent outlet must be located on the same surface same wall roof etc See Figures 4 and 5 This is required so that equal pressure zones are ...

Page 161: ... Vent Outlet Installations 2 2 COMBUSTION AIR PIPE SIZING The maximum length is the combined length of straight horizontal and vertical runs and the equivalent straight length of fittings The required lengths for each unit are as follows Model No INN600 INN800 INN1060 Combustion Air Diameter 4 102 mm 6 152 mm 6 152 mm Maximum Combustion Air Equivalent Feet Meters 140 42 7 m 140 42 7 m 140 42 7 m P...

Page 162: ...ot length of combustion air pipe and 1 sharp 90 elbow plus two termination 90 elbows add up to 40 ft 10 ft 2 x 10 ft 70 equivalent ft 21 3 m 2 A 30 foot length of combustion air pipe and 2 sharp 90 elbows plus two termination 90 elbows add up to 30 ft 2 x 10 ft 2 x 10 ft 70 equivalent ft 21 3 m 2 3 COMMON COMBUSTION AIR PIPE SIZING Refer to Figures 6 and 7 for typical common combustion air inlet i...

Page 163: ... 140 equivalent ft contact your AERCO sales representative or AERCO International for design assistance and approval It is important to use a WYE as a means to connect the individual combustion air pipe into the common combustion air pipe This will ensure the least amount of pressure drop Do NOT use a TEE 90 or 45 elbow The maximum pressure drop of the vent is also 140 equivalent feet 42 7 m See S...

Page 164: ...n Air Guide Page 164 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 Figure 6 Roof Mounted Combustion Air Inlet Vent Installation Figure 7 Wall Mounted Combustion Air Inlet Vent Installation Pg 12 of 22 ...

Page 165: ...d with manufacturer specified vent system components and installation practices 2 Install vent pipe beginning at the water heater exhaust manifold vent connector and work toward the vent cap To attach the exhaust connector to the flue collector use the screws and the gasket supplied inside the plastic bag Use a cross tip Phillips screwdriver at least 12 inches 300 mm long See Figure 1 for exhaust ...

Page 166: ...eas where snow accumulates With a vent termination clearance of at least 4 feet 122 cm from any air openings into a building b In Massachusetts when side wall venting is used the vent termination must be located a minimum of 4 feet above grade For detailed information pertaining to side wall venting within the Commonwealth of Massachusetts see pages 11 and 12 in GF 128 c At least 3 feet 92 cm abov...

Page 167: ...00 GF 5050 TAG 0043_0C VENT TERMINATIONS MUST BE AT LEAST 3 FEET 92 CM ABOVE ANY FORCED AIR INLET LOCATED WITHIN 10 FEET 305 CM Figure 8 Acceptable Vent Termination Locations CATEGORY IV VENT TERMINATIONS MUST NOT TERMINATE OVER PUBLIC WALKWAYS OR OVER AREAS WHERE CONDENSATE OR VAPOR COULD CREATE A NUISANCE OR HAZARD Pg 15 of 22 ...

Page 168: ...ugh a roof of a building and at least 2 ft 0 6 m higher than any portion of the building within a horizontal distance of 10 ft 3 m Terminations that extend more than 2 ft above the roof must be laterally supported c Combustion air inlet must also face away from the vent outlet see Figure 9 d Use vent pipe manufacturers vent cap fire stop support collar roof flushing and storm collar LESS THAN 10 F...

Page 169: ...Ft m Maximum Length Equiv Ft m INN600 4 102 mm 10 ft 3 05 m 5 ft 1 5 m 5 ft 1 5 m 5 ft 1 5 m 140 ft 42 7 m INN800 INN1060 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 140 ft 42 7 m The maximum pressure drop of the combustion air piping is also 140 equivalent feet 42 7 m See Section 2 2 Note that this does NOT mean the allowed combined pressure drop between the vent and combustion air is 280 equ...

Page 170: ...ths Examples Maximum Length à Individual Connector plus Common Vent Equivalent Ft m Sharp 90 Elbow Equiv Ft m Sweep 90 Elbow Equiv Ft m 45 Elbow Equiv Ft m WYE or Termination Tee or Rain Cap Equiv Ft m 1 212 000 6 152 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 140 ft 42 7 m 2 120 000 8 203 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1 5 m 140 ft 42 7 m 3 180 000 10 254 mm 10 ft 3 05 m N A 5 ft 1 5 m 5 ft 1...

Page 171: ...quivalent feet 42 7m even if the combustion air is less than 140 equivalent feet and vice versa Example The vent system of two INN800 2 x 800 000 BTU hr 1 600 000 BTU hr consists of 30 foot length of vent pipe and 2 sharp 90 elbows A termination cap is also installed Each individual vent connector consists of 5 ft straight run and one WYE Common Vent pipe 30 ft 2 x 10ft 5 ft 55 equivalent ft 16 7 ...

Page 172: ...GF 5050 TAG 0043_0C Venting and Combustion Air Guide Page 172 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank Pg 20 of 22 ...

Page 173: ..._______________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ____________________________________________________________________...

Page 174: ...ting and Combustion Air Guide Page 174 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 AERCO INTERNATIONAL INC 100 ORITANI DRIVE BLAUVELT NY 10913 Visit Us at www aerco com Pg 22 of 22 ...

Page 175: ... Water Heaters GF 128 GF 5060 Power Guide USER MANUAL OMM 0079_0B 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 175 of 200 APPENDIX L GF 5060 INNOVATION WATER HEATER ELECTRICAL POWER GUIDE ...

Page 176: ...vation Series Water Heaters Appendix L OMM 0079_B USER MANUAL GF 5060 Power Guide Page 176 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 177: ...Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 177 of 200 GF 5060 TAG 0045_0A ELECTRICAL POWER GUIDE Natural Gas Modulating Condensing Water Heater Models INN600 INN800 INN1060 Released 05 26 2011 INNOVATION Series Gas Fired Water Heaters ...

Page 178: ...AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Pg 2 of ...

Page 179: ... fusible fire switches break glass stations and other electrical requirements should be considered and installed whenever necessary Heater Electrical Requirements The Innovation water heater requires 120 1 60 Hz electrical supply The distribution block for field connection is located in the upper right of the control box All copper wire must be connected to the terminal distribution block 110 VAC ...

Page 180: ... instructed as to where the wiring conduit should be located such as away from the relief valve discharge drains etc All electrical conduit and hardware should be installed so that it does not interfere with the removal of any cover inhibit service or maintenance or prevent access between the unit and walls or another unit Boiler Wiring A dedicated protected circuit should be provided from the pow...

Page 181: ...___________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________________________...

Page 182: ...0A Electrical Power Guide Page 182 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 AERCO INTERNATIONAL INC 100 ORITANI DRIVE BLAUVELT NY 10913 Visit Us at www aerco com Pg 6 of 6 ...

Page 183: ...Heaters GF 128 GF 5080 Sizing Guide USER MANUAL OMM 0079_0A PR1 07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 183 of 200 APPENDIX M GF 5080 INNOVATION WATER HEATER COMMERCIAL LAUNDRY SIZING GUIDE ...

Page 184: ...ation Series Water Heaters Appendix M OMM 0079_0A USER MANUAL GF 5080 Sizing Guide Page 184 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 This Page Is Intentionally Blank ...

Page 185: ...i Dr Blauvelt NY 10913 Ph 800 526 0288 Page 185 of 200 GF 5080 TAG 0046_0A COMMERCIAL LAUNDRY SIZING GUIDE Natural Gas Modulating Condensing Water Heater Models INN600 INN800 INN1060 Released 05 26 2011 INNOVATION Series Gas Fired Water Heaters ...

Page 186: ...ational Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Pg 2 of 10 Technical...

Page 187: ...ashed This figure is recommended by most machine manufacturers Most heavy work requires a nominal one hour wash cycle inclusive of loading and unloading the machine and is based on a 50 60 second fill time The use of the shorter 30 second fill time will shorten the total cycle only 3 to 4 minutes The shorter cycles more commonly used are not shorter because of shorter fill time but instead are ach...

Page 188: ...1 75 Total 775 AHHWR 2 775 1550 Heater Capacity 2 775 26 GPM from Chart A 2 INN800 s 60 Tank Capacity 2 775 738 gallons 3 0 7 Circulator Capacity 26 GPM from Chart B DETERMINATION OF MAXIMUM INSTANTANEOUS DEMAND MID The nominal machine cycle of 45 to 50 minutes exclusive of loading and unloading is generally based on a 50 to 60 second time to fill to high fill level Many machine manufacturers are ...

Page 189: ...s below 7 fps Note on Figure 1 and Figure 2 that the piping between the tank and heater s does not see the MID only the pumped flow rate Therefore this piping only needs to be selected for the pumped flow rate ALTERNATE SIZING DESIGNING FOR NO SUPLEMENTAL STORAGE In a small laundry up to 200 pound total machine capacity and where fill times of 1 minute or longer are acceptable it is practical to c...

Page 190: ...3 3 91 2 92 2 27 1 44 100 9 56 6 70 4 34 3 25 2 52 1 60 1 11 125 11 97 8 38 5 43 4 06 3 15 2 01 1 39 150 14 36 10 05 6 51 4 87 3 78 2 41 1 67 175 16 75 11 73 7 60 5 68 4 41 2 81 1 94 200 19 14 13 42 8 68 6 49 5 04 3 21 2 22 225 15 09 9 77 7 30 5 67 3 61 2 50 1 44 250 10 85 8 13 6 30 4 01 2 78 1 60 275 11 94 8 93 6 93 4 41 3 05 1 76 300 13 00 9 74 7 56 4 81 3 33 1 92 325 14 12 10 53 8 19 5 21 3 61 ...

Page 191: ...07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 191 of 200 GF 5080 TAG 0046_0A Commercial Laundry Sizing Guide Pg 7 of 10 ...

Page 192: ...Page 192 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 GF 5080 TAG 0046 0A Commercial Laundry Sizing Guide Pg 8 of 10 ...

Page 193: ..._________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ ______...

Page 194: ...nternational Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 GF 5080 TAG 0046 0A Commercial Laundry Sizing Guide AERCO INTERNATIONAL INC 100 ORITANI DRIVE BLAUVELT NY 10913 Visit Us at www aerco com Pg 10 of 10 ...

Page 195: ...07 21 11 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 195 of 200 GF 128 OMM 0079_0B Innovation Series Water Heaters USER MANUAL APPENDIX N WARRANTY INNOVATION WATER HEATER LIMITED WARRANTY ...

Page 196: ...Page 196 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 Innovation Series Water Heaters USER MANUAL GF 128 OMM 0079_0B This Page Is Intentionally Blank ...

Page 197: ...e for 2 two years from shipment OTHER COMPONENTS 18 MONTHS FROM SHIPMENT All other components with the exception of the igniter and flame detector are conditionally guaranteed against any failure for 18 months from shipment The warranty as set forth on the back page of the Operations Maintenance Manual is in lieu of and not in addition to any other express or implied warranties in any documents or...

Page 198: ...t parts not manufactured or sold by AERCO will void any warranty express or limited AERCO shall accept no responsibility if such item has been damaged due to contaminated combustion air containing but not limited to sheetrock particles plaster board particles dirt dust lint and corrosive chemicals such as chlorine gas halogenated hydrocarbons and Freon In order to process a warranty claim a formal...

Page 199: ...____________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _______________________________________________________...

Page 200: ...Page 200 of 200 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 07 21 11 AERCO International Inc 2011 ...

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