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SmartPlate EV Installation, Operation and Maintenance Manual

APPENDIX B

–SCHEMATIC

OMM-0147_C

• SP-102 • 3/2/2021 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

(This Page Is Intentionally Blank)

Summary of Contents for Aerco SmartPlate EV

Page 1: ...0 SPDW EV60 SPDW EV90 SPDW EV140 OMM 0147_C SP 102 3 2 2021 Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty...

Page 2: ...ENCHMARK PLATINUM BOILERS 15 2 6 ELECTRICAL WIRING CONNECTIONS 16 2 6 1 Modbus Connection 18 2 7 PRESSURE RELIEF INSTALLATION 19 FUNCTIONAL DESCRIPTION 21 3 1 INTRODUCTION 21 3 2 MECHANICAL OVERVIEW 2...

Page 3: ...E 47 8 2 1 HEAT EXCHANGER MAINTENANCE 47 8 2 1 1 HEAT EXCHANGER CLEANING AND DE SCALING 48 8 2 1 2 HEAT EXCHANGER REPLACEMENT 48 8 2 2 CONTROL VALVE ACTUATOR REPLACEMENT AND VALVE REMOVAL 50 8 2 2 1 3...

Page 4: ...SmartPlate EV Installation Operation and Maintenance Manual CONTENTS OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 72 This Page Is Intentionally Blank...

Page 5: ...be maintained in legible condition It must be given to the user by the installer and kept in a safe place for future reference WARNING Fluids under pressure may cause injury to personnel or damage to...

Page 6: ...SmartPlate EV models and sizes There are five SmartPlate EV Double Wall Heat Exchanger Water Heater models available SPDW EV30 SPDW EV40 SPDW EV60 SPDW EV90 Figure 1 1 shows the major components and...

Page 7: ...r DHW Domestic Hot Water Outlet Dual Temperature Sensors Type J Thermocouples Boiler Water Inlet Temperature Sensor Type J Thermocouple Over Temperature Alarm With Safety Shutdown 3 Way Control Valve...

Page 8: ...s the unit s outlet temperature to ensure it does not exceed the preset high temperature limit The over temperature limit is factory set 20 F above the unit s setpoint temperature specified on the sal...

Page 9: ...Type J thermocouples The first thermocouple connects directly to the Temperature Controller to provide feedback PID control for the outlet water temperature The second thermocouple connects to the Ove...

Page 10: ...ly includes the following components Flow Meter Strainers Boiler Water DHW Sides Blow down Valves 2 Piping and support brackets 3 Way Valve Heat Exchanger DHW Relief Valve Boiler Relief Valve optional...

Page 11: ...ve is powered by 24 VAC from the ECS II Control Box The Temperature Controller in the Control Box supplies a 4 to 20 mA control signal to precisely modulate the 3 Way Valve to accurately control the t...

Page 12: ...te EV Installation Operation and Maintenance Manual CHAPTER 1 GENERAL INFORMATION OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 12 of 72 This Page Is Intentional...

Page 13: ...the ECS II Control Box 2 2 RECEIVING AND UNPACKING Each SmartPlate EV Water Heater is shipped as a single crated unit The packaged shipping weight will vary from approximately 500 to 760 pounds depen...

Page 14: ...The minimum clearance dimensions recommended by AERCO are listed below However if local building codes require additional clearances these codes shall supersede AERCO s recommendations Sides 0 in 0 c...

Page 15: ...from the factory all four isolation ball valves see Figure 1 3 are open CLOSE ALL VALVES DURING INSTALLATION Do not open the valves until instructed to do so in Chapter 5 of this manual 2 5 SmartPlate...

Page 16: ...CONNECTIONS The SmartPlate EV ECS II Control Box and all other electrical components are installed on the unit prior to shipment from the factory As a result electrical connections to the ECS II consi...

Page 17: ...he power cable through the cut out in the side of the Power Box Figure 2 6 2 Power Cable Connection 4 Connect the power cable s wires to the connectors in the Power Box as follows Figure 2 6 3 Power C...

Page 18: ...ons do not exceed 4 000 feet maximum MODBUS WIRING CONNECTIONS Instructions 1 Refer to Table 2 1 below and connect the appropriate wire leads to the Temperature Controller terminals listed Refer to th...

Page 19: ...6 1 Eurotherm 3504 Temperature Controller Terminal Connection Diagram 2 7 PRESSURE RELIEF INSTALLATION SmartPlate EV units are shipped with the Pressure Relief Valve assembled Pressure Relief Valve an...

Page 20: ...ombo as shown in Figure 2 7 2 Figure 2 7 2 Relief Valve Installation New York City Option NOTE There is a port on the boiler inlet s combination valve that can be used to install a boiler side relief...

Page 21: ...eat exchanger passes through the inlet connection and strainer The boiler water heats the colder domestic water and is then discharged through the boiler water outlet connection The boiler water flow...

Page 22: ...thin 4 F of the desired setpoint based on a load change of 50 or less 3 4 OVER TEMPERATURE CONTROL AND SAFETY FEATURES The Control Box contains an Over Temperature switch that continuously monitors an...

Page 23: ...1 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 23 of 72 Figure 3 4 SmartPlate EV Water Heater Functional Block Diagram 3 way Characterized Valve responds to hot water demand deviation fro...

Page 24: ...EV Installation Operation and Maintenance Manual CHAPTER 3 FUNCTIONAL DESCRIPTION OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 24 of 72 This Page Is Intentiona...

Page 25: ...xtent necessary prior to placing the SmartPlate EV Water Heater into operation Also the applicable procedures MUST be performed following replacement of the 3 Way Control Valve or ECS II components to...

Page 26: ...N AND WIRING Instructions 1 Remove the three bolts and nuts from the old actuator Be sure to hold the back end of the mounting plate to prevent the nuts from dropping as the bolts are removed Figure 4...

Page 27: ...ONTROL VALVE INSTALLATION AND WIRING Instructions Figure 4 2 1 3 Control Valve Installation 6 Connect the actuator s Molex connector to the SmartPlate EV s 3 circuit actuator connector 7 Ensure that t...

Page 28: ...a Philips screw driver and turn the adjustment screws on the actuator This ensures that the adjustment does not reset to full stoke if the unit is turned off NOTE The valve can be manually positioned...

Page 29: ...3 2 to adjust the required parameters Figure 4 3 Control Box Front View NOTE When the Power switch is set to the ON position the internal 24 VAC Transformer in the Control Box it also energized This i...

Page 30: ...when a 4 to 20 mA signal is being supplied to the ECS Valve Actuator OP2 Output 2 indicator Not used for the ECS II application SP2 Setpoint 2 indicator Not used for the ECS II application REM Remote...

Page 31: ...the ON position 2 Press the SET button on the Over Temperature switch SP will appear in the display 3 Press the SET button again The current over temperature limit value stored in memory will be displ...

Page 32: ...ly exit the programming mode 12 Once the programming mode has been exited the display will show the unit s current outlet water temperature Figure 4 3 2 Over Temperature Switch TABLE 4 2 Over Temperat...

Page 33: ...he ECS and Control Valve When power is initially applied the ECS II Temperature Controller automatically performs a self test sequence for approximately three seconds The valve will go through it s au...

Page 34: ...d toggle the Temperature Controller to AUTO mode The AUTO indicator will light and the MAN indicator will go off When in AUTO mode the upper display will continue to show the outlet water temperature...

Page 35: ...of 72 SHUTTING DOWN THE SYSTEM Instructions Figure 5 3 Typical SmartPlate EV Piping 7 To place the unit back in service fill the unit and perform the pre operational checks and start up procedures des...

Page 36: ...rtPlate EV Installation Operation and Maintenance Manual CHAPTER 5 OPERATION OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 36 of 72 This Page Is Intentionally Bl...

Page 37: ...cedure TABLE 6 1 Scheduled Maintenance Actions Interval Maintenance Task In Section Weekly Check plate packs for leakage 6 2 Quarterly Check the operation of the Over Temp switch in the ECS II Control...

Page 38: ...an over temp alarm is generated and that the following events occur a The 3 Way Control Valve closes b The Over Temp switch generates an audible alarm 3 Following successful completion of the Over Te...

Page 39: ...o scale build up SENSOR CHECKS Instructions 1 Turn the power switch on the side of the ECS II Control Box to OFF to disconnect AC power from the unit 2 Close all 4 Inlet and Outlet Isolation Valves on...

Page 40: ...hown in Table 6 2 TABLE 6 2 Heat Exchanger Cleaning Guidelines Operating Conditions Projected Cleaning Frequency Bi Annually Annually Semi Annually Monthly Boiler Water Inlet Temp 150 F 150 170 F 170...

Page 41: ...he Boiler Operation and Maintenance Manual being used with the Water Heater and any other ancillary equipment manuals associated with the installation 7 2 TROUBLESHOOTING PROCEDURES Troubleshooting pr...

Page 42: ...rly or defective 1 Check the 4 to 20 mA control signal being supplied to Actuator If signal is greater than 4 mA when heater outlet temperature is 10 F or more above the desired setpoint proceed to ne...

Page 43: ...mperature sensor T5 Rapid fluctuations in heater outlet temperature which do not follow load changes 1 Temp Controller is not functioning properly 1 Refer to Table 7 2 and troubleshoot the Temp Contro...

Page 44: ...ature Controller Readjust if necessary 2 Verify Outlet Temp Sensor is securely connected to cable plug Replace the Dual Sensor if necessary T4 Over Temp Alarm occurs repeatedly NOTE Audible alarms wil...

Page 45: ...T7 Wide fluctuations in outlet water temperature during large flow changes 1 Boiler water temperature drops below DHW setpoint but does not recover until load is reduced 2 Boiler water supply temperat...

Page 46: ...re coming to setpoint Dynamic loop response time variation from the engineering development system Many factors contribute to this type of dynamic system variation Increase Proportional Pb or Pb2 firs...

Page 47: ...ble internal components and maintenance for major assemblies and components which come in contact with boiler water or domestic hot water during Water Heater operation Section 8 3 SmartPlate EV Electr...

Page 48: ...ulating cleaning agents Rydlyme Chemical Descaler from Apex Engineering Products Corp or equivalent through the assembly 8 2 1 2 HEAT EXCHANGER REPLACEMENT The heat exchanger used in all SmartPlate EV...

Page 49: ...ssembly and the two nuts that connect the heat exchanger to the mounting bracket Figure 8 2 1 2 Heat Exchanger Replacement Front View WARNING Depending on the SmartPlate EV model the heat exchanger we...

Page 50: ...the Electronic Actuator needs to be replaced see Section 4 2 1 Figure 8 2 2 3 Way Control Valve 8 2 2 1 3 Way Control Valve Replacement Complete the instructions below to replace the 3 Way Control Va...

Page 51: ...ns to prevent pipe rotation and avoid leaks 8 Using two 2 pipe wrenches secure the Control Valve unions to the Boiler Water piping 9 Refer to Figure 8 2 2 1 and ensure that the three 3 DIP switches on...

Page 52: ...trainer and ball valve on the boiler side and a strainer on the DHW side to prevent fouling of the heat exchanger by trapping foreign material before it enters the unit NOTE If normal maintenance does...

Page 53: ...forming the replacement procedures which follow 8 3 2 TEMPERATURE CONTROLLER REPLACEMENT The Temperature Controller is mounted in the Control Box as shown in Figure 4 3 To remove and replace it comple...

Page 54: ...ect the wires 3 To remove the Over Temperature switch push in the tabs of both side retaining clips shown below slide toward rear and remove 4 Insert the replacement Over Temperature switch into the p...

Page 55: ...ONTROL AND COMMUNICATION OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 55 of 72 APPENDIX A Modbus Control and Communication TEMPERATURE CONTROLLER Eurotherm 3504...

Page 56: ...ature Controller Parts Needed a Temperature Controller P N 64167 b Communications Board P N 64009 TAB REPLACING THE COMMUNICATION BOARD Instructions 1 Turn the Enable Disable switch on the Control Box...

Page 57: ...power up unit A 1 2 Changing the Temperature Controller s Communication Addresses The Temperature Controller s factory default address is 51 To change the MODBUS address proceed as follows 1 Press th...

Page 58: ...hanging Baud Rate Screen 2 Under Goto press the arrows until Config is reached 3 Enter Pass code 303 4 Press the Page button until the Comms screen appears 5 Figure A 2 2 Changing Baud Rate Screen 6 P...

Page 59: ...0 GPM Domestic Hot Water Flow Read Only 2 370 Mod 3A PV Module 3 C PV 40 190 F Boiler Water Inlet Temperature Read Only 2 373 Mod 4A PV Module 4 C PV 40 180 F Domestic Hot Water Inlet Temperature Read...

Page 60: ...ssure sensor communication loss A 4 Process Diagnostic Alarms The Process and Diagnostic Alarms that can appear in the Temperature Controller display are listed in the following Tables PROCESS ALARMS...

Page 61: ...message normally occurs when pre configuring a Controller without installing any of the required I O modules rmt F Remote input failure The remote DC input is open or shorted Check for open or short c...

Page 62: ...r A4 1 Clearing Hardware Error Hw Er Display To clear a Hardware Error and reset the Temperature Controller proceed as follows CLEARING HARDWARE ERROR DISPLAY Instructions 1 The display flashes Hw Er...

Page 63: ...stallation Operation and Maintenance Manual APPENDIX B SCHEMATIC OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 63 of 72 APPENDIX B SCHEMATIC SmartPlate EV Schema...

Page 64: ...tPlate EV Installation Operation and Maintenance Manual APPENDIX B SCHEMATIC OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 64 of 72 This Page Is Intentionally Bl...

Page 65: ...Heat Exchanger 29519 8 300 PSI 29519 4 150 PSI 90 Plate Heat Exchanger 29519 9 300 PSI 29519 5 150 PSI 140 Plate Heat Exchanger 29519 10 300 PSI AERCO International Inc Blauvelt NY 10913 SmartPlate E...

Page 66: ...19 1 Base 2 SEE TABLE C 5 Heat Exchanger 3 93693 4 Reducing Coupling 2 1 2 x 2 4 94303 TAB 3 2 NPT Machined Pipe 5 93159 8 Coupling Quik Flex 2 6 97148 1 Control Valve 2 NPT 7 22424 1 2 NPT X Groove C...

Page 67: ...si 10 37173 1 Front Side Lower Rail 3 61067 1 Thermal Limit Switch 11 37174 1 Front Side Upper Rail 4 50018 1 2 Pipe Clamping U Bolt 12 30183 1 Rear Side Upper Rail 5 24694 1 Power Box Assy 13 69343 1...

Page 68: ...V DC Fan 8 30195 1 Control Panel 3 81240 2 Cover Gasket 9 60045 1 On Off Rocker Switch 4 36125 1 Louver Plate 10 64088 1 Temp Controller Limit Switch 5 92134 5 1 Relief Valve 3 4 x 1 150 psi 11 See Ta...

Page 69: ...gh TABLE C 9 Temperature Controller Part Numbers Part Description 64174 1 SPEV 30 150 PSIG Temperature Controller 64174 2 SPEV 40 150 PSIG Temperature Controller 64174 3 SPEV 60 150 PSIG Temperature C...

Page 70: ...ate EV Recommended Emergency Spare Parts DESCRIPTION PART NUMBER Heat Exchanger See Table C 5 in Appendix C Valve Actuator 69343 Temperature Controller See Table C 9 in Appendix C Domestic Water Inlet...

Page 71: ...SmartPlate EV Installation Operation and Maintenance Manual OMM 0147_C SP 102 3 2 2021 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 71 of 72 NOTES...

Page 72: ...v B Added model SPDW EV140 Moved Temp Controller P N to Table C 9 in Appendix C Revised list of Recommended Spare Parts in Appendix D Updated schematic Appendix B Revised Table 6 2 Heat Exchanger Clea...

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