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SmartPlate Installation, Operation & Maintenance Manual

CHAPTER 7

– TROUBLESHOOTING

OMM-0069_0H

• SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

134

TABLE 7-2. Troubleshooting

– Electronic Control System (ECS/SP)

No.

Fault Indication

Probable Cause

Corrective Action

Over-Temp. Alarm
condition cannot be
cleared.

Over-Temp Switch
displays erroneous
temperature readings

1. Shorted Outlet Temp.

Sensor.

2. Defective Over-Temp.

Switch.

3. 3-Way Control Valve

not closing fully during
no-load conditions.

A “No-Flow” condition
caused a gradual
buildup of heat to the
water in vessel.

5. Water Heater

recirculation pump
shut off or failed.

1. Replace Outlet Temp, Sensor.

2. Replace Over-Temp Switch.

3. Calibrate 3-Way Control Valve per section

4.2.1.

4. Open hot water valve at sink or tub outlet

to see if fault clears. If there is no flow
through heater, go to Probable Cause 5.

5. Check recirculation pump to ensure it is

turned on and functioning properly. Also,
check pump fuse on side of Control Box.

Outlet water temp. far
below Setpoint

1. Incorrect Temp

Controller setting

2. Defective Temp.

Controller.

3. Heat exchanger

fouled on Boiler Water
side.

4. Defective Control

Valve Actuator

5. Boiler water supply

temp. is too low.

6. Boiler Failure

1. Refer to Chapter 4 and check the current

setting of Over-Temp. Switch. Readjust if
necessary.

2. Remove the cover from the Electronics

Module of the Control Valve and verify that
the Temp. Controller is generating a
control signal greater than 0 VDC. If not
replace Temp. Controller.

3. Clean Boiler Water Inlet Strainer.

Clean heat exchanger.

4. Replace Valve Actuator (SEE TABLE 7.1)

5. Increase boiler water temperature.

6. Check operational status of Boiler.

Wide fluctuations in outlet
water temperature during
large flow changes.

1. Water Heater

Recirculation Pump
not operating.

2. Boiler water temper-

ature drops below
DHW setpoint during
heavy demand, then
recovers.

3. Boiler water temper-

ature drops below
DHW setpoint but
does not recover until
load is reduced.

4. Boiler water supply

temperature is too
high.

1. Check Control Box fuse and power to

pump.

2. Install Boiler Water Buffer Tank to provide

hot water reservoir for the Water Heater to
draw from during large load swings.

3. The boiler water supply is under-sized.

Add more boilers or reduce DHW usage.

4. Control Valve is not seating properly. See

Chapter 4 and auto-stroke valve.

Summary of Contents for AERCO SmartPlate SP23

Page 1: ...l Heater Models Double Wall Heater Models SP23 SP33 SP45 SP69 SP150 SPDW23 SPDW32 SPDW42 SPDW61 SPDW113 Installation Operation Maintenance Manual SmartPlate Domestic Hot Water Heaters OMM 0069_0H SP 100 1 30 2020 ...

Page 2: ...6 2 6 ADDITIONAL COMPONENT INSTALLATION 21 FUNCTIONAL DESCRIPTION 23 3 1 INTRODUCTION 23 3 2 MECHANICAL OVERVIEW 23 3 3 ELECTRONIC CONTROL OVERVIEW 24 3 4 OVER TEMPERATURE CONTROL AND SAFETY FEATURES 24 ADJUSTMENT 27 4 1 INTRODUCTION 27 4 2 SMARTPLATE 3 WAY CONTROL VALVE MXG 461 ADJUSTMENT 27 4 2 1 Control Valve Calibration and Status Indications 27 4 2 2 Manual Control of 3 Way Valve Removable Ha...

Page 3: ...EMOVAL AND INSERTION OF PLATES 69 8 7 3 CLOSING HEAT EXCHANGER 70 8 8 DOUBLE WALL HEAT EXCHANGER GASKET REPLACEMENT 73 8 8 1 Replacing Gaskets on Channel Plates 73 8 8 2 Replacing Gaskets on End Plate First Plate Against Frame Plate 74 8 9 DOUBLE WALL HEAT EXCHANGER REPLACEMENT 76 8 10 CONTROL VALVE ELECTRONIC MODULE REPLACEMENT AND VALVE REMOVAL 80 8 10 1 Electronics Module Replacement 80 8 10 2 ...

Page 4: ...SmartPlate Installation Operation Maintenance Manual CONTENTS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 4 of 134 This Page Is Intentionally Blank ...

Page 5: ...sizes The following SmartPlate Single Wall and Double Wall Heat Exchanger Water Heater models are available Type SmartPlate Models Pressure Options Power Options Single Wall SP23 SP33 SP45 SP69 SP150 150 PSI 120V 60 Hz 220V 50 Hz 220V 60 Hz 200 PSI Double Wall SPDW23 SPDW32 SPDW42 SPDW61 SPDW113 150 PSI 200 PSI Appropriate add on kits differentiate overall product for given DHW side operating pres...

Page 6: ...y devices which provide temperature and flow control information to the Control Box circuitry The Control Box and the additional devices included in the ECS are shown in Figure 1 2 The additional devices included in the ECS SP include Feed Forward Mixed Water Temperature Sensor Type J Thermocouple DHW Outlet Dual Temperature Sensors Type J Thermocouples Boiler Water Inlet Outlet Temperature Sensor...

Page 7: ...ature Controller an Over Temperature Indicator Switch and Boiler Water In Out Temperature Indicators The Temperature Controller is the brain of the ECS SP which processes data received from the temperature sensors Using feed forward and PID Proportional Integral Derivative algorithms the Temperature Controller provides a 0 to 10 VDC control signal to the Control Valve Actuator which precisely modu...

Page 8: ...RWARD TEMPERATURE SENSORS The Feed Forward Temperature Sensor Type J thermocouple is installed in the cold water inlet mixing box on the unit The Temperature Sensor monitors a portion of the inlet flow to the unit and provides a feed forward signal to the Temperature Controller which is proportional to the change in flow through the unit 1 2 3 OUTLET TEMPERATURE SENSORS The Control System includes...

Page 9: ... SPDW42 SPDW61 SPDW113 2 In addition to the heat exchanger and piping components each SmartPlate Piping Assembly contains a number of other important components and assemblies The items include Mixing box Recirculation Pump Continuously ON Isolation Drain Valves Strainers Boiler Water DHW Sides Blow down Valves Relief Valve Air Vent Valve Figure 1 3 illustrates the locations of the above mentioned...

Page 10: ...e Piping Assembly 2 Piping Shown ELECTRONICS MODULE PORT A PORT B PORT AB HANDWHEEL VALVE BODY Figure 1 4 Electronic Control Valve RELIEF VALVE ISOLATION BALL VALVE 4 PLCS BOILER WATER DIFFERENTIAL PRESSURE GAUGE DRAIN VALVE RECIRCULATION PUMP STRAINERS WITH BLOWDOWN VALVES INTAKE MIXING BOX BOILER WATER INLET DHW OUTLET COLD WATER INLET BOILER WATER OUTLET HEAT EXCHANGER 3 WAY CONTROL VALVE AIR V...

Page 11: ...CEIVING AND UNPACKING SMARTPLATE Each SmartPlate Water Heater is shipped as a single crated unit The packaged shipping weight will vary from 380 to approximately 1100 pounds depending on the model ordered The unit must be moved with the proper equipment forklift pallet jack etc to avoid possible injury to personnel or damage to the shipping container or unit The shipping carton should be inspected...

Page 12: ...ce dimensions recommended by AERCO are listed below However if local building codes require additional clearances these codes shall supersede AERCO s recommendations Sides 24 in 61 cm Front 24 in 61 cm Rear 24 in 61 cm Top 12 in 30 5 cm All water piping and electrical conduit must be arranged so that it does not interfere with the removal of any Water Heater assemblies parts or inhibit service or ...

Page 13: ...wrap the lifting strap around the threaded bolts protruding from the heat exchanger Figure 2 2 b 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 Figure 2 2 a SmartPlate Lifting Pr...

Page 14: ...ollows REPOSITIONING ECS SP CONTROL BOX Instructions 1 Power the unit off 2 Disconnect external cables at their respective connections Molex 3 From the rear of the unit Figure 2 3 below remove the four Phillips head screws securing the base of the Control Box to the unit s frame assembly 4 Position the Control Box to the desired orientation to provide easy viewing of the control panel displays 5 E...

Page 15: ...and size of the unit being installed Refer to Table 2 1 for applicable piping sizes TABLE 2 1 Pipe Sizing Chart Type SmartPlate Water Heater Model Pipe Diameter Single Wall SP23 SP33 1 5 inches SP45 SP69 SP150 2 0 inches Double Wall SPDW23 SPDW32 1 5 inches SPDW42 SPDW61 SPDW113 2 0 inches CAUTION Two pipe wrenches MUST be used when installing boiler water and DHW piping unions to prevent pipe rot...

Page 16: ... Box The system can be powered by a single phase AC voltage of 120 VAC 60 Hz 220 VAC 50 Hz or 220 VAC 60 Hz However if the ECS SP was ordered with the Modbus Communication option several additional signal lead connections will need to be made inside the Control Box These signal leads will permit the ECS SP to be controlled by an external Energy Management System EMS Building Automation System BAS ...

Page 17: ...S SP Control Box 4 Feed the external 120 220 VAC power leads through the cutout labeled POWER IN on the bottom of the Control Box 5 Connect the LINE NEUTRAL and GROUND leads to the TB 2 terminals shown in Figure 2 6 6 Check the connection of wire 100 on the right side of TB 2 to ensure the power is routed to the proper connection for the 24 VAC transformer If the incoming power is 120 VAC wire 100...

Page 18: ... of 134 ELECTRICAL WIRING CONNECTIONS Instructions INTERIOR BOTTOM SURFACE REAR TB 2 GND LINE NEUTRAL GND INSTALL EXTERNAL POWER WIRING THROUGH THIS CUT OUT WHITE TO TRANSFORMER BLACK ORANGE 220 24 VAC 120 24 VAC 101 GND POWER SWITCH 100 102 102 100F FROM FUSE FOR 220 VAC WIRE 100 MUST BE CONNECTED TO THIS TERMINAL Figure 2 6 ECS SP Control Box AC Power Connections ...

Page 19: ...es ONLY to SmartPlate Control Systems that include a Temperature Controller Eurotherm model 2408 equipped with a Communications Board that allows connection to Modbus Networks The required signal connections will depend on the ports available on the Energy Management System EMS Building Automation System BAS or Computer being used with the ECS SP CAUTION DO NOT route Modbus communication wiring in...

Page 20: ...nication information related to Modbus NOTE The complete wiring diagram for the SmartPlate Electronic Control System is provided in Appendix B of this Instruction Manual In addition the wiring connections for Control Box Terminal Blocks TB 1 and TB 2 are also provided for reference purposes NOTE AERCO recommends that shielded twisted pair cable be used for communication wiring Examples of suitable...

Page 21: ...DW32 SPDW42 SPDW61 SPDW113 200 PSI 58128 3 SP23 SP33 SPDW23 SPDW32 150 PSI Yes 58128 4 SP45 SP69 SP150 SPDW42 SPDW61 SPDW113 58128 5 SP23 SP33 SPDW23 SPDW32 200 PSI 58128 6 SP45 SP69 SP150 SPDW42 SPDW61 SPDW113 The contents of the kits are shown below see Appendix E for a full list and quantity per kit Part Description 92070 Air Vent Valve 1 150 PSI 92130 Air Vent Valve 200 PSI 92065 1 Relief Valv...

Page 22: ...u must install a second Relief Valve P N 92111 in the Boiler Water Intake Ball Valve Strain combo as shown in Figure 2 11 If the unit has 2 inch piping models SP 42 SP 61 or SP 113 you must include the 1 to bushing P N 93505 Units with 1 piping do not need this bushing Figure 2 11 Relief Valve Installation New York City Option Relief Valve P N 92134 1 Bushing 1 to P N 93521 Air Vent Valve P N 9213...

Page 23: ...ed through the Domestic Hot Water DHW outlet connection A portion of hot water is pumped into the mixing box where it is mixed with the cold water entering the heater thereby providing a load sensing feed forward function Boiler water supplied to the heat exchanger passes through the inlet connection and strainer The boiler water heats the colder domestic water and is then discharged through the b...

Page 24: ...tion from fully closed 0 VDC to fully open 10 VDC The control signal varies as necessary to maintain the setpoint temperature programmed into the Controller Under normal conditions the unit s outlet temperature is maintained within 4 F of the desired setpoint based on a load change of 50 or less Surface mount sensors and digital displays are also provided in the ECS SP Control System to monitor th...

Page 25: ... OUT B FEED FORWARD TEMP DHW OUT BOILER WATER BW OUT STRAINER POWER SWITCH TO CIRC PUMP TCOUT TC IN BOILER WATER BW IN SEE NOTE 1 SEE NOTE 2 NOTES 1 THE BW TC IN BW TC OUT THERMOCOUPLES ARE CONNECTED TO DISPLAY DEVICES IN THE CONTROL BOX THESE ARE INDICATION ONLY DISPLAYS WHICH MAY BE USER CONFIGURED FOR ALARM SETTINGS 2 THE BOILER WATER BYPASS LINE IS NORMALLY OPEN 3 WAY VALVE CONFIGURATION FOR A...

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Page 27: ...all parameters are properly set CAUTION As a precaution ensure that all heating fluid hot boiler water shutoff valves are fully closed prior to performing any of the following adjustment procedures 4 2 SMARTPLATE 3 WAY CONTROL VALVE MXG 461 ADJUSTMENT The 3 Way Control Valves Siemens MXG 461 used on all SmartPlate models are powered by 24 VAC For SmartPlate Water Heater applications each 3 Way Val...

Page 28: ...alve to access the internal components shown in Figure 4 2 1 2 3 ON LED AUTO STROKE BUTTON DIP SWITCHES HAND WHEEL Figure 4 2 Control Valve with Electronics Module Cover Removed NOTE When external 120 240 VAC power is properly connected to the ECS SP Control Box 24 VAC power is supplied to the MXG 461 Control Valve when the Control Box POWER switch is set to the ON position The POWER switch is loc...

Page 29: ...rocess the LED indicator will stop flashing and remain ON continuously green 8 The two color Red Green indicator is useful in determining the operating status of the Control Valve Refer to Table 4 1 for descriptions of the possible LED status displays which may be encountered TABLE 4 1 Control Valve MXG 461 LED Status Indicators LED Display Status Description LED green On continuously Automatic Mo...

Page 30: ... 4 To set the Valve for automatic AUTO operation rotate the handwheel to the AUTO position The handwheel will pop up when in the AUTO position thereby allowing it to be controlled by the ECS SP Temperature Controller AUTO OFF MANUAL CCW CW Push down to rotate Push down to rotate Figure 4 3 Control Valve Auto Manual and Off Positions The SmartPlate Electronic Control System ECS SP is preset at the ...

Page 31: ...ese controls and displays are illustrated and described in Figure 4 5 and Table 4 2 If necessary setpoint temperature adjustment is accomplished as follows SETPOINT TEMPERATURE ADJUSTMENT Instructions 1 With the Control Box door open set the ON OFF POWER switch on the right side to the ON position The Temperature Controller will initiate a self test for approximately 3 seconds Following the self t...

Page 32: ...USTMENT Instructions 3 If the lower display does not show the desired setpoint temperature press the or arrow button to change the display to the desired value 4 Two seconds after the or arrow button is released the display will blink to indicate that the Temperature Controller has accepted and stored the displayed value AUTO RUN MAN HOLD OP 1 OP 2 SP2 REM 2408 Figure 4 5 Temperature Controller ...

Page 33: ...lled by a Remote Modbus signal REM will also flash when Modbus communication is active AUTO MAN Auto Manual Button and Indicators When button is pressed the Controller is toggled between the automatic AUTO and manual MAN modes When first set to manual the valve will close and show zero percentage 0 on the display AUTO lights when in the automatic mode Setpoint temperature setting appears in lower ...

Page 34: ...does not show the desired over temperature alarm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting is displayed press the SET button to store the setting in memory 6 To calibrate the offset P1 press and hold the SET button for 8 seconds on the Over Temperature Switch Access code value 0 is shown in the displ...

Page 35: ...L BOX Instructions TABLE 4 3 Over Temperature Switch Controls and Indicators CONTROL or INDICATOR MEANING FUNCTION LED Display TEMP status Displays current water temperature or setpoint RST RESET Button Resets the unit after an alarm condition UP Button Increases the displayed temperature DOWN Button Decreases the displayed temperature SET SET Button Used to access and store parameters in the unit...

Page 36: ...martPlate Installation Operation Maintenance Manual CHAPTER 4 ADJUSTMENT OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 36 of 134 This Page Is Intentionally Blank ...

Page 37: ...ers 5 2 PRE OPERATIONAL CHECKS PROCEDURES All SmartPlate Water Heater installation procedures provided in Chapter 2 must be fully completed prior to performing Pre Operational checks In addition the following items should be checked PRE OPERATIONAL CHECKS PROCEDURES Instructions 1 Ensure that external single phase AC power at 120 VAC 60 Hz or 240 VAC 50 Hz is properly connected to the ECS SP Contr...

Page 38: ... line Connect a hose to the field piped Hose Connection see Piping Diagrams in Appendix C or open several hot water fixtures in the building to ensure water flow through the heater 7 Slowly open the isolation valves in the boiler water inlet and boiler water outlet connections of the heater 8 Using the arrow button set the MXG 461 Control Valve to the 10 position and monitor the outlet water tempe...

Page 39: ...let water temperature and setpoint Figure 5 1 Double Wall Heat Exchanger Only 5 5 SHUTTING DOWN THE SYSTEM To shut down the Water Heater for a short period of time simply turn OFF power and close the isolation valves as described in steps 1 and 2 below However if the unit will be shut down for an extended period of time it will be necessary to drain the unit using the appropriate steps listed belo...

Page 40: ... to SmartPlate Double Wall models Skip this step for all Single Wall models 7 For SmartPlate Double Wall Water Heater models it is also advisable to separate and clean the plates using the procedures in Chapter 8 section 8 6 2 Leave the double wall heat exchanger in an un tightened or slightly tightened condition Cover the heat exchanger with dark plastic to protect it from welding light and dirt ...

Page 41: ...Annually A annually and P periodic Maintenance Action Column This column lists the required maintenance action which corresponds to the interval symbol in the previous column Reference Column This column lists the section number containing the required procedure TABLE 6 1 Scheduled Maintenance Actions Interval Maintenance Task Reference W Check Boiler Water Differential Pressure Gauge 6 2 W Double...

Page 42: ... valve at the base of the Strainer Cycle the blow down valve open and closed 6 times 4 If the Gauge still reads in the Red area on the dial you may have too much boiler water flow through the unit or the strainer may be clogged If the strainer has just been cleaned try reducing the flow rate Refer to Chapter 8 Corrective Maintenance to repair or replace the Differential Pressure Gauge 5 If the Gau...

Page 43: ...e cause of the leakage 3 Check for leakage between plates to the outside see Figure 6 2 B a If there is evidence of leakage mark the area with a felt tip marker on the two plates next to the leakage b Refer to Chapter 8 section 8 7 and 8 8 to correct the cause of the leakage 4 If there is no evidence of leakage replace the splash guard on the Plate Pack and return the unit to service use A LEAKAGE...

Page 44: ... to Chapter 8 Corrective Maintenance section 8 12 6 6 CONTROL VALVE OPERATIONAL CHECK Refer to Chapter 4 section 4 2 and recalibrate the Control Valve Also check the LED indicator to ensure the Valve is functioning correctly NOTE To avoid repeated draining of the Water Heater perform the annual scheduled maintenance checks specified in section 6 9 at the same time 6 7 TEMPERATURE SENSOR CHECKS Sma...

Page 45: ...the Mixing Box WARNING PRIOR TO PERFORMING THE FOLLOWING STEPS ENSURE THAT THE POWER SWITCH ON THE SIDE ECS SP CONTROL BOX IS OFF AND THE HEATER HAS BEEN DRAINED AS SPECIFIED IN THE PREVIOUS SECTION PLATE PACK LEAKAGE CHECKS Instructions 1 Make sure that the POWER switch on the Control Box is OFF 2 Ensure that the Drain Valve is open and the water has been drained from the unit 3 Locate the Recirc...

Page 46: ...p 150ºF 170ºF 200ºF 220ºF Domestic Water Setpoint 130ºF 140 160ºF 160 180ºF Calcium Hardness Level 20 mg L 20 40 mg L 40 60 mg L 80 mg L If calcium hardness level boiler water inlet temperature and domestic water setpoint fall under different cleaning intervals in Table 6 2 the heat exchanger may be cleaned between those periods starting with the most frequent interval During the next few cleaning...

Page 47: ...he ECS SP Control Box NOTE In addition to the procedures contained in this chapter also check the troubleshooting sections of the 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 procedures for SmartPlate Water Heaters are provided in Tables 7 1 7 2 and ...

Page 48: ...r if necessary Proceed to Table 7 2 and check Over Temp Switch and 24 VAC Transformer circuit breaker to ensure they have not tripped 2 Verify presence of a 0 to 10 VDC control signal at pin 5 of terminal strip If control signal is not present troubleshoot ECS SP per Table 7 2 T2 System over heats by more than 10 F above the desired setpoint Outlet temp is below Over Temp limit setting 1 Control V...

Page 49: ...k the current setpoint temperature setting on the Temp Controller If the setting is below the desired setpoint readjust as necessary T3 Continued 5 Control Valve is not opening properly 6 Heat exchanger is fouled on boiler water side 7 Heat exchanger is scaled on boiler water side 8 Heat exchanger is too small for load 5 Remove Electronics module cover on Valve and view the Status LEDs See Table 7...

Page 50: ...e which do not follow load changes 1 Temp Controller is not functioning properly 1 Refer to Table 7 2 and troubleshoot the Temp Controller TABLE 7 1A Control Valve MXG 461 LED Status Indicators LED Display Status Description LED green On continuously Automatic Mode normal no faults Flashing Mechanically set to MANUAL Mechanically set to OFF Currently in Auto Calibrate Mode LED red On continuously ...

Page 51: ...24 VAC is not present replace the 24 VAC transformer in the Control Box T3 Water Heater outlet temp consistently above Setpoint by 10 F or more However temperature is below Over Temp limit setting 1 Temp Controller is not properly set 2 Faulty Temp Sensor thermocouple is connected to Temp Controller 1 Refer to Chapter 4 Adjustment and check current setting of Temp Controller Readjust if necessary ...

Page 52: ...Defective Temp Controller 3 Heat exchanger fouled on Boiler Water side 4 Defective Control Valve Actuator 5 Boiler water supply temp is too low 6 Boiler Failure 1 Refer to Chapter 4 and check the current setting of Over Temp Switch Readjust if necessary 2 Remove the cover from the Electronics Module of the Control Valve and verify that the Temp Controller is generating a control signal greater tha...

Page 53: ... 3 for Temperature Control Troubleshooting 2 Replace Outlet Temp Dual Sensor at the Water Heater outlet port 3 Replace Mixed Water Temp Sensor 4 Replace Recirculation Pump T10 Wide fluctuations in outlet water temperature under low flow conditions 1 Outlet Temp Sensor connected to Temp Controller gives inconsistent or intermittent readings 2 Mixed Water Temp Sensor is open shorted or gives inconsi...

Page 54: ... this type of dynamic system variation Increase Proportional Pb or Pb2 first If that has little or no effect then increase FeedForward FFpb Note A change in FFpb will cause the valve to fully open initially and over temperature may occur Be sure the domestic outlet is shut to prevent scalding T9 4 On increase in flow outlet temperature initially goes down but then overshoots setpoint too much befo...

Page 55: ...ff Temp Gsch SP23 SPDW23 180 F 40 40 20 5 30 20 5 145 200 F 40 50 20 5 40 20 5 145 220 F 50 50 20 5 40 20 5 145 250 F 50 60 20 5 50 20 5 145 SP33 SPDW32 180 F 50 50 20 5 40 20 5 145 200 F 50 60 20 5 50 20 5 145 220 F 60 60 20 5 50 20 5 145 250 F 60 70 20 5 60 20 5 145 SP45 SPDW42 180 F 60 60 20 5 50 20 5 145 200 F 60 70 20 5 60 20 5 145 220 F 70 70 20 5 60 20 5 145 250 F 70 80 20 5 70 20 5 145 SP6...

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Page 57: ...ic hot water during Water Heater operation These assemblies and components are used on all SmartPlate models Single Wall and Double Wall Section IV SmartPlate Electronic Control System ECS SP This section provides removal and replacement procedures for the internally mounted assemblies and components contained in the ECS SP Control Box SECTION I SMARTPLATE SINGLE WALL HEAT EXCHANGER MODELS 8 2 SIN...

Page 58: ... IMPORTANT The De Scaling Solution used must be compatible with wetted materials of stainless steel copper brass and bronze AERCO recommends creating a cleaning solution of Rydlyme Chemical Descaler from Apex Engineering Products Corp and water Contact Apex Engineering Products to obtain this product and instructions for its use ECS CONTROL BOX AIR VENT VALVE ISOLATION BALL VALVES DRAIN VALVE RECI...

Page 59: ...ntil the Mixing Box is full 9 Replace the 1 NPT Air Vent 10 Set the Control Box POWER Switch to the ON position and ensure that the Recirculation Pump is operating 11 Allow the cleaning solution to circulate through the heat exchanger and piping for 1 to 3 hours depending on the amount of scale deposit that is inside the heat exchanger Since the amount of scaling will be hard to estimate it should...

Page 60: ...e to the Strainer on the Boiler Water side of the piping assembly Figure 8 2 Open the valve on the Strainer and drain the boiler water from the unit It will be necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe during draining 4 Next connect a hose the Drain Valve on the DHW Side of the piping assembly and then open the Relief Valve to allow air into the pipe...

Page 61: ...the rear of the heat exchanger 10 Use a ratchet with a 9 16 socket through the hand holes in the sides of the heat exchanger mounting bracket and a 9 16 wrench on the outside to remove the four 4 bolts washers and nuts secure the heat exchanger to the Support Frame WARNING THE SINGLE WALL HEAT EXCHANGER CAN WEIGH UP TO 300 POUNDS DEPENDING ON THE SMARTPLATE MODEL THEREFORE USE EXTREME CARE WHEN RE...

Page 62: ...n Fri 8 am 5 pm EST Page 62 of 134 SINGLE WALL HEAT EXCHANGER REPLACEMENT Instructions SUPPORT FRAME HAND HOLE CUTOUT BOTH SIDES HEAT EXCHANGER HX MOUNTING ATTACHMENT 4 PLACES VIEW A A A A SUPPORT FRAME HEAT EXCHANGER MOUNTING TAB 4 PLACES FLAT WASHER HEX HEAD BOLT HEAT EXCHANGER REAR VIEW VIEW A A HEX NUT Figure 8 4 Heat Exchanger Mounting Details ...

Page 63: ...e Double Wall models Figure 8 5 include procedures for Cleaning in place or by disassembly Opening closing heat exchanger and removal replacement of plate Replacement of gaskets Heat exchanger replacement The procedures listed above are provided in sections 8 6 through 8 9 Figure 8 5 SmartPlate Double Wall Model SPDW61 Shown HEAT EXCHANGER ISOLATION BALL VALVES DRAIN VALVE RECIRCULATION PUMP INTAK...

Page 64: ...ing Products Corp and clean water through the assembly Perform the procedures specified in Section I section 8 3 of this chapter 8 6 2 HEAT EXCHANGER CLEANING BY DISASSEMBLY If the heat exchanger is encrusted with hardened scale or sediment the Water Heater will have to be drained and the Double Wall heat exchanger opened as follows HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions 1 Set the POW...

Page 65: ... PLATES Water of more than 300 ppm chlorine may not be used in the preparation of cleaning solutions It is very important that carrying bars and support columns in aluminum are protected against chemicals Do NOT use brushes with carbon steel bristles or steel wool A fiber type brush is recommended As a last resort use a brush of similar material to the thermal plate Be careful not to scratch the p...

Page 66: ...n 4 Max Temp 140 F Sediment Corrosion Products Metal Oxides Silt Alumina 1 Soft brush running water NOTE Avoid Gasket Damage 2 High pressure hose 3 Chemical cleaning 4 Addition of surfactants can improve cleaning effect Nitric Acid Sulfamic Acid Citric Acid Phosphoric Acid Complex Agents EDTA NTA Sodium Poly phosphates Maximum concentration 8 Max Temp 140 F 11 Upon completion of the cleaning proce...

Page 67: ...all heat exchanger 4 Inspect the sliding surfaces of the upper and lower support bars Figure 8 7 and wipe clean Figure 8 7 Double Wall Heat Exchanger 5 Brush the threads of the tightening bolts clean using a steel wire brush 6 Lubricate the threads of the tightening bolts with a thin layer of grease such as molybdenum disulfide or equivalent 7 Remove the protective splash guard to provide access t...

Page 68: ...tion 8 9 and Figure 8 18 If the unit is a model SPDW61 remove the U bolt and L bracket at the rear of the heat exchanger mount to permit the pressure plate to be moved 11 Opening of the heat exchanger is now possible by loosening diagonally opposite pairs Figure 8 9 Opening must be carried out evenly so that the pressure plate is not out of parallel with the frame plate by more than 3 8 2 turns pe...

Page 69: ...nsert the channel heat transfer plates proceed as follows WARNING TO AVOID HAND INJURIES WHEN HANDLING PLATES USE PROTECTIVE GLOVES NOTE If defective gaskets are detected during removal of plates they must be replaced using the procedures in section 8 8 REMOVAL AND INSERTION OF PLATES Instructions 1 Push the pressure plate back away from the plate pack 2 When removing the plates number or stack th...

Page 70: ...ons 1 Check that all the sealing surfaces i e surfaces in contact with the heat transfer medium are clean 2 Check that connection fittings are in position and are in good condition 3 Clean and lubricate the sliding surfaces of the upper and lower support bars 4 If the plates are correctly assembled the edges form a honey comb pattern as shown below Figure 8 12 Heat Exchanger Plates 5 Slide the pre...

Page 71: ...l wire brush 7 Lubricate the threads with a thin layer of grease 8 Place the bolts in position and tighten the plate pack using diagonally opposite bolt pairs the opposite of the opening procedure in section 8 7 1 step 10 until the plate pack length is reduced to 1 of dimension A in the channel plate assembly instructions supplied with unit During tightening The pressure plate must not be out of p...

Page 72: ...te corners it is important that the corner bolts are not used for closing the heat exchanger 12 The nominal plate pack length A can be exceeded in some cases The tightening can be stopped at A 2 and pressure tested NOTE When a pneumatic tightening device is used it should be set at the maximum tightening torque of 550 ft lbs for DW for 3 4 bolts Dimension A must however must still be measured duri...

Page 73: ...f the Double Wall heat exchanger utilize Clip Type glueless gaskets The following sections provide the instructions to replace gaskets on channel plates and on the end plate first plate against frame plate Refer to the appropriate procedures in sections 8 7 1 and 8 7 2 to open the heat exchanger and remove the required plates Following gasket replacement close the heat exchanger using the procedur...

Page 74: ...the plates of the heat exchanger are assembled and tightened the gasket provides a tight seal around the plate 5 Before closing the plate pack check to ensure that the gasket prongs are in the correct position 8 8 2 REPLACING GASKETS ON END PLATE FIRST PLATE AGAINST FRAME PLATE Replacing Gaskets on End Plate Instructions 1 Obtain two standard plate gaskets P N 81128 for DW units 2 Cut the gaskets ...

Page 75: ...APTER 8 CORRECTIVE MAINTENANCE OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 75 of 134 Replacing Gaskets on End Plate Instructions Figure 8 16 Cutting Gaskets For End Plate Figure 8 17 End Plate with Gasket Installed ...

Page 76: ...ve on the Strainer and drain the boiler water from the unit It will be necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe during draining 4 Next connect a hose the Drain Valve on the DHW Side of the piping assembly Open the Relief Valve to allow air into the pipe during draining 5 After the boiler water and domestic water have been drained from the unit close...

Page 77: ...l View 8 For larger SmartPlate units models SPDW61 SPDW113 remove the U bolt securing the heat exchanger support bar not shown above and if there is an L bracket remove it 9 For smaller SmartPlate units models SPDW23 SPDW32 SPDW42 use a 3 4 socket wrench to remove the horizontal hex head screw and washer shown in Figure 8 19 Also remove the hex nut securing the L bracket to the heat exchanger moun...

Page 78: ...EL THE DOUBLE WALL HEAT EXCHANGER WEIGHS BETWEEN 350 AND 800 POUNDS YOU MUST THEREFORE USE EXTREME CARE WHEN REMOVING THE HEAT EXCHANGER FROM ITS MOUNT USE A STRAP SUITABLE FOR SUCH WEIGHT TO LIFT AND REMOVE THE HEAT EXCHANGER FROM ITS MOUNT 10 Insert a lifting strap through the four 4 holes in the frame plate and pressure plate as shown in Figure 8 20 to safely lift the heat exchanger off its mou...

Page 79: ... reverse the previous steps Support the replacement heat exchanger using a suitable lifting strap shown in Figure 8 20 above and lower into position on the heat exchanger mount Ensure it is properly aligned with the Piping Assembly and heat exchanger mount Ensure that the bolts on all four Victaulic couplings or flange connectors are securely tightened For model SPDW61 or SPDW113 re install the re...

Page 80: ... 10 1 ELECTRONICS MODULE REPLACEMENT To remove and replace the Control Valve Electronics Module ELECTRONICS MODULE REPLACEMENT Instructions 1 Turn OFF the POWER Switch on the side of the ECS SP Control Box 2 Loosen the two 2 captive screws securing the Electronics Module cover Figure 8 22 3 Remove the Module cover to access the wiring terminals Figure 8 23 Disconnect and tag the power and control ...

Page 81: ...position 8 Reconnect the power and control signal wire leads to the Electronics Module 9 Turn ON the POWER Switch on the side of the ECS SP Control Box 10 Recalibrate the Control Valve using the procedures in Chapter 4 section 4 2 1 11 Replace the cover on the Electronics Module after the Valve has been successfully calibrated 12 Return the unit to service COVER SCREWS 2 HAND WHEEL Figure 8 22 Con...

Page 82: ... pipe Strainer Figure 8 24 5 Close both Isolation Ball Valves on the Boiler Water pipe side of the unit 6 Open the Blow Down Drain Valve on the Strainer Figure 8 24 Boiler Water Piping Components 7 While supporting the Control Valve from above loosen all three 3 unions securing the Valve 8 Inspect the union seals and seats 9 Install the replacement Control Valve and ensure that the seals are not p...

Page 83: ...1 Turn OFF the external power circuit breaker to the Water Heater and also turn OFF the POWER Switch on the side of the ECS SP Control Box 2 Connect a hose to the DHW Drain Valve Figure 8 25 3 Close both Isolation Ball Valves on the DHW piping 4 Open the DHW Drain Valve 5 Open the Relief Valve to allow air to enter the piping while draining 6 Disconnect the power leads from the Pump Head 7 Remove ...

Page 84: ...20 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 84 of 134 RECIRCULATION PUMP REPLACEMENT Instructions Figure 8 25 Domestic Water Piping Components AIR ELIMINATOR 200 PSI SHOWN ISOLATION BALL VALVES INLET STRAINER RECIRCULATION PUMP HEAT EXCHANGER STRAINER BLOW DOWN VALVE RELIEF VALVE DHW DRAIN VALVE ...

Page 85: ...trainer and open it to drain the piping It may be necessary to temporarily loosen a union on the Control Valve to allow air into the piping 3 Refer to Figure 8 26 and loosen the two compression fitting nuts on the Differential Pressure Gauge tubes which are inserted into the brass Strainer body 4 Pull and wiggle the tubes and Gauge and lift the assembly straight upward to remove it from the Strain...

Page 86: ...l Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 86 of 134 DIFFERENTIAL PRESSURE GAUGE REPLACEMENT Instructions Figure 8 26 Differential Pressure Gauge Strainer Ball Valve Combo Boiler Side ISOLATION BALL VALVE STRAINER BODY BLOW DOWN VALVE GAUGE BODY FITTINGS 2 PLCS DIFFERENTIAL PRESSURE GAUGE COMPRESSION FITTINGS 2 PLCS ...

Page 87: ...follow 8 14 CONTROL BOX ASSEMBLY REPLACEMENT If necessary the complete ECS SP Control Box Assembly can be removed and replaced as follows CONTROL BOX ASSEMBLY REPLACEMENT Instructions 1 Loosen the captive screws on the Control Box door and the recessed panel Figures 2 3 2 4 2 Open the swing down recessed panel Locate and disconnect the Line Neutral and Ground leads connected to Terminal Block TB 2...

Page 88: ...moval and replacement is accomplished as follows TEMPERATURE CONTROLLER REPLACEMENT Instructions 1 Switch power off and open the Control Box door to access the Temperature Controller 2 The Temperature Controller is installed in a sleeve as shown in Figure 8 27 To unplug and remove the Controller from its sleeve simply pry the latching ears outward and pull the Controller out of the panel 3 To inst...

Page 89: ...WITCH and TEMPERATURE INDICATOR REPLACEMENT Instructions 1 Open the Control Box door to locate the Switch or Indicator to be replaced 2 Loosen the captive screw on the recessed panel behind the door Open the swing down panel to access the Switch Indicator wiring connections and panel retaining clips 3 Remove the Switch Indicator rear cover and loosen the terminal wiring connection screws Disconnec...

Page 90: ...and secure the Control Box door 8 17 24 VAC STEP DOWN TRANSFORMER REPLACEMENT The 24 VAC Transformer is mounted on the back interior wall of the Control Box Figure 8 30 View D D Replacement is accomplished as follows STEP DOWN TRANSFORMER REPLACEMENT Instructions 1 Open the Control Box door and loosen the captive screw on the recessed panel behind the door 2 Open the swing down panel and locate th...

Page 91: ...ce Manual CHAPTER 8 CORRECTIVE MAINTENANCE OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 91 of 134 STEP DOWN TRANSFORMER REPLACEMENT Instructions Figure 8 30 ECS SP Control Box Assembly 69096 Sheet 1 of 2 ...

Page 92: ...age 92 of 134 STEP DOWN TRANSFORMER REPLACEMENT Instructions VIEW D D INTERIOR BACK WALL 7 TERMINAL BLOCK TB 1 1 TEMPERATURE CONTROLLER L N G V V 1A 1B 3A 3D OVERTEMP SWITCH 7 8 9 10 11 1 2 7 8 9 10 11 1 2 7 8 9 10 11 1 2 3 3 3 2 BOILER WATER TEMP IN OUT VIEW C C FRONT PANEL VIEWED FROM BACK 24 VAC TRANSFORMER Figure 8 30 ECS SP Control Box Assembly 69096 Sheet 2 of 2 ...

Page 93: ...SEMBLY 69096 PARTS LIST Item Qty Part No Description 1 1 65082 TRANSFORMER X075CBA 120 240 TO 24 VAC 2 1 64008 TEMPERATURE INDICATOR CONTROLLER 3 2 64056 OVER TEMP SWITCH TEMP INDICATOR 4 3 60003 ON OFF SWITCH 6 1 65087 TERMINAL BLOCK 12 POSITION TB 2 7 1 65008 TERMINAL BLOCK 20 POSITION TB 1 12 1 63047 AC WIRE HARNESS 13 1 63048 CONTROL WIRING HARNESS 15 1 63009 3 EXTERNAL HARNESS 22 5 62003 PLUG...

Page 94: ...te Installation Operation Maintenance Manual CHAPTER 8 CORRECTIVE MAINTENANCE OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 94 of 134 This page left intentionally blank ...

Page 95: ...OL AND COMMUNICATION OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 95 of 134 APPENDIX A MODBUS CONTROL AND COMMUNICATION TEMPERATURE CONTROLLER Eurotherm 2408 PROCEDURES MODBUS COMMUNICATION INFORMATION PROCESS DIAGNOSTIC ALARM MESSAGES ...

Page 96: ...roller Parts Needed a ECS SP Control Box Assembly P N 69096 TAB b Temperature Indicating Controller P N 64008 c Communications Board P N 64009 TAB ADDING A COMMUNICATION BOARD Instructions 1 Turn off power to ECS SP Control Box Assembly 2 Slide out Temperature Indicating Controller P N 64008 from Control Box Assembly by gently pushing the indicated latching ears to the side See Figure A 1 Figure A...

Page 97: ...gure A 3 5 The Controller will report a hardware error as indicated in Figure A 3 Press the up arrow key located on the right side of the Temperature Controller until 8 appears on the lower half of the screen 6 Press the page button located on the left side of the Temperature Indicating Controller until Exit appears on the top half of the screen 7 Press the up down arrow key to choose yes 8 Wait a...

Page 98: ...4 A 1 2 Changing the Temperature Controller Communication Addresses NOTE Refer to the button map at the bottom of the display Figure A 4 for all panel navigation instructions Figure A 4 The Temperature Controller address is defaulted to 1 from the factory To change the MODBUS address proceed as follows 1 Page to the ACCS list and Scroll down to codE Page Scroll Down Arrow Up Arrow Button Map ...

Page 99: ...sing the Up Arrow The number will flash and display PASS 3 Scroll to Goto current value is OPEr and use the Down Arrow to enter a value of Full The entry confirms by flashing the lower display momentarily off and then on 4 Go to the home screen by pressing the Page and Scroll buttons at the same time 5 Page to the cmS list 6 Scroll to the Addr screen 7 Use the Up Arrow to select the desired addres...

Page 100: ...and Scroll buttons at the same time 9 Page to the ACCS list and change the code to anything other than 24 The codE number you enter will flash off and then on to 0 to confirm that access is now set to the OPEr level and it is safe to return to use 10 Confirm that the Addr is set properly by pressing the Page button until the cmS list is displayed Scroll to Addr If the value is correct you are done...

Page 101: ... 133 LoGH Peak Temp 40 205 F Resets on Power Loss Read Only 5 15 135 LoGA Average Temp 40 205 F Resets on Power Loss Read Only 5 15 134 LoGL Low Temp 40 205 F Resets on Power Loss Read Only 5 15 13 set 74 status 0 safe 1 alarm AL 1 Over Temp Alarm 40 205 F 20 F above setpoint Alarm Type 17 Deviation High Read Only 5 7 5 20 14 set 74 status 0 safe 1 alarm AL 2 FSH Full Scale High Alarm 205 F 205 F ...

Page 102: ...re returning to Operator level Once in Operator level check all of the operator parameters before resuming normal operation If the fault persists or occurs frequently contact your supplier S br Sensor Break Input sensor is unreliable or the input signal is out of range Check that the sensor is correctly connected Hw Er Hardware Error Indication that a module is of the wrong type missing or faulty ...

Page 103: ...r isolation problem ErrA Module 3 ID failure Faulty or loose module or isolation problem dCF DC output failure Return Controller for repair OPEn Secondary Input Missing or Disconnected This error may result from no power to the flow meter check for green power light on rear of meter or 0 5V flowmeter signal connections or a disconnection of the Molex connector between feedforward sensor and the Eu...

Page 104: ...tallation Operation Maintenance Manual APPENDIX A MODBUS CONTROL AND COMMUNICATION OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 104 of 134 This page left intentionally blank ...

Page 105: ...aintenance Manual APPENDIX B ECS SP WIRING DIAGRAM OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 105 of 134 APPENDIX B ECS SP WIRING DIAGRAM TERMINAL BLOCK CONNECTIONS Drawing Number 69008 2 rev F ...

Page 106: ...SP WIRING DIAGRAM OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 106 of 134 INTERNAL RECIRC PUMP 120 240 VAC 120 24 VAC 220 24 VAC TRANSFORMER POWER IN FROM FUSE POWER SWITCH FOR 220 VAC WIRE 100 MUST BE CONNECTED TO THIS TERMINAL ...

Page 107: ...ation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 107 of 134 APPENDIX C SMART PLATE PIPING DRAWINGS Drawing Number SD A 772 rev C ...

Page 108: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 108 of 134 Drawing Number SD A 773 rev C ...

Page 109: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 109 of 134 Drawing Number SD A 774 rev D ...

Page 110: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 110 of 134 Drawing Number SD A 775 rev D ...

Page 111: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 111 of 134 Drawing Number SD A 776 rev C ...

Page 112: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 112 of 134 Drawing Number SD A 777 rev C ...

Page 113: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 113 of 134 Drawing Number SD A 796 rev D ...

Page 114: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 114 of 134 Drawing Number SD A 792 rev D ...

Page 115: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 115 of 134 Drawing Number SD A 793 rev D ...

Page 116: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 116 of 134 Drawing Number SD A 794 rev E ...

Page 117: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 117 of 134 Drawing Number SD A 783 rev D ...

Page 118: ...te Installation Operation Maintenance Manual APPENDIX C SMARTPLATE PIPING DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 118 of 134 Drawing Number SD A 784 rev C ...

Page 119: ...on Operation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 119 of 134 APPENDIX D DIMENSIONAL DRAWINGS Drawing Number AP A 846 rev C ...

Page 120: ...Plate Installation Operation Maintenance Manual APPENDIX D DIMENSIONAL DRAWINGS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 120 of 134 Drawing Number AP A 847 rev E ...

Page 121: ...ly drawings below 5 1 24198 SUPPORT BRACKET ASSEMBLY BRAZED HEAT EXCHANGER 6 1 35015 SUPPORT A FRAME SMARTPLATE 7 1 33084 1 BRACKET UPPER PIPES 8 2 33084 2 ADJUSTER PIPE SUPPORT 9 1 33083 BRACKET MIXING BOX 10 2 33085 BRACKET LOWER PIPES SUPPORT 20 1 33086 SUPPORT CONTROL BOX 22 1 73072 PLATE RATING 31 1 69096 CONTROL BOX ASSY SMARTPLATE Description Item 2 Item 3 A Item 3 B Item 3 C Item 4 A Item ...

Page 122: ...ENDIX E PART LISTS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 122 of 134 AERCO International Inc Blauvelt NY 10913 SmartPlate Single Wall Part List 02 27 2017 29381 TAB rev F Sheet 2 of 2 1 31 6 2 3 4 22 5 8 9 10 7 ...

Page 123: ...ARTPLATE DW 12 1 69096 CONTROL BOX ASSY SMARTPLATE 18 1 73072 PLATE RATING 20 1 33106 BRACKET ADJUSTER PIPING SUPPORT Pressure Description Item 1 Item 3 A Item 3 B Item 4 A Item 4 B Item 8 150 PSI Pressure SPDW 23 120V 60 Hz 28104 1 22263 2 220V 50 Hz 22263 4 SPDW 32 120V 60 Hz 28104 2 22263 2 220V 50 Hz 22263 4 SPDW 42 120V 60 Hz 28104 3 22264 2 220V 50 Hz 22264 4 SPDW 61 120V 60 Hz 28104 4 22264...

Page 124: ...NDIX E PART LISTS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 124 of 134 2 12 6 1 3 4 18 20 5 9 7 10 AERCO International Inc Blauvelt NY 10913 SmartPlate Double Wall Part List 02 22 2017 29382 TAB rev E Sheet 2 of 2 ...

Page 125: ... SP33 SPDW23 SPDW32 Double Wall 200 PSI 58128 6 SP45 SP69 SP150 SPDW42 SPDW61 SPDW113 Double Wall The contents of each kit are shown in the table below Quantity Per Kit 150 PSI Kits 200 PSI Kits Part Description 58128 1 58128 3 58128 4 58128 2 58128 5 58128 6 92070 Air Vent Valve 150 PSI 1 1 1 92130 Air Vent Valve 200 PSI 1 1 1 92065 1 Relief Valve M X F 150 PSI 1 1 1 92134 1 Relief Valve 200 PSI ...

Page 126: ... Models Pressure Type Power 22263 1 SP23 SP33 150 PSI Single Wall 120V 60 Hz 200 PSI 22263 2 SPDW23 SPDW32 150 PSI Double Wall 200 PSI 22263 3 SP23 SP33 150 PSI Single Wall 220V 50 Hz 200 PSI 22263 4 SPDW23 SPDW32 150 PSI Double Wall 200 PSI Appropriate add on kit differentiates overall product for given DHW side operating pressure The table below lists the parts and quantities in each piping asse...

Page 127: ...nce Manual APPENDIX E PART LISTS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 127 of 134 AERCO International Inc Blauvelt NY 10913 SmartPlate 1 5 Piping Assembly 11 15 2016 22263 TAB rev D Sheet 2 of 2 ...

Page 128: ...69 SP150 150 PSI Single Wall 120V 60 Hz 200 PSI 22264 2 SPDW42 SPDW61 SPDW113 150 PSI Double Wall 200 PSI 22264 3 SP45 SP69 SP150 150 PSI Single Wall 220V 50 Hz 200 PSI 22264 4 SPDW42 SPDW61 SPDW113 150 PSI Double Wall 200 PSI 22264 5 SPDW42 SPDW61 SPDW113 200 PSI Double Wall 220V 60 Hz Appropriate add on kit differentiates overall product for given DHW side operating pressure The table below list...

Page 129: ...nce Manual APPENDIX E PART LISTS OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 129 of 134 AERCO International Inc Blauvelt NY 10913 SmartPlate 2 0 Piping Assembly 11 15 2016 22264 TAB rev D Sheet 2 of 2 ...

Page 130: ...63009 52 HOT WATER OUT TO TEMP CTRL WIRING HARNESS 1 63009 53 HOT WATER OUT TO OVER TEMP SW WIRING HARNESS 1 63009 55 BOILER WATER IN WIRING HARNESS 1 63009 57 BOILER WATER OUT WIRING HARNESS 1 63009 58 MIXED INLET TEMP WIRING HARNESS 1 63009 61 RECIRCULATION PUMP WIRING HARNESS 1 63009 64 CONTROL VALVE WIRING HARNESS THE FOLLOWING PART NUMBERS ARE SUB COMPONENTS OF 63009 64 63009 62 ACTUATOR SIGN...

Page 131: ...ix E Part Lists Item 2 Sheet 1 Valve Electronic Module 65092 Temperature Controller See Control Box previous page Circulator Pump 120 VAC 60 Hz 69259 1 Circulator Pump 220 VAC 50 Hz 69259 2 Circulator Pump 220 VAC 60 Hz 69259 3 Domestic Water Inlet Thermocouple 99042 1 Domestic Water Outlet Thermocouple 99042 2 TABLE F 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Boiler Water ...

Page 132: ...ance DESCRIPTION PART NUMBER Pump Flange Gasket Set 89011 1 Pump Casing O Ring 89011 2 Pump Capacitor 120 VAC 89011 3 Pump Capacitor 220 VAC 89011 4 Pump Cartridge Assembly 89011 5 Pump Fuse 69098 3 TABLE F 4 Optional Spare Parts DESCRIPTION PART NUMBER Over Temperature Switch BW Temp Indicator 64056 Boiler Water Sensor 61018 TABLE F 5 Spare Parts Recommended for Control Valve DESCRIPTION PART NUM...

Page 133: ...SmartPlate Installation Operation Maintenance Manual OMM 0069_0H SP 100 1 30 2020 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 133 of 134 NOTES ...

Page 134: ...us various updates reference DIR 393 DIR 17 001 Added recommendation in Section 2 4 to use 2 pipe wrenches when tightening pipe connections Chris Blair 1 30 2020 Rev H DIR 18 31 Clarified over temperature fault relay connections in Figure 2 7 DIR 18 72 Replaced references to Hydro Skrub cleaning solution with Rydlyme Chemical Descaler from Apex Engineering Products Corp DIR 20 11 Replaced gasket 8...

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