Watts Aerco INN 1060N User Manual Download

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Disclaimer

The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials.

Heating and Hot Water Solutions

AERCO International, Inc.

• 100 Oritani Drive • Blauvelt, NY 10913

USA: T: (845) 580-

8000 • Toll Free: (800) 526

-

0288 • AERCO.com

Technical Support

• (800) 526

-

0288 • Mon

-Fri, 8 am - 5 pm EST

© 2019 AERCO

Innovation Water Heaters

With Edge [i] Controller

Installation, Operation and Maintenance Manual

OMM-

0143_A • GF

-216

•

9/6/2019

Applies to models:

•

INN 600N

•

INN 800N

•

INN 1060N

•

INN 1350N

Other documents for this product include:

•

GF-5036 Gas Supply Design Guide

•

GF-5056 Venting & Combustion Air Design Guide

•

GF-5066 Electric Power Design Guide

•

GF-5086 Sizing Guide

This manual applies to serial numbers:

G-19-2230 and above

U.S. Patent No. 9,243,848

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Summary of Contents for Aerco INN 1060N

Page 1: ... use of these materials Heating and Hot Water Solutions AERCO International Inc 100 Oritani Drive Blauvelt NY 10913 USA T 845 580 8000 Toll Free 800 526 0288 AERCO com Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST 2019 AERCO Innovation Water Heaters With Edge i Controller Installation Operation and Maintenance Manual OMM 0143_A GF 216 9 6 2019 Applies to models INN 600N INN 800N INN 1060N I...

Page 2: ...ESSURE TEMPERATURE RELIEF VALVE INSTALLATION 22 2 9 CONDENSATE DRAIN PIPING 22 2 10 GAS SUPPLY PIPING 24 2 10 1 Gas Supply Specifications 24 2 10 2 Manual Gas Shutoff Valve 25 2 10 3 External Gas Supply Regulator 25 2 11 AC ELECTRICAL POWER WIRING 26 2 11 1 Electrical Power Requirements 27 2 12 FIELD CONTROL WIRING 28 2 12 1 OUTDOOR AIR IN Terminal 29 2 12 2 COMBUSTION AIR Terminals 29 2 12 3 O2 S...

Page 3: ... the Analyzer Probe Port 57 4 2 4 Connecting Multimeter to Flame Detector 57 4 2 5 Recommendations for Temperature Calibration 58 4 2 6 Recommendations for WHM Operation 58 4 3 COMBUSTION CALIBRATION 59 4 4 REASSEMBLY 63 4 5 TEMPERATURE CONTROL CALIBRATION 63 4 5 1 Setting the Outlet Water Temperature Setpoint 64 4 5 2 Minimum Load Adjustment 65 4 5 3 Maximum Load Adjustment 65 4 6 OVER TEMPERATUR...

Page 4: ...IT BACK IN SERVICE AFTER A PROLONGED SHUTDOWN 94 6 14 SPARK MONITOR AC CURRENT TRANSDUCER 95 CHAPTER 7 TROUBLESHOOTING GUIDE 97 7 1 INTRODUCTION 97 7 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 109 CHAPTER 8 WATER HEATER MANAGEMENT 111 8 1 GENERAL DESCRIPTION 111 8 2 WHM PRINCIPLES OF OPERATION 112 8 3 NEW AERCO WHM FEATURES 112 8 3 1 Valve Feedback 112 8 3 2 Valve Supervisor 112 8 3 3 Val...

Page 5: ...ve Description 132 8 10 2 Sequencing Valve Operating Characteristics 134 APPENDIX A Startup Status and Fault Messages 135 APPENDIX B Temperature Sensor Resistance Voltage Chart 136 APPENDIX D Dimensional Drawings 137 APPENDIX E Parts List Drawings 139 APPENDIX F Piping Drawings 151 APPENDIX G Edge i Controller Views 161 APPENDIX H Wiring Diagrams 163 APPENDIX I Recommended Spares 167 ...

Page 6: ...Innovation Edge i Installation Operation Maintenance Manual CONTENTS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 6 of 170 This Page Is Intentionally Blank ...

Page 7: ...th or without Sequencing Valves 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 1 South Coast Air Quality Management District SCAQMD Rule 1146 2 2 Texas Commission on Environmental Quality TCEQ Title 30 Chapter 117 Rule 117 465 Whether used in singular or modular arr...

Page 8: ...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 Edge Controller A control system developed by AERCO and used in all Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide COMM Comm Communication Cal Calibration CNTL Control CPU Central Processing ...

Page 9: ...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 AERCO s on line remote system monitoring system PCB Printed Circuit Board PMC Board Primary Micro Controller PMC ...

Page 10: ...hrow a type of switch SSD Client to Client 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 communication Tip N Tell A device that indicates if a package was tipped d...

Page 11: ...nwealth 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 do n...

Page 12: ...g 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 Figure 1 2 Manual Gas Shutoff Valve 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the initial startup procedures in Chapter 4...

Page 13: ...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 horizontally vented gas fueled equipment is installed ...

Page 14: ... 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 special venting systems the following requ...

Page 15: ...work 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 s enclosure when cutting away packaging materials After unpacking closely inspect the unit to make sure there is no evidence of damage ...

Page 16: ...e The minimum clearance dimensions required by AERCO are listed below However if Local Building Codes require additional clearances these codes shall supersede AERCO s requirements Minimum acceptable clearances required are as follows Sides 24 inches 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...

Page 17: ...on Two lifting lugs are provided with the unit and are wire tied to the top of the heat exchanger The top sheet metal cover of the unit must first be removed and the lifting lugs must be installed as shown in Figure 2 4 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 shippi...

Page 18: ...t to building piping first make sure the threads are thoroughly clean AERCO recommends using Teflon tape followed by RectorSeal T 2 when plumbing the inlet and outlet water connections IMPORTANT If the Innovation Water Heater is equipped for use with the Edge Controller s Water Heater Management WHM system then an actuator controlled ball valve will be included with the shipment Refer to Section 2...

Page 19: ...d proceed as follows WHM BALL VALVE INSTALLATION Instructions 3 Remove the ball valve from its stowed location within the shipping container 4 Attached the valve to the cold water inlet of the unit using the pipe union and nipple provided 5 Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 2 5 1 6 AERCO recommends that another pipe nipple and union be atta...

Page 20: ... heat exchanger dome which protrudes through a hole in the center of the top enclosure panel Remove this hex nut 2 Fasten the Automatic Float Vent P N 99285 to top of the Service Check valve P N 99268 as shown below Leave the red and black plastic caps in place on the Automatic Float Vent 3 Install the Service Check valve and Automatic Float Vent in place of the hex nut removed instep 1 Figure 2 5...

Page 21: ...to 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 to the unit Temperature sensors located in the hot water outlet and cold water inlet provide temperature data to the Edge Controller The Controller utilizes this data to modulate the fire rate Air Fuel Valve position to prec...

Page 22: ...ater Heater is designed to condense water vapor from the flue products Therefore the installation must have provisions for suitable condensate drainage or collection The condensate drain port is located on the exhaust manifold at the rear of the unit Figure 2 9 1 This drain port must be connected to the Condensate Trap P N 99259 which is packed within the unit s shipping container PARTIAL REAR VIE...

Page 23: ... trap outlet Use PVC stainless steel aluminum or polypropylene for condensate drain piping DO NOT USE carbon or copper components 5 Route the hose from the trap outlet to a nearby floor drain and secure it with a hose clamp Figure 2 9 2 Sample Condensate Trap Installation Left Side View NOTE As a general guideline AERCO recommends use of its Condensate Neutralizer Kit to raise the pH level of the ...

Page 24: ...on 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 fittings Piping must be supported from the floor ceiling or walls only and must not be supported by the unit A suitable piping compound approved for use with natural gas should be used Any excess must be wiped off to prevent clogging o...

Page 25: ...3 180 000 BTU Hr 58 61 kW to 932 0 kW of natural gas while maintaining a gas pressure of 8 0 W C 1 99 kPa minimum to the unit A lock up style regulator is required when gas supply pressure exceeds 14 W C 3 49 kPa 2 10 3 1 Massachusetts Installations Only For Massachusetts installations a mandatory external gas supply regulator must be positioned as shown in Figure 2 10 3 2 below The gas supply reg...

Page 26: ... Power Box on the front of the unit Remove the front door of the unit to access the Power Box mounted directly above the Edge Controller Loosen the four Power Box cover screws and remove the cover to access the AC terminal connections inside the Power Box POWER BOX LOCATION POWER BOX WITH COVER REMOVED Figure 2 11 1 Power Box Location Partial Front View Front Panel Removed The Power Box contains t...

Page 27: ... or another unit Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE HEATER A double pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enclosures of the unit After placing the unit in servic...

Page 28: ... in Figure 2 12 2 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 12 1 Input Output I O Box Location Partial Front View Refer to the wiring diagram provided on the cover of the I O Box Figure 2 12 2 when making all wiring connections Since identical I O Boxes are used ...

Page 29: ...IN Terminal The OUTDOOR AIR IN and AIR SENSOR COMMON terminals are not applicable to this unit 2 12 2 COMBUSTION AIR Terminals The COMBUSTION AIR and AIR SENSOR COMMON terminals are not applicable to this unit 2 12 3 O2 SENSOR Terminals The O2 SENSOR and O2 SENSOR terminals are not currently used in this unit 2 12 4 SPARK SIGNAL Terminals The SPARK SIGNAL terminals connect to the spark monitor P N...

Page 30: ...e signal they are linearly mapped to a 40 F 4 44 C to 240 F 115 6 C setpoint or a 0 to 100 air fuel valve position No scaling for 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 p...

Page 31: ...ssories These interlocks are called the Remote Interlock and Delayed Interlock REMOTE INTL K IN and DELAYED INTL K IN in Figure 2 12 2 Both interlocks described below are factory wired in the closed position NOTE Both the Remote Interlock and Delayed Interlock must be in the closed position for the unit to fire 2 12 12 1 REMOTE INTL K Terminals The remote interlock circuit is provided to remotely ...

Page 32: ...G 0090 GF 5056 must be consulted before any flue or combustion air venting is designed or installed Suitable U L approved positive pressure watertight vent materials MUST be used for safety and UL certification Because the unit is capable of discharging low temperature exhaust gases the flue must be pitched back towards the unit a minimum of 1 4 per foot 21 mm per m to avoid any condensate pooling...

Page 33: ...t 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 compounds plastic processing and refrigerants Whenever the environment contains these types of chemicals combustion air MUST be supplied from a clean area outdoors fo...

Page 34: ... AERCO Innovation Water Heater is UL listed for 100 ducted combustion air For ducted combustion air installations the 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 considered when calculating the total maximum allowable venting run When using the heater in a ducted combustion air c...

Page 35: ...to start the unit WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 110 OR 220 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 PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY 3 2 EDGE CONTROLLER DESC...

Page 36: ... and then down as in reading a book Edit This button allows the editing of the parameter that is currently selected through use of up down arrows 1 Multi Function Bar shows either Fire Rate Valve Position 2 Parameter Indicator for both temperature read outs LEFT Inlet temperature or Setpoint temperature RIGHT Outlet temperature or System Header temperature 3 Temperature scale indicator Fahrenheit ...

Page 37: ...akes you to the touchscreen s Main Menu see Figure 3 3 If pressed during a procedure it aborts the procedure Left Right The LEFT arrow moves to previous point in the array or list and RIGHT arrow moves to next point in the array or list Up Down The UP arrow increases a value DOWN decreases value Page Left Page Right The arrows on left and right edges of the touchscreen scroll Page Left or Page Rig...

Page 38: ...nstructions below to log in to the Edge Controller LOGGING IN Instructions 1 Go to the Main Menu press Advanced Setup then press the Access button The Enter Password screen appears Figure 3 2 2 Enter Password Screen 2 Use the number keypad to enter the password each number appears as a X then press Save 3 You are now directed to the Main Menu see Figure 3 3 or returned to the last screen opened be...

Page 39: ...etpoint Read Only The unit s current Setpoint Outlet Read Only The current Outlet temperature Exhaust Read Only The current Exhaust temperature Main Menu WHM Cascade Status Avg Fire Rate Read Only The average Fire Rate 0 to 100 Units Online Read Only The number of units in the WHM cascade online Setpoint Read Only The WHM cascade s current Setpoint Units Available Read Only The number of units in ...

Page 40: ... speed for current Valve Position Blower Speed Reading Read Only Actual blower speed for current Valve Position Air Temperature Reading Read Only The current air temperature Downstream Gas pressure Numeric Entry Appears only when fire rate 100 Blower Voltage Adjust Adjust as needed to match targets to actual readings 3 3 2 1 Main Menu Calibration Input Output Main Menu Calibration Input Output Tem...

Page 41: ...e Enables disables running in Manual Mode Fire Rate Adjust Manual fire rate adjustment 0 to 100 O2 Read Only The percentage of O2 in the unit s exhaust Flame Strength Read Only The flame strength sensed in the burner 0 to 100 3 3 3 2 Main Menu Diagnostics Front Panel Main Menu Diagnostics Front Panel Touchscreen Display Test On Off Starts the Touchscreen Display Test Touchscreen Test On Off Starts...

Page 42: ...osition Blower voltage Read Only The current Blower voltage Blower RPM Read Only The current Blower RPM Spark Current Read Only The current Spark Current Main Menu Diagnostics System Versions Serial Number Read Only The unit s serial number Software Version Read Only The Controller s software version Graphic Data Version Read Only The Controller s graphic version Display Version Read Only The Cont...

Page 43: ...artbeat Enable Initiates test of the onAER heartbeat Main Menu Diagnostics Comm Network USB Storage Status Read Only Status of the USB device Serial Number Read Only The serial number of the USB device Size Read Only The size of the USB device Available Space Read Only The amount of free space on the USB device 3 3 3 7 Main Menu Diagnostics Input Output Summary Main Menu Diagnostics Input Output S...

Page 44: ...The amount of time internal recirculation pump is disabled during unit standby Pump is continually cycled during standby Post Fire Pump Time Numeric Entry The amount of time internal recirculation pump runs after unit has entered standby mode Beeper Toggle Enables disables the audible fault alarm Run Cycles Numeric Entry Displays number of run cycles since last system reset Can be reset to 0 or an...

Page 45: ...es the unit s Modbus address Operating Mode Remote Setpoint Remote Signal Network Cascade Baud Rate Numeric Entry Specifies Modbus baud rate Operating Mode Remote Setpoint Remote Signal Network Main Menu Advanced Setup Unit Maintenance 12 Month Maintenance Complete Yes No Specifies 12 Month Maintenance completed Fire Side Inspection Yes No Specifies Fire Side Inspection completed Optical Burner In...

Page 46: ...ckup Client unit to turn on 15 300 WHM Unit Mode WHM Manager Main Menu Advanced Setup WHM Cascade WHM Application Configuration Application Read Only The WHM Cascade s application DHW Operating Mode Read Only The WHM Cascade s operating mode Constant Setpoint WHM Setpoint Numeric Entry The WHM Cascade s Setpoint Operating Mode Constant Setpoint Main Menu Advanced Setup WHM Cascade Operating Contro...

Page 47: ...unit 0 to 127 Lead Lag Setting Select Lead Lag Lag Unit Numeric Entry Specify the address of the Lag unit 0 to 127 Lead Lag Setting Select Lead Lag 3 3 4 3 Main Menu Advanced Setup Com Network Main Menu Advanced Setup Comm Network BAS BAS Select To enable communication with a BAS select Off or Modbus TCP Communication Address Numeric Entry Specify the network address of the Edge Controller on the ...

Page 48: ...etup Performance Temperature Control Main Menu Advanced Setup Performance Temperature Control PID Setting Proportional Band Numeric Entry Generates a fire rate based on the error that exists between the setpoint and the actual outlet temperature If the error is less than Proportional Band fire rate will be less than 100 If the error is equal to or greater than proportional band the fire rate will ...

Page 49: ...chart at maximum flow 50 50 F Outlet Feedback Yes No Enables Outlet Feedback functionality Feedback Gain Numeric Entry The percentage of feedback from the water outlet sensor the algorithm factors to determine fire rate 0 01 1 00 Fdback Start Pos Numeric Entry The Feedback start position 0 100 Fdback End Pos Numeric Entry The Feedback end position 0 100 Max Feedback Numeric Entry Specifies the max...

Page 50: ...en 2 00 and 0 volts on individually vented units in positive pressure mechanical rooms to compensate 0 0 to 10 0V Air Compensation Enable Disabled Innovation Only Vlv Position Change Rate Numeric Entry Defines the rate at which the valve position will progress from one step to the next 0 5 to 60 sec Skip Range Cntr Numeric Entry Together these 3 parameters define an optional Fire Rate the Controll...

Page 51: ...ill light and the unit will be in the Standby mode When there is a demand for hot water the following events will occur NOTE If any of the Pre Purge safety device switches are open the appropriate fault message will be displayed Also if the required conditions are not observed at any point during the start sequence appropriate messages will be displayed and the unit will go into fault mode START S...

Page 52: ...icate the elapsed time of the purge cycle in seconds Figure 3 4 3 Blower Proof Switch 5 Upon completion of the purge cycle the Edge Controller 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 will read between 25 and 35 Figure 3 4 4 to indicate that the valve is in...

Page 53: ... 7 After 2 seconds of continuous flame FLAME PROVEN will be displayed and the flame strength will be indicated After 5 seconds the current date and time will be displayed in place of the flame strength 8 With the unit firing properly it will be controlled by the temperature controller circuitry The heater s VALVE POSITION will be continuously displayed on the front panel bar graph Once the demand ...

Page 54: ...ween the energy input and Air Fuel Valve position for units running on natural gas TABLE 3 5 Relationship Between Air Fuel Valve Position and Energy Input Valve Position INN 600N INN 800N INN 1060N INN 1350N BTU Hr kWh BTU Hr kWh BTU Hr kWh BTU Hr kWh 20 50 000 14 65 50 000 14 65 50 000 14 65 50 000 14 65 30 93 000 27 26 99 000 29 01 108 000 31 65 124 000 36 34 40 161 000 47 18 210 000 61 54 222 0...

Page 55: ...nit safely and at a high thermal efficiency with low flue 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 ...

Page 56: ...ange and it is then installed on the downstream side of the SSOV to measure gas pressure during the combustion calibration process INSTALLING GAS SUPPLY MANOMETER Instructions 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 detecti...

Page 57: ...yzer Probe Port The unit contains a 1 8 NPT port at the rear of the exhaust manifold This port is located above the condensate drain connection as shown in Figure 4 2 3 Prepare the port for the combustion analyzer probe as follows ACCESSING ANALYZER PROBE PORT Instructions 1 Refer to Figure 4 2 3 and remove the 1 8 NPT plug from the rear of the exhaust manifold 2 If necessary adjust the stop on th...

Page 58: ...he unit Ignoring this commissioning step may cause water temperature faults poor water temperature control and rapid cycling of the unit 4 2 6 Recommendations for WHM Operation Installations with multiple Innovation units must operate in Water Heater Management WHM mode see Section 2 5 1 for instructions on installing the actuator controlled ball valve Operation in WHM mode ensures that the system...

Page 59: ...Combustion Calibration Instructions 1 Ensure that the Controller s Enable Disable switch is set to Disable 2 Ensure that external AC power to the unit is ON 3 Ensure that the water supply and return valves to the unit are open and that the system pumps are running 4 Open the main manual gas supply shut off valve upstream of the unit 5 On the Controller go to Main Menu Calibration Combustion 6 The ...

Page 60: ...age below PRESET CALIBRATION POINTS METHOD FINE VP STEP METHOD Figure 4 3 3 Combustion Calibration Screens 9 Set the Controller s Enable Disable switch to Enable 10 Change the valve position to 30 press the Go button then verify that the unit has ignited and is operating as expected 11 Use the Right arrow key to change the valve position to 100 then press Go 12 Verify that the gas pressure on the ...

Page 61: ...and enter the value 14 Enter the downstream manometer s gas pressure reading in the Downstream Gas Pressure field Note this field appears only when Valve Position 100 15 Enter the Flame Strength NOx and CO readings from the Combustion Analyzer and multi meter in the Reading cells 16 Enter the same values plus the O2 value on the Combustion Calibration Data Sheet provided with the unit 17 Compare t...

Page 62: ...ions in Table 4 3 2 TABLE 4 3 2 Combustion Calibration Readings All Models Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO Flame µA 100 6 0 0 2 20 ppm 100 ppm 7 90 6 0 0 2 20 ppm 100 ppm 7 80 6 0 0 2 20 ppm 100 ppm 7 60 6 0 0 2 20 ppm 100 ppm 7 50 6 0 0 2 20 ppm 100 ppm 7 40 6 0 0 2 20 ppm 100 ppm 7 30 6 0 0 2 20 ppm 100 ppm 7 20 5 5 0 2 20 ppm 100 ppm 7 20 If the oxygen level at th...

Page 63: ...obe from the 1 8 3 18 mm vent hole in the exhaust manifold Replace the 1 8 NPT plug in the manifold 6 Replace the unit s side panels and front door 4 5 TEMPERATURE CONTROL CALIBRATION Carefully follow the procedures below to properly set up the temperature control for the unit Ignoring this commissioning step may cause water temperature faults poor water temperature control and rapid cycling of th...

Page 64: ...d Upon completion of calibration set the Outlet Feedback back to ENABLE Temperature control calibration is accomplished by first performing the procedure in Section 4 5 2 Minimum Load Adjustment Once that is complete you can then perform the procedure in Section 4 5 3 Maximum Load Adjustment below 4 5 1 Setting the Outlet Water Temperature Setpoint If the setpoint is already set to the correct val...

Page 65: ...he outlet temperature to stabilize under load conditions 5 Once stabilized the outlet temperature displayed on the Controller should read no more than 2 to 3 F 1 1 to 1 65 C above the unit s setpoint 6 If the outlet temperature is stabilized proceed to Section 4 5 3 Maximum Load Adjustment If the temperature is not stabilized proceed to step 7 7 Raise or lower the Min Load Adj by one or two degree...

Page 66: ...ot maintain setpoint after a reasonable amount of time and adjustment contact your local AERCO representative 10 Set the Outlet Feedback parameter back to Yes 4 6 OVER TEMPERATURE LIMIT SWITCHES The unit contains both Automatic Reset and Manual Reset Over Temperature Limit switches shown in Figure 4 6 They can be accessed by opening the front panel door of the unit The Manual Reset Over Temperatur...

Page 67: ...TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 5 2 LOW GAS PRESSURE FAULT TEST To simulate a low gas pressure fault refer to Figure 5 2 and proceed as follows Low Gas Pressure Fault Test Instructions 1 Refer to Figure 5 2 and ensure that the leak detection ball valve located at the Low Gas Pressure switch is closed 2 Remove the 1 4 plug from the ball valve at the Low Gas Pressure switch 3 Ins...

Page 68: ...ressure using the adjustment screw on the SSOV 7 The unit should shut down and display a High Gas Pressure fault message when the gas pressure exceeds the setting on the high gas pressure switch The FAULT indicator should also start flashing The switch should be set for 1 W C more than the Manifold Pressure Setpoint written on the Manifold Gas Pressure Setting tag For example if the tag states tha...

Page 69: ...r shut off valve in the return piping to the unit 10 Open the water supply shut off valve to the unit to refill 11 After the shell is full press the Low Water Level Reset button to reset the low water cutoff 12 Press the CLEAR button to reset the FAULT LED and clear the displayed error message 13 Set the Enable Disable switch to the Enable position The unit is now ready for operation 5 5 WATER TEM...

Page 70: ...ese 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 Instructions 1 Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals see Figure 2 12 2 2 Put the unit in Manual Mode by going to the Main Menu Diagnostics Manual Run an...

Page 71: ...hese fault conditions proceed as follows Flame Fault Tests Instructions 1 Set the Controller s Enable Disable switch to the Disable position 2 Put the unit in Manual Mode by going to the Main Menu Diagnostics Manual Run and setting the Manual Mode toggle to Enabled then set the valve position between 25 and 30 3 Close the manual gas shutoff valve located between the Safety Shut Off Valve SSOV and ...

Page 72: ...S These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5 8 2 Air Flow Fault Tests Instructions 1 Put the unit in Manual Mode by going to the Main Menu Diagnostics Manual Run and setting the Manual Mode toggle to Enabled then set the valve position to 25 2 Disable the blower output drive voltage as follows a Go to Main Menu Diagnostics Analog Outputs a...

Page 73: ...g steps a Go to Main Menu Diagnostics Analog Outputs and Relays Analog Outputs b Press the Manual button the Blower is now operational again c Press the CLEAR button the unit should restart 6 Once the unit has proved flame turn off the blower again by repeating Step 1 7 The Blower Proof switch will open and the blower should stop The unit should shut down and display Airflow Fault During Run 8 Re ...

Page 74: ...s the Proof Of Closure switch The Proof Of Closure switch circuit is checked as follows SSOV Proof of Closure Switch Instructions 1 Set the Controller s Enable Disable switch to the Disable position 2 Put the unit in Manual Mode by going to the Main Menu Diagnostics Manual Run and setting the Manual Mode toggle to Enabled then set the valve position between 25 and 30 3 Locate the SSOV see Figure 5...

Page 75: ... Purge switch and Ignition switch is located on the Air Fuel Valve To check the switch proceed as follows Purge Switch Open During Purge Instructions 1 Set the Controller s Enable Disable switch to the Disable position 2 Put the unit in Manual Mode by going to the Main Menu Diagnostics Manual Run and setting the Manual Mode toggle to Enabled then set the valve position between 25 and 30 3 Remove t...

Page 76: ... unlock and lift up to remove 4 Remove one of the two wires 169 or 170 from the Ignition switch Figure 5 11 2 5 Initiate a unit start sequence 6 The unit should begin its start sequence and then 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 11 1 Typical Air Fuel Valve Cover Location Figure...

Page 77: ...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 if necessary Replace 15 min 6 3 Flame Detector Kit P N 24356 2 ...

Page 78: ...e any water entering the water heater that contains polyphosphates warrants that the heat exchanger be inspected every 6 months and cleaned as needed Chloride limits are set to prevent corrosion of the heat exchanger The EPA also recommends levels lower than 250 ppm for potable systems Free chlorine is added to systems to protect from harmful microbes Most public water supplies have been treated t...

Page 79: ...the burner plate 6 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present clean the component using fine emery cloth Repeated carbon build up is an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion ...

Page 80: ...iter Injector Flame Detector Mounting Details 9 Torque the ignitor injector to 15 ft lbs Do Not Over Tighten 10 Connect the ignition assembly to the gas injector tube of the igniter injector by securing the compression nut to the elbow of the ignition assembly 11 Reconnect the igniter injector cable and ground wire 12 Reinstall the side and rear panels on the unit GAS INJECTOR TUBE DO NOT POSITION...

Page 81: ...1 and 6 2 The flame detector is secured to the burner intake manifold with one 1 10 32 and one 1 8 32 hex standoff 5 Remove the flame detector and gasket from the manifold flange 6 Thoroughly inspect the flame detector If eroded the detector should be replaced Otherwise clean the detector with a fine emery cloth 7 Reinstall the flame detector and flame detector gasket 8 Reconnect the flame detecto...

Page 82: ...de Inspection Instructions 1 Set the Controller s Enable Disable switch to the Disable position Disconnect AC power from the unit and turn off the gas supply 2 Remove the exhaust vent from the exhaust manifold Use a scraper or blade to separate the high temperature silicon sealant between the exhaust manifold and vent connector and remove all sealant from both surfaces in preparation for reassembl...

Page 83: ...12 Carefully lower and remove the intake manifold burner assembly two burner gaskets 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 7 3 by unscrewing it from the exhaust manifold 14 While supporting the exhaust manifold remove the two 2 side nuts Figure 6 7 3 securing the manifold to the heat exchanger Loos...

Page 84: ...old and Burner Cross Section Exploded PARTIAL RIGHT SIDE VIEW WITH SUPPORT REMOVED Figure 6 7 3 Intake and Exhaust Manifolds BURNER ASSEMBLY INTAKE MANIFOLD EXHAUST MANIFOLD 5 16 18 STUDS 6 SIDE NUTS 2 FRONT NUT 1 EXHAUST SENSOR BURNER ASSEMBLY EXHAUST MANIFOLD BURNER MOUNTING PLATE BURNER FLANGE GASKETS P N GP 18899 INTAKE MANIFOLD FLANGE GASKET P N 81198 BURNER MOUNTING PLATE EXHAUST MANIFOLD TO...

Page 85: ... 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 16 5 Nm 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 ...

Page 86: ...ected by the quality of the inlet water see Section 6 2 Water Quality Guideline but it generally follows the inspection schedule shown in Table 6 2 If the inlet water contains orthophosphates the unit must be inspected every 6 months and cleaned as needed TABLE 6 8 Required Heat Exchanger Inspection and Cleaning Schedule Operating Conditions Inspection Cleaning Frequency 24 months 12 months 6 mont...

Page 87: ... to enter the chamber then open the lower drain valve and allow all water to drain from the shell 4 Remove the lower 2 NPT plug a little additional water may flow from the port 5 Use a boroscope or a camera and flashlight to inspect and take photos of the visible tubes and tubesheet area 6 If sediment and deposits exist on the lower tubesheet and or there is a buildup of scale deposits follow inst...

Page 88: ...ns A sample pumping set up diagram is shown in Figure 6 8 3 1 The heat exchanger is cleaned by pumping the cleaning 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 unit Set up the pumping system as follows Set Up Instructions Instructions 1 Turn off the water heater 2 Close the hot water outlet ...

Page 89: ...s flowing from the circulation bucket through the pump and the unit and back to the top of the top of the bucket 5 Return discharge foaming indicates an active cleaning solution and the presence of mineral deposits in the equipment 6 Additional cleaning solution and or water may be required to maintain circulation and to prevent the pump from cavitating 7 Circulate the cleaning solution through th...

Page 90: ...um carbonate Foaming and bubbling indicates the solution is still active Little or no reaction indicates that the solution is expended This test should be performed near the end of the circulating time If the solution has been expended more cleaning solution 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 Chartin...

Page 91: ...a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the inlet flange of the air fuel valve Remove the filter and clamp 5 Each replacement air filter is equipped with its own clamp Therefore simply install the replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat tip screwdriver or 5 16 nut driver 6 Replace the side panels on th...

Page 92: ...the Edge Controller The LWCO probe is located on the front of the heat exchanger body near the top Figure 6 11 shows its location and components Figure 6 11 LWCO Probe Location INN 1350 Shown 6 11 1 Low Water Cutoff LWCO Capacitor Electrical Short Test This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger Perform the capacitor electrical short test ...

Page 93: ...rness Connector removed from the Edge Controller as shown on right in Figure 6 11 1 2 Figure 6 11 1 2 Connecting Ohmmeter LWCO Probe Shell Harness Cable 5 Confirm that the ohmmeter does NOT read a short NOTE If the ohmmeter reads a short the capacitor assembly needs to be replaced Refer to document TID 0094 provided with the 24 month maintenance kit for LWCO replacement instructions 6 Remove both ...

Page 94: ... 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 Open the drain valve and drain all water from the unit 7 If the temperature in the storage location will ever get below freezing for even a short time you must drain all water from the unit before the temper...

Page 95: ...ted to the ignition transformer It passes through the spark monitor s orifice If an adequate AC current is not detected in the wire during ignition the unit automatically shuts down Figure 6 14 2 Spark Detector Sensor Wiring If the spark monitor needs to be replaced open the monitor s orifice by pulling on the tab at the side remove Wire 140 disconnect the monitor s wires are from the I O board re...

Page 96: ...vation Edge i Installation Operation Maintenance Manual CHAPTER 6 MAINTENANCE OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 96 of 170 This Page Is Intentionally Blank ...

Page 97: ...rect the fault General Troubleshooting Instructions 1 Observe the fault messages displayed in the Edge Controller 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 checks and pro...

Page 98: ...n Edge i Installation Operation Maintenance Manual CHAPTER 7 TROUBLESHOOTING GUIDE OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 98 of 170 This Page Is Intentionally Blank ...

Page 99: ...ading is greater than zero ohms replace the switch 6 Defective Blocked Air Inlet switch 6 Measure the Blocked Air Inlet 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 7 Loose temperature to AUX connection in I O Box 7 Check the actual inlet air temperature and measure voltage ...

Page 100: ... ground If 24 VAC is not present refer to qualified service personnel 6 PROBABLE CAUSES from AIRFLOW FAULT DURING IGNITION above items 3 to 12 applies to this fault 6 See CORRECTIVE ACTIONS from AIRFLOW FAULT DURING IGNITION above items 3 to 12 AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 1 Check combustion blower for signs of excessive heat or high current ...

Page 101: ...install retighten Burner Ground Screw 2 Worn flame detector 2 Remove and inspect the flame detector for signs of wear Replace if necessary 3 No spark from Spark Plug 3 Close the internal gas valve in the unit Install and arc a spark igniter injector outside the unit 4 Defective Ignition Transformer 4 If there is no spark check for 120 VAC at the primary side to the ignition transformer during the ...

Page 102: ...AT DEMAND FAILURE 1 The Heat Demand Relays on the Ignition Stepper board failed to activate when commanded 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Relay is activated when not in Demand 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Poor combustion calibration 1 Check combustion calibration using procedures in Chapter 4 ...

Page 103: ...han the unit s setpoint 6 System flow rate changes are occurring faster than units can respond 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 1 See HIGH WATER TEMPERATURE SWITCH OPEN 2 Temp HI Limit setting is too low 2 Check...

Page 104: ...ignition position check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Edge Controller Refer fault to qualified service personnel 2 Defective Ignition switch 2 If the Air Fuel Valve does rotate to the ignition position check the ignition position switch for continuity between the N O and COM terminals when in contact with the cam 3 Defective P...

Page 105: ...evel circuitry 1 Check system for sufficient water level 2 Test water level circuitry using the Edge Controller front panel LOW WATER TEST and RESET buttons Replace water level circuitry if it does not respond 3 Defective water level probe 3 Check continuity of probe end to the shell change probe if there is no continuity MODBUS COMM FAULT Unit not seeing information from Modbus network Check netw...

Page 106: ...ive Power Supply Board or fuse 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Defective IGST 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 1 Inspect Outdoor Temperature sensor for loose or broken wiring 2 Defective Sensor 2 Check resistance...

Page 107: ...e actuator SSOV RELAY FAILURE 1 SSOV relay failed on IGST board 1 Press CLEAR button and restart unit If fault persists replace Ignition Stepper IGST Board 2 Floating Neutral 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 than a few millivolts 3 Hot and Neutral reversed at SSOV...

Page 108: ...e Stepper Feedback Calibration GF 112 section 6 2 1 2 Air Fuel Valve unplugged 2 Check that the Air Fuel Valve is connected to the Edge Controller 3 Loose wiring connection to the 3 Inspect for loose connections between the Air Fuel Valve 4 stepper motor 4 motor and the wiring harness 5 Defective Air Fuel Valve stepper motor 5 Replace stepper motor 6 Defective Power Supply Board or fuse 6 Check DS...

Page 109: ...AYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Fluctuating Gas Pressure 1 Gas pressure going into unit is fluctuating 1 Stabilize gas pressure going into unit If necessary troubleshoot Building Supply Regulator Air Fuel Valve hunting at the 80 Valve Position 1 IGST and Power Supply Boards in Edge Controller are outdated 1 Check to ensure that the IGST and Power Supply Boards are Rev E or...

Page 110: ...fold 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 IGNITION SOLENOID SSOV ACTUATOR COVER ACTUATOR COVER SCREW BRASS HEX HEAD CAP Remove to access gas pressure adjustment screw OPEN CLOSED INDICATOR WINDOW Figure 7 2 3 SSOV Actuator with Gas Pressu...

Page 111: ...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 in the WHM network see Figure 8 1 8 1 GENERAL DESCRIPTION The Edge Controller s Water Heater Management System WHM is designed to ensure that all water he...

Page 112: ...attempts to balance the system so that all units operate for approximately the same number of hours 8 3 NEW AERCO WHM FEATURES The following sections describe new Water heater Management 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 Edge Controller The Valve Feed...

Page 113: ...he Temperature Sensors screens allows you calibrate the unit s temperature sensors to achieve optimal performance Complete the following to calibrate the temperature sensors Figure 8 3 5 Temperature Sensors Screen Temperature Sensor Calibration Instructions 1 Go to Main Menu Calibration Input Output Temperature Sensors 2 Press the Sensor parameter and select the temperature sensor you want to cali...

Page 114: ...un cycles Once a user hits enter the changes made will be permanent and this feature will not allow changing to the previous value Only AERCO personnel are permitted to change this menu item To increase the Run Hours or Run Cycles go to Main Menu Advanced Setup Unit Unit Settings 8 3 9 High Temperature Governor The High Temperature Governor is a feature that aggressively prevents the outlet temper...

Page 115: ... Client has been disabled and is not available CLIENT STANDBY The Client is Cycled Off and is available to be lit off CLIENT IGNITED The Client is ignited 8 5 WATER HEATER MANAGEMENT ALTERNATING STATUS DISPLAYS Manager Client Status Displays On both WHM Manager and Client units the following status information will alternate and be displayed on the WHM Cascade Status screen Figure 8 5 WHM Cascade ...

Page 116: ... Manager Off This menu option enables disables the WHM mode and sets the unit to function as a WHM Client or WHM Manager Set the WHM Unit Mode option to WHM Manager for the unit designated as the WHM Manager and to WHM Client for all other units on the network Auto Manager Transfer Enable Disable Disable This item enables Password Level 2 required an Automatic WHM Manager Switch Over function When...

Page 117: ...e number of Modbus Comm errors allowed before invoking a Modbus Comm Fault Comm Error 1 8 0 9 0 WHM Manager only Displays the number of comm errors on Clients 1 8 Comm Error 9 16 0 9 0 WHM Manager only Displays the number of comm errors on Clients 9 16 SSD Address 0 250 0 WHM Manager only The Client Client Device address for backwards compatibility SSD Temp Format Degrees or Points Degrees WHM Man...

Page 118: ...time the WHM Manager must wait for a Client unit to turn on WHM MANAGER SCREEN Figure 8 6 2 Cascade Communication Screens TABLE 8 6c WHM Cascade Application Configuration Parameters Menu Item Display Available Choices or Limits Default Minimum Maximum Application Read Only DHW Specifies the application for the entire WHM Cascade Operating Mode Read Only Constant Setpoint Specifies the operating mo...

Page 119: ...e Sensor is mounted in the individual unit and drastically increases the response time to precisely control temperature Low Flow Threshold 10 35 25 For low flow applications this parameter allows the unit to operate without excessive cycling This parameter specifies the valve position below which the unit plant will enter this mode Next On Valve Pos 16 100 50 Determines the valve position that tri...

Page 120: ...wn is enabled on a unit if the unit is run at a fire rate above Off Delay Threshold and then shuts down the fire rate will be reduced to the Stop Level for a period of time defined in Off Delay This feature prevents units running at high fire rates from being quickly turned off and flushed with cold water thereby possibly damaging the heat exchanger Off Delay 0 9999 60 sec Specifies the amount of ...

Page 121: ...Default Minimum Maximum Select Output Standard Setup Read Only Select the output you want to configure Output Signal Type Current or Voltage Voltage Select the output signal type of the selected output Control Mode On Off Read Only Select the Control Mode for the selected output Standard Setup Valve Feedback Enabled Disabled Enabled Allows Valve Feedback functionality to be enabled Valve Feedback ...

Page 122: ...g units will be selected Run Hours 25 225 72 Specify the number of hours after which the Lead unit is rotated Lead Unit 0 16 0 Specify the address of the Lead unit Lag Unit 0 16 16 Specify the address of the Lag unit Figure 8 6 7 Operating Controls Lead Lag Control Screen 8 7 WHM HARDWARE INSTALLATION SET UP INSTRUCTIONS The following sections provide the basic installation and set up instructions...

Page 123: ...per e Once the installation is working properly as a WHM system install the ProtoNode Device f Make sure that the Modbus load and bias resistors are properly configured for the system to operate with the ProtoNode installed g Set the WHM system for desired mode of operation Setpoint mode h Test the system completely with the ProtoNode installed 8 7 2 Hardware Installation All Innovation Water Heat...

Page 124: ...l Modbus networks are wired in a daisy chain configuration using a Manager Client scenario as shown in Figure 8 7 3 Figure 8 7 3 Typical Daisy Chain Modbus RS485 Network NOTE The WHMS Manager does not necessarily have to be on either end of the Daisy Chain loop Any one of the Edge WHM units included in the Modbus network can be the Manager However it is recommended that you decide which unit will ...

Page 125: ... necessarily Manager activate the DIP switch labeled MODBUS TERM by placing it in the up position This will connect a termination resistor across the terminals at the source end 3 Refer to Figure 8 7 4 and run the shielded cable to the next unit in the daisy chain and connect the and wire leads to to DO NOT terminate the shield of the RS485 Comm leads to the SHIELD terminal at the Client Instead c...

Page 126: ...on Operation Maintenance Manual CHAPTER 8 WATER HEATER MANAGEMENT OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 126 of 170 Figure 8 7 4 1 WHM Network Wiring Diagram Reference SD A 1192 rev A ...

Page 127: ...on Operation Maintenance Manual CHAPTER 8 WATER HEATER MANAGEMENT OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 127 of 170 Figure 8 7 4 2 WHM Network Wiring Diagram Reference SD A 1190 rev A ...

Page 128: ...on Operation Maintenance Manual CHAPTER 8 WATER HEATER MANAGEMENT OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 128 of 170 Figure 8 7 4 3 WHM Network Wiring Diagram Reference SD A 1191 rev A ...

Page 129: ...Unit Mode to WHM Manager b You have the option of designating one of the units in the WHM Cascade as a Backup Manager If the WHM Manager fails manager functionality will automatically transfer to the designated Backup Manager To use this functionality enable the Auto Manager Transfer parameter then specify the address of the Backup Manager in the Backup Manager Addr parameter You can also enter a ...

Page 130: ...configure the Setpoint Limit Band parameter which allows you to set the number of degrees below Setpoint High Limit the unit s outlet temperature must fall before the unit restarts c Configure the Setback Start Time and Setback End Time which together define when the Setback period will be in effect 7 If you want to change the Lead Lag Hours go to Main Menu Advanced Setup WHM Cascade Operating Con...

Page 131: ...S485 Modbus wiring 2 Improper Comm address 3 Unit Comm address is not unique 1 Check the polarity of the RS485 Comm connections on the I O board of the affected unit Also ensure that all Modbus wiring connections to the unit are secure 2 Verify that the address of the affected unit is within the allowable range 1 thru 16 3 Check to ensure that none of the units have the same Comm address Actuator ...

Page 132: ...Description The Actuator Controlled Sequencing Valve shown in Figure 8 10 1 1 is comprised of the following main components 2 Brass Ball Valve Actuator Linkage Actuator Housing Valve Shaft Handle Figure 8 10 1 1 Actuator Controlled Sequencing 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 ...

Page 133: ... 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 Instructions 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 button show...

Page 134: ...e Innovation Water Heater The 24 VAC power output and a 2 to 10 VDC 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 2 VDC will rotate the valve to the fully open 90 position Conversely a control signal above 8 VDC will rotate the valve to the fully closed 0 pos...

Page 135: ...S OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 135 of 170 APPENDIX A Startup Status and Fault Messages All Startup Status and Fault messages are included in Section 8 of the Edge i Controller Manual for Benchmark Boilers and Innovation Water Heaters OMM 0141 GF 213 ...

Page 136: ...00 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 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 1391 0 1418 2 14...

Page 137: ...lation Operation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 137 of 170 APPENDIX D Dimensional Drawings Drawing Number AP A 1053 rev A ...

Page 138: ...on Edge i Installation Operation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 138 of 170 Drawing Number AP A 1054 rev A ...

Page 139: ...MIC LOAD ANTICIPATOR ASSY 5 1 34061 BASE FORMED 26 X 40 2 1 80090 SHELL INSULATION Ø16 00 INNOVATION 6 1 92060 VALVE 3 4 DRAIN 3 1 24648 1 AIR FUEL DELIVERY COMPONENTS INN 600N 7 1 44085 1 6 EXHAUST MANIFOLD INNOVATION 1 24648 2 AIR FUEL DELIVERY COMPONENTS INN 800N 8 1 93410 COUPLING 1 8 NPT 304 SST 150PSI 1 24648 3 AIR FUEL DELIVERY COMPONENTS INN 1060N 9 1 93357 PLUG 1 8 NPT HEX PIPE 304 STAINL...

Page 140: ... 1060N 1350N Parts List Page 2 Item Qty Part Description Item Qty Part Description 1 1 65175 THERMOSTAT JUMO 6 1 22332 GAS TRAIN FM SSOV INN 600 800N 2 1 122843 LOW WATER CUTOFF 1 22353 GAS TRAIN 1 SSOV INN 1060N FM 3 1 80106 INSULATION WRAP 16 DIAMETER SHELL 1 22363 GAS TRAIN 1 SSOV INN 1350N FM 4 1 55033 U BOLT 1 1 2 7 1 59138 FILTER AIR 6 5 2 PLUG 8 1 24234 6 EXHAUST MANIFOLD INNOVATION 3 6 1 8...

Page 141: ...3_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 141 of 170 Innovation 600N 800N 1060N 1350N Parts List Page 3 Item Qty Part Description Item Qty Part Description 1 1 25074 ENCLOSURE FRAME ASSY 3 1 37095 FRONT PANEL 2 5 59133 LATCH COMPRESSION 4 1 37098 TOP PANEL 1 2 3 4 ...

Page 142: ...ion 600N 800N 1060N 1350N Parts List Page 4 Item Qty Part Description Item Qty Part Description 1 1 44106 INTAKE MANIFOLD 5 2 GP 18899 BURNER FLANGE GASKET 2 1 44085 1 EXHAUST MANIFOLD 6 1 122537 EXHAUST MANIFOLD TO COMBUSTION CHAMBER GASKET 3 123449 TEMPERATURE SENSOR 4 1 24233 2 BURNER ASSEMBLY 7 2 92060 DRAIN VALVE 3 4 4 3 1 2 5 6 7 INTAKE MANIFOLD BURNER EXHAUST MANIFOLD CROSS SECTION VIEW ...

Page 143: ...ption Item Qty Part Description 1 1 37101 REAR PANEL UPPER RIGHT 8 1 37097 PANEL LEFT REAR 2 2 37099 PANEL SIDE 9 1 80107 INLET INSULATION 3 1 37102 ACCESS PANEL RIGHT REAR 10 1 80109 INLET INSULATION 4 1 37104 RIGHT SIDE ZERO CLEARANCE PANEL 11 1 80118 INLET INSULATION not shown 5 1 37103 LOWER PANEL RIGHT REAR 12 1 80108 INLET INSULATION not shown 6 1 37063 PANEL REAR 13 2 92060 DRAIN VALVE 3 4 ...

Page 144: ...on Item Qty Part Description 1 1 64163 POWER BOX 120 220 VAC INNOVATION 4 1 69245 I O BOX WITH ONAER SEQ VALVE CABLES 2 1 30090 PANEL ELECTRICAL 5 1 72082 POWER BOX LABEL 3 1 64134 CONTROL BOX EDGE V1 ACCESSORIES 92123 2 DOMESTIC WATER MOTORIZED SEQUENCING BALL VALVE 1 93100 UNION 2 NPT 304 STAINLESS 1 90046 3 NIPPLE 2 NPT 304 SS 69126 LWCO CAPACITOR ASSEMBLY KIT 1 122843 LOW WATER CUT OFF 1 63070...

Page 145: ...LL VALVE CLOSED 6 1 92006 4 VALVE FULL PORT BAL 3 4 NPT 23 2 9 22 PIPE PLUG 1 4 NPT STEEL 9 1 92101 VALVE SSOV NPT 25 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 12 1 5018 1 1 2 NPT MALE FEMALE UNION 28 1 99017 SNUBBER PRESSURE 1 4 14 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 29 1 60032 SWITCH GAS PRESSURE 2 20 W C 15 1 69005 ACTUATOR SSOV W REGULATOR 33 1 97087 12 TUBE FLEXIBLE 12 19 2 12951 2 BUSHING ...

Page 146: ... BALL VALVE CLOSED 6 1 92006 5 VALVE BALL 1 NPT 23 2 9 22 PIPE PLUG 1 4 NPT STEEL 9 1 92036 VALVE SSOV 1 NPT 25 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 12 1 5018 1 1 2 NPT MALE FEMALE UNION 28 1 99017 SNUBBER PRESSURE 1 4 14 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 29 1 60032 SWITCH GAS PRESSURE 2 20 W C 15 1 69005 ACTUATOR SSOV W REGULATOR 33 1 97087 12 FLEXIBLE TUBE 12 20 2 12951 2 BUSHING CONTRO...

Page 147: ...L VALVE CLOSED 5 1 92006 6 VALVE BALL BRASS 1 1 4 NPT 23 2 9 22 PIPE PLUG 1 4 NPT STEEL 9 1 92036 VALVE SSOV 1 NPT 25 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 12 1 5018 1 1 2 NPT MALE FEMALE UNION 29 1 99017 SNUBBER PRESSURE 1 4 14 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 30 1 60032 SWITCH GAS PRESSURE 2 20 W C 15 1 69005 ACTUATOR SSOV W REGULATOR 35 1 97087 12 Flex Tube 12 20 2 12951 2 BUSHING CONT...

Page 148: ... Part Description Item Qty Part Description 1 1 43101 BLOWER INTAKE MANIFOLD 11 1 61002 4 HIGH GAS PRESSURE SWITCH 4 0 2 1 81160 GASKET 8 9 BLOWER 15 1 61024 AIR INLET TEMPERATURE SENSOR 1 8 NPT 3 1 69329 FASCO BLOWER GPM 7 0 16 1 124149 1 WIRE ASSY JUMPER O T SWITCHES 5 1 88004 O RING 2 244 BUNA N 17 1 24298 1 A F VALVE ASSY 9 1 60011 4 SWITCH ASSY BLOWER PROOF 18 1 59138 FILTER AIR 6 10 1 9 21 P...

Page 149: ...59104 OBSERVATION PORT 13 1 24233 2 BURNER ASSEMBLY 3 1 66026 IGNITER INJECTOR 14 1 122977 TWO WAY CONNECTOR 4 1 81048 FLAME DETECTOR GASKET 5 1 66037 FLAME DETECTOR 6 2 93358 PLUG 1 4 NPT HEX HD PIPE 7 2 GP 18899 BURNER FLANGE GASKET 8 2 52037 STUD 10 32 9 2 59027 STANDOFF THREADED 10 32 10 3 53033 WASHER CLOCKING 11 1 24247 STAGED IGNITION ASSY 81048 66037 are supplied as kit 24356 2 66026 53033...

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Page 151: ...nstallation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 151 of 170 APPENDIX F Piping Drawings Drawing Number SD A 829 rev C ...

Page 152: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 152 of 170 Drawing Number SD A 830 rev C ...

Page 153: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 153 of 170 Drawing Number SD A 831 rev C ...

Page 154: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 154 of 170 Drawing Number SD A 845 rev C ...

Page 155: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 155 of 170 Drawing Number SD A 848 rev D ...

Page 156: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 156 of 170 Drawing Number SD A 851 rev D ...

Page 157: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 157 of 170 Drawing Number SD A 852 rev D ...

Page 158: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 158 of 170 Drawing Number SD A 854 rev G ...

Page 159: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 159 of 170 Drawing Number SD A 856 rev D ...

Page 160: ...ation Edge i Installation Operation Maintenance Manual APPENDIX F PIPING DRAWINGS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 160 of 170 Drawing Number SD A 939 rev B ...

Page 161: ...ion Maintenance Manual APPENDIX G EDGE i CONTROLLER VIEWS OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 161 of 170 APPENDIX G Edge i Controller Views Figure G 1 Edge Controller P N 64134 Exploded View ...

Page 162: ... Board Behind Front Face DIP Switch Function Default SW2 SW1 1 Bias OFF 2 Termination OFF 3 Bias OFF 4 Not Used 5 Not Used 6 Not Used 1 CO Sensor mA 2 Flow Sensor V 3 O2 Sensor V 4 Analog In mA 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 ...

Page 163: ...lation Operation Maintenance Manual APPENDIX H Wiring Diagrams OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 163 of 170 APPENDIX H Wiring Diagrams Drawing Number 68056 rev D Sheet 1 of 2 ...

Page 164: ... Edge i Installation Operation Maintenance Manual APPENDIX H Wiring Diagrams OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 164 of 170 Drawing Number 68056 rev D Sheet 2 of 2 ...

Page 165: ... Edge i Installation Operation Maintenance Manual APPENDIX H Wiring Diagrams OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 165 of 170 Drawing Number 68057 rev D Sheet 1 of 2 ...

Page 166: ... Edge i Installation Operation Maintenance Manual APPENDIX H Wiring Diagrams OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 166 of 170 Drawing Number 68057 rev D Sheet 2 of 2 ...

Page 167: ... per three units SSOV Actuator Without Proof of Closure switch Used ONLY on Upstream SSOV on models with a DBB IRI gas train 27086 1 One per three units Temperature Sensor Water Exhaust 123449 Three per unit Flame Detector Kit 24356 2 One kit per unit Igniter Kit One kit per unit Staged Ignition Current production 58023 Direct Spark older units 58047 TABLE I 2 Spare Parts Recommended for Maintenan...

Page 168: ...PTION PART NO QUANTITY Circulator Pump for Dynamic Load Anticipator 22246 One per site Edge Controller 64134 Stock one if site has difficulty getting parts Burner 24233 2 Stock one if site has difficulty getting parts Air Inlet Temperature Sensor 61024 One per site Low Gas Pressure Switch One per three units Nat Gas INN600N to INN1350N 61002 1 High Gas Pressure Switch 60032 One per three units Nat...

Page 169: ...Innovation Edge i Installation Operation Maintenance Manual OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 169 of 170 NOTES ...

Page 170: ...Maintenance Manual OMM 0143_A GF 216 9 6 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 170 of 170 AERCO International Inc 2019 Change Log Date Description Changed By 9 6 2019 Rev A Initial release internal reference DIR 19 43 ...

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