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SmartPlate 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

1.4 SmartPlate EV PIPING ASSEMBLIES

All SmartPlate EV models include

a 2” diameter piping assembly. This assembly 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

Figure 1.3. SmartPlate EV Piping Assembly plus Other Components

PRESSURE RELIEF

VALVE

ISOLATION BALL

VALVES & STRAINER

HEAT EXCHANGER

3-WAY CONTROL

VALVE

ISOLATION BALL VALVES

POWER BOX

STRAINER WITH
BLOW-DOWN VALVE

CONTROL BOX

RETURN TO

BOILER

DHW

OUTLET

BOILER

WATER INLET

DHW INLET

FLOW METER

Содержание Aerco SmartPlate EV

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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