Aerco INNOVATION INN600 User Manual
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Aerco INNOVATION INN600 User Manual

Gas-fired
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Download this manual See also: User Manual
Natural Gas Modulating,
Condensing Water Heater
Models:
· INN600
· INN800
· INN1060
Applicable to Serial Numbers
G-10-1350 to G-11-0563
Other documents for this product
include:
· GF-5030
INN Gas Supply Guide
· GF-5050
INN Venting Guide
· GF-5060
INN Elect. Power Guide
· GF-5080
INN Sizing Guide
Copies of these documents are
included in Appendices J thru M
of this Manual
Released: 07/21/2011
AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, New York 10913 · Phone: 800-526-0288
INNOVATION Series
Gas-Fired Water Heaters
USER MANUAL
Installation, Operation, and Maintenance
GF-128
OMM-0079_0B

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Summary of Contents for Aerco INNOVATION INN600

  • Page 1 INN Elect. Power Guide · GF-5080 INN Sizing Guide Copies of these documents are included in Appendices J thru M of this Manual Released: 07/21/2011 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, New York 10913 · Phone: 800-526-0288...
  • Page 2 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.

  • Page 3: Table Of Contents

    2.13 FLUE GAS VENT INSTALLATION ................. 25 2.14 COMBUSTION AIR ......................25 2.14.1 Combustion From Outside the Building ..............26 2.14.2 Combustion Air from Inside the Building ..............26 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 3 of 200 07/21/11...
  • Page 4 5.6.1 Remote Interlock .......................52 5.6.2 Delayed Interlock .......................53 5.7 FLAME FAULT TESTS ..................... 53 5.8 AIR FLOW FAULT TESTS ....................54 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 4 of 200 07/21/11...
  • Page 5 8.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION ......... 87 8.4 DATA LOGGING ......................88 8.4.1 Fault Log ........................88 8.4.2 Operation Time Log ....................89 8.4.3 Sensor Log ........................89 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 5 of 200 07/21/11...
  • Page 6 APPENDIX L: GF-5060: ELECTRICAL POWER GUIDE ......... 175 APPENDIX M: GF-5080: COMMERCIAL LAUNDRY SIZING GUIDE ..... 183 APPENDIX N: LIMITED WARRANTY ............... 195 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 6 of 200 07/21/11...

  • Page 7: Foreword

    Energy Management Systems. For service or parts, contact your local sales representative or AERCO INTERNATIONAL. NAME: ORGANIZATION: ADDRESS: TELEPHONE: INSTALLATION DATE: ___________________________________________________ AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 7 of 200 07/21/11...
  • Page 8 Innovation Series Water Heaters USER MANUAL Foreword OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 8 of 200 07/21/11...

  • Page 9: Chapter 1. Safety Precautions

    SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT SHEET METAL ENCLOSURES. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 9 of 200 07/21/11...

  • Page 10: Emergency Shutdown

    Chapter 6 of this manual be performed, to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO heater and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.
  • Page 11 248 CMR 5.08(2)(a)1 through 4. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 11 of 200 07/21/11...
  • Page 12 ______________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 12 of 200 07/21/11...

  • Page 13: Chapter 2. Installation

    · Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps. · Access to Natural Gas line at a minimum pressure of 4 inches W.C. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 13 of 200...

  • Page 14: Installation Clearances

    Figure 2-1. 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: ·...

  • Page 15: Setting The Unit

    All piping must be arranged so that it does not interfere with removal of any covers, inhibit service or maintenance, or prevent access between the unit and walls, or another unit. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 15 of 200...

  • Page 16: Test Hose Bib Connection

    (Figure 2-4). The pipe diameter should be a minimum of 3/4". The Test Hose Bib cannot be omitted. Figure 2-4. Test Hose Bib Location AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 16 of 200 07/21/11...

  • Page 17: Pressure & Temperature Relief Valve Installation

    Condensate Trap (part no. 24060) which is packed separately within the unit’s shipping container. The Condensate Trap inlet and outlet connections contain tapped 3/4” NPT ports. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 17 of 200...
  • Page 18 · The base of the condensate trap must be supported to ensure that it is level (horizontal). · The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.

  • Page 19: Gas Supply Piping

    OMM-0079_0B Figure 2-7. Sample Condensate Trap Installation 2.10 GAS SUPPLY PIPING The AERCO Innovation Gas Components and Supply Design Guide, GF-5030 (see Appendix J) must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF...

  • Page 20: Gas Supply Specifications

    A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C. Figure 2-8. Manual Gas Shut-Off Valve Location AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 20 of 200 07/21/11...

  • Page 21: Ac Electrical Power Wiring

    2.11.1 Electrical Power Requirements The AERCO Innovation Heater accepts 120 VAC, single-phase, 60 Hz @ 20A. The Power Box contains a terminal block as shown in Figure 2-8. In addition, a wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.

  • Page 22: Field Control Wiring

    Figure 2-11. Input/Output (I/O) Box Location Since identical I/O Boxes are used with both AERCO gas-fired boilers and water heaters, some of the input and output connections apply only to boilers while others are common to both boilers and heaters.

  • Page 23: Outdoor Air Sensor

    This input is always enabled and is a view only input that can be seen in the operating menu. The sensor must be wired to the AUX SENSOR IN and SENSOR COMMON and must be similar to AERCO BALCO wire sensor P/N 12449. A resistance chart for this sensor is located in APPENDIX C. 2.12.3 ANALOG IN The ANALOG IN + and –...

  • Page 24: Pwm) In

    Start On Dly can be programmed from 0 to 120 seconds. This option is locate in the Configuration Menu (Chapter 3). AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 24 of 200 07/21/11...

  • Page 25: Fault Relay

    2.13 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-5050 (see Appendix K) 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"...

  • Page 26: Combustion From Outside The Building

    2.15 SEALED COMBUSTION The AERCO Innovation Water Heater is UL listed for 100%-sealed combustion. For sealed combustion installations, the screen inlet air ductwork must then be attached directly to the unit’s air inlet. In a sealed combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run.

  • Page 27: Chapter 3. Operation

    Table 3-1. Additional information on these items is provided in the individual operating procedures provided in this Chapter. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 27 of 200...
  • Page 28 Innovation Series Water Heaters Chapter 3 USER MANUAL Operation OMM-0079_0B Figure 3-1. Control Panel Front View AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 28 of 200 07/21/11...
  • Page 29 Low Water Level alarm. Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 29 of 200...
  • Page 30 VALVE POSITION 20 segment red LED bargraph continuously shows the Bargraph Air/Fuel Valve position in 5% increments from 0 to 100% AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 30 of 200 07/21/11...

  • Page 31: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 31 of 200...

  • Page 32: Operating Menu

    (Top-Down). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up). AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 32 of 200...

  • Page 33: Setup Menu

    Unit of Temp Fahrenheit or Celsius Fahrenheit Comm Address Baud Rate 2400, 4800, 9600, 19.2K 9600 Software Ver 0.00 Ver 9.99 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 33 of 200...

  • Page 34: Configuration Menu

    (If Mode = Outdoor Reset) Outdoor Sensor Enabled or Disabled Disabled System Start Tmp 30°F 100°F 60°F (If Outdoor Sensor = Enabled) AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 34 of 200 07/21/11...

  • Page 35: Tuning Menu

    8°F 1°F Integral Gain 0.00 2.00 Derivative Time 0.0 min 2.00 min 0.10 min Reset Defaults? Yes, No, Are You Sure? 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 35 of 200...

  • Page 36: Start Sequence

    Air/Fuel Valve (Figure 3-4) will read 100 to indicate that it is full-open (100%). The VALVE POSITION bargraph will show 100%. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 36 of 200...
  • Page 37 The igniter relay is activated and provides ignition spark. The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 37 of 200...

  • Page 38: Start/Stop Levels

    Note that the energy input of the heater is not linearly related to the Air/Fuel Valve position. Refer to Table 3-6 for the relationship between the energy input and Air/Fuel Valve position for a unit running on natural gas. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 38 of 200 07/21/11...
  • Page 39 (% Open) (BTU/Hr) (% of Full Capacity) 45,000 4.2% (Stop Level) 97,000 222,000 416,000 520,000 645,000 715,000 845,000 930,000 100% 1,060,000 100% 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 39 of 200...
  • Page 40 Innovation Series Water Heaters Chapter 4 USER MANUAL Initial Start-Up OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 40 of 200 07/21/11...

  • Page 41: Chapter 4. Initial Start-Up

    Testing procedures specified in Chapter 5 to complete all initial unit start-up requirements. An AERCO Gas Fired Startup Sheet, included with each Innovation Heater, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at: AERCO International, Inc.

  • Page 42: Installing Gas Supply Manometer

    2. If necessary, adjust the stop on the combustion analyzer probe so it will extend mid-way into the flue gas flow. DO NOT install the probe at this time. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 42 of 200...

  • Page 43: Natural Gas Combustion Calibration

    9. Change the valve position to 29% using the ▲ arrow key. The unit should begin its start sequence and fire. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 43 of 200...
  • Page 44 17. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed. 18. This completes the combustion calibration procedure. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 44 of 200...

  • Page 45: Reassembly

    4. Press the ▲ or ▼ arrow key until the desired setpoint is displayed. 5. Press the ENTER key to save the change. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 45 of 200...

  • Page 46: Minimum Load Adjustment

    9. Press ENTER to save the change. Allow time for the system to stabilize between adjustments. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 46 of 200...

  • Page 47: Over-Temperature Limit Switches

    Set the automatic over-temperature switch to the desired setting. Figure 4-4. Over Temperature Limit Switch Location 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 47 of 200...
  • Page 48 Innovation Series Water Heaters Chapter 4 USER MANUAL Initial Start-Up OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 48 of 200 07/21/11...

  • Page 49: Chapter 5. Safety Device Testing

    8. The fault message should clear and the FAULT indicator should go off. The unit should restart. 9. Upon test completion, close the ball valve and remove the manometer. Replace the 1/8“ plug removed in step 1. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 49 of 200...

  • Page 50: High Gas Pressure Test

    4. Continue draining the unit until a LOW WATER LEVEL fault message is displayed and the FAULT indicator flashes. 5. Place the unit in the Manual Mode and raise the valve position above 30%. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 50 of 200 07/21/11...

  • Page 51: Water Temperature Fault Test

    7. Reset the adjustable over-temperature switch to its original setting. 8. The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 51 of 200...

  • Page 52: Interlock Tests

    4. The unit should shut down and display INTERLOCK OPEN. 5. Once the interlock connection is reconnected, the INTERLOCK OPEN message should automatically clear and the unit should restart. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 52 of 200 07/21/11...

  • Page 53: Delayed Interlock

    DURING IGNITION following the IGNITION RETRY cycle. 11. Open the valve previously closed in step 8. 12. Press the CLEAR button. The unit should restart and fire. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 53 of 200...

  • Page 54: Air Flow Fault Tests

    8. Go to the Configuration Menu, Analog Output item and select VALVE POSITION 0-10v. 9. Press the CLEAR button. The unit should restart. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 54 of 200...
  • Page 55 14. Unblock the air inlet and press the CLEAR button. The unit should restart. Figure 5-4. Blower Proof & Blocked Inlet Switch Locations Figure 5-5. Water Heater Rear View Showing Air Inlet Location AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 55 of 200...

  • Page 56: Ssov Proof Of Closure Switch

    5. The unit should begin it’s start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. 6. Replace the wire on the Purge Switch and depress the CLEAR button. The unit should restart. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 56 of 200 07/21/11...

  • Page 57: Ignition Switch Open During Ignition

    7. Replace the wire on the Ignition Switch and press the CLEAR button. The unit should restart. Figure 5-7. Typical Air/Fuel Valve Cover Location Figure 5-8. Air/Fuel Valve Purge and Ignition Switch Locations AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 57 of 200...

  • Page 58: Safety Pressure Relief Valve Test

    5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code, Section VI. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 58 of 200 07/21/11...

  • Page 59: Chapter 6. Maintenance

    The Innovation Water Heater requires regular routine maintenance to ensure continued reliable operation throughout the service life of the unit. For optimum operation, AERCO recommends that the following routine maintenance procedures be performed in the time periods specified in Table 6-1.

  • Page 60: Igniter-Injector

    Repeated carbon build-up is an indication that the combustion settings of the unit should be checked. Refer to Chapter 4 for combustion calibration procedures. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 60 of 200...

  • Page 61: Flame Detector

    1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power from the unit. 2. Remove the side and rear panels from the unit. 3. Disconnect the flame detector lead wire. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 61 of 200...

  • Page 62: Combustion Calibration

    4. Disconnect the lead wire from the flame detector installed on the intake manifold flange (Figure 6-2). AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 62 of 200 07/21/11...
  • Page 63 12. Carefully lower and remove the blower side intake manifold (44106), burner assembly (46023), burner gasket (18899) and fiber frax gasket (124749) from the unit. See Figures 6-3 and 6-4. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11...
  • Page 64 18. This completes the fireside inspection of the unit. Figure 6-4. Innovation Heater – Partial Left-Side View Figure 6-5. Innovation Heater – Partial Cut-Away View AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 64 of 200 07/21/11...

  • Page 65: Waterside Inspection

    6). Prior to performing the inspection, ensure that the following replacement gaskets are available: GP-18556 Release Gasket GP-18532 Shell Gasket To inspect the waterside of the heat exchanger, proceed as follows: AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 65 of 200...
  • Page 66 11. Replace the unit Cap. Close the drain valve and reopen the inlet, outlet, and recirculation valve. Figure 6-7. Flat Style Head Configuration AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 66 of 200...

  • Page 67: Heat Exchanger Cleaning

    OMM-0079_0B HEAT EXCHANGER CLEANING AERCO recommends that the heat exchanger of the unit be cleaned annually using a solution of Hydroskrub and water. Hydroskrub is distributed by AERCO International, Inc. and is designed to dissolve the toughest water scale, lime, mud and rust deposits from virtually any type of water-based equipment.

  • Page 68: Cleaning Procedure

    Continue water flushing the equipment for a minimum of 10 minutes or until discharge runs clear. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 68 of 200 07/21/11...

  • Page 69: Testing Hydroskrub Effectiveness

    8. Reassemble all piping and hose connections to the condensate trap inlet and outlet. Reconnect the trap to exhaust manifold drain. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 69 of 200...

  • Page 70: Air Filter Replacement

    5/16” nut driver. 6. Replace the side panels on the unit and return heater to service use. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 70 of 200 07/21/11...

  • Page 71: Shutting The Water Heater Down For An Extended Period Of Time

    4. Perform initial startup per Chapter 4. 5. Perform safety device testing and scheduled maintenance procedures per Chapters 5 and 6 of this manual. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 71 of 200...
  • Page 72 Innovation Series Water Heaters Chapter 7 USER MANUAL Troubleshooting Guide OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 72 of 200 07/21/11...

  • Page 73: Chapter 7. Troubleshooting Guide

    If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 73 of 200...
  • Page 74 Innovation Series Water Heaters Chapter 7 USER MANUAL Troubleshooting Guide OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 74 of 200 07/21/11...
  • Page 75 12. Defective Air-Fuel Valve potentiometer positions. The positions on the VALVE POSITION bargraph should match the dial readings on the Air/Fuel Valve dial. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 PR1 - 07/21/11 Page 75 of 200...
  • Page 76 6. See CORRECTIVE ACTIONS from 3 to 16 for AIRFLOW FAULT AIRFLOW FAULT DURING IGNITION DURING IGNITION. applies for this fault AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 76 of 200 PR1 - 07/21/11...
  • Page 77 If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 PR1 - 07/21/11 Page 77 of 200...
  • Page 78 1. Poor combustion calibration TEMPERATURE 2. Heat exchanger has scale. 2. Clean heat exchanger using procedures in Chapter 6. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 78 of 200 PR1 - 07/21/11...
  • Page 79 1. Press CLEAR button and restart unit. If fault persists, contact COMM FAULT between the PMC board and qualified Service Personnel. Ignition/Stepper (IGST) board AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 PR1 - 07/21/11 Page 79 of 200...
  • Page 80 4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 80 of 200 PR1 - 07/21/11...
  • Page 81 Air/Fuel Valve or the Control Box. Refer fault to qualified service personnel. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 PR1 - 07/21/11 Page 81 of 200...
  • Page 82 Check control signal type set in type (voltage or current). Configuration Menu. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 82 of 200 PR1 - 07/21/11...
  • Page 83 Air/Fuel Valve track each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (GF-112, para. 6.2.1). AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 PR1 - 07/21/11 Page 83 of 200...

  • Page 84: Additional Faults Without Specific Fault Messages

    1. Check to ensure that the IGST and Power Supply Boards are 80% Valve Position Control Box are outdated. Rev. E or higher. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 84 of 200 PR1 - 07/21/11...
  • Page 85 Chapter 7 Troubleshooting Guide USER MANUAL OMM-0079_0B Figure 7-1. Gas Train Component Locations Figure 7-2. Blower-Side Intake Manifold (Shown removed from Heater) AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 85 of 200...
  • Page 86 Innovation Series Water Heaters Chapter 7 USER MANUAL Troubleshooting Guide OMM-0079_0B Figure 7-3. SSOV Actuator With Gas Pressure Adjustment & Damping Orifice AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 86 of 200 07/21/11...

  • Page 87: Chapter 8. Rs232 Communication

    2. Press the Enter key on the laptop. An asterisk (*) prompt should appear. 3. At the prompt, enter the valid RS232 password (jaguar) in lower case letters and press Enter. 4. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices:...

  • Page 88: Data Logging

    10 faults, the earliest fault is overwritten when a new fault occurs. A sample Fault Log display is shown in Table 8-1. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 88 of 200...

  • Page 89: Operation Time Log

    Run, Direct Drive 1/15/02 1:21pm Ignition 1/15/02 1:20pm Off, Switch 1/15/02 12:30pm Run, Manual 1/15/02 11:55am Ignition 1/15/02 11:55am Power-up 1/15/02 11:50am AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 89 of 200...
  • Page 90 180 OPEN OPEN OPEN OPEN OPEN 1/15/02 5:16pm 179 OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm 180 OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 90 of 200 07/21/11...

  • Page 91: Appendix A: Water Heater Menu Item Descriptions

    19.2K). Default is 9600. Software Version Identifies the current software version of the control box (Ver 0.0 to Ver 9.9). AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 91 of 200...
  • Page 92 Specifies the timeout value (seconds) before a Modbus fault is declared. Available settings range from 5 to 999 seconds. Default is 30 seconds. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 92 of 200 07/21/11...
  • Page 93 Valve Position corrections. Setting range is 0 to 25. (Default is 0 for both Deadband High and Deadband Low) AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 93 of 200...
  • Page 94 Allows Tuning Menu options to be reset to their Factory Default values. *Only displayed when Heater Tuning Display is enabled by factory authorized personnel. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 94 of 200 07/21/11...

  • Page 95: Appendix B: Startup, Status And Fault Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 95 of 200...
  • Page 96 The Low Water Cutoff board is indicating low water LEVEL level. NETWORK COMM The RS-485 network information is not present or is FAULT corrupted. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 96 of 200 07/21/11...
  • Page 97 FAILURE control the SSOV. STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to FAILURE the desired position. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 - 07/21/11 Page 97 of 200...
  • Page 98 Innovation Series Water Heaters Appendix B USER MANUAL Display Messages OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 98 of 200 07/21/11...

  • Page 99: Appendix C 99Temperature Sensor Resistance/Voltage Chart

    2.50 1311.4 2.52 1337.7 2.54 1364.2 2.56 1391.0 2.58 1418.2 1445.7 *Voltage at AUX & Common terminals in the I/O Box AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 99 of 200...
  • Page 100 Innovation Series Water Heaters Appendix C USER MANUAL Sensor Res./Volt. Chart OMM-0079_0B This Page Is Intentionally Blank Page 100 of 200 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 06/10/11...

  • Page 101: Appendix D: Water Heater Default Settings

    Setpt Limiting Disabled Setpt Limit Band 0°F Network Timeout 30 seconds HI DB Setpt En Demand Offset Deadband High Deadband Low AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 101 of 200...
  • Page 102 Breakpoint At 40% 92°F Breakpoint At 30% 105°F Breakpoint At 20% 124°F Breakpoint At 10% 136°F Breakpoint At 0% 138°F Reset Defaults? AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 102 of 200 07/21/11...

  • Page 103: Appendix E: Parts List Drawings

    DWG. NO.: CHAMBER 1/4" WALL WELDED TUBE SA-312 TP316 SCALE_______ SIZE ________ AP-A-888 [ALL ELECTROLESS NICKEL PLATED] CHKD BY______ APPD _______ AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 103 of 200...
  • Page 104 INNOVATION SERIES HEATER Appendix E USER MANUAL Parts Lists Drawings OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 104 of 200 07/21/11...
  • Page 105 GF-128 Innovation Series Water Heaters Appendix E Parts Lists Drawings USER MANUAL OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 105 of 200...
  • Page 106 INNOVATION SERIES HEATER Appendix E USER MANUAL Parts Lists Drawings OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 106 of 200 07/21/11...
  • Page 107 GF-128 Innovation Series Water Heaters Appendix E Parts Lists Drawings USER MANUAL OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 107 of 200...
  • Page 108 INNOVATION SERIES HEATER Appendix E USER MANUAL Parts Lists Drawings OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 108 of 200 07/21/11...
  • Page 109 GF-128 Innovation Series Water Heaters Appendix E Parts Lists Drawings USER MANUAL OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 109 of 200...
  • Page 110 INNOVATION SERIES HEATER Appendix E USER MANUAL Parts Lists Drawings OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 110 of 200 07/21/11...
  • Page 111 GF-128 Innovation Series Water Heaters Appendix E Parts Lists Drawings USER MANUAL OMM-0079_0B AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 111 of 200...
  • Page 112 INNOVATION SERIES HEATER Appendix E USER MANUAL Parts Lists Drawings OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 112 of 200 07/21/11...

  • Page 113: Appendix F: Piping Drawings

    GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B APPENDIX F: PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 113 of 200...
  • Page 114 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 114 of 200 07/21/11...
  • Page 115 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 115 of 200...
  • Page 116 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 116 of 200 07/21/11...
  • Page 117 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 117 of 200...
  • Page 118 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 118 of 200 07/21/11...
  • Page 119 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 119 of 200...
  • Page 120 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 120 of 200 07/21/11...
  • Page 121 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 121 of 200...
  • Page 122 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 122 of 200 07/21/11...
  • Page 123 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 123 of 200...
  • Page 124 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 124 of 200 07/21/11...
  • Page 125 GF-128 Innovation Series Water Heaters Appendix F Piping Drawings USER MANUAL OMM-0079_0B PIPING DRAWINGS AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 125 of 200...
  • Page 126 Innovation Series Water Heaters Appendix F USER MANUAL PipingDrawings OMM-0079_0B This Page Is Intentionally Blank Page 126 of 200 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288...

  • Page 127: Appendix G: C-More Control Panel Views

    Innovation Series Water Heaters Appendix G Control Panel Views USER MANUAL OMM-0079_0B APPENDIX G: C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL EXPLODED VIEW AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 127 of 200 07/21/11...
  • Page 128 Innovation Series Water Heaters Appendix G USER MANUAL Control Panel Views OMM-0079_0B C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL REAR VIEW Page 128 of 200 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288...

  • Page 129: Appendix H: C-More Wiring Diagrams

    Appendix H Innovation Series Water Heaters C-More Wiring Diagrams USER MANUAL APPENDIX H: C-MORE WIRING DIAGRAMS...
  • Page 130 Innovation Series Water Heaters USER MANUAL OMM-0079_0B This Page Is Intentionally Blank...
  • Page 131 Appendix H Innovation Series Water Heaters C-More Wiring Diagrams USER MANUAL...
  • Page 132 Innovation Series Water Heaters USER MANUAL OMM-0079_0B This Page Is Intentionally Blank...
  • Page 133 Appendix H Innovation Series Water Heaters C-More Wiring Diagrams USER MANUAL...
  • Page 134 Innovation Series Water Heaters USER MANUAL OMM-0079_0B This Page Is Intentionally Blank...
  • Page 135 Appendix H Innovation Series Water Heaters C-More Wiring Diagrams USER MANUAL...
  • Page 136 Innovation Series Water Heaters USER MANUAL OMM-0079_0B This Page Is Intentionally Blank...

  • Page 137: Appendix I: Recommended Spares

    Temperature Switch - Auto Reset (SEE NOTE 1) 123966 NOTE 1: If unit is installed in the State of Kentucky, contact your local AERCO Sales Representative for Temperature Switch rated for 200°F. AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288...
  • Page 138 Innovation Series Water Heaters Appendix J USER MANUAL Recommended Spares OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Phone: 800-526-0288 Page 138 of 200 07/21/11...

  • Page 139: Appendix J: Gf-5030: Gas Components & Supply Design Guide

    Innovation Series Water Heaters Appendix J GF-5030 Gas Guide USER MANUAL OMM-0079_0B APPENDIX J: GF-5030 INNOVATION WATER HEATER GAS COMPONENTS & SUPPLY DESIGN GUIDE AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 139 of 200...
  • Page 140 Innovation Series Water Heaters Appendix J USER MANUAL GF-5030 Gas Guide OMM-0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 140 of 200 07/21/11...
  • Page 141 GAS SUPPLY DESIGN GUIDE INNOVATION Series Natural Gas Modulating, Condensing Water Heater Gas-Fired Water Heaters Models: · INN600 · INN800 · INN1060 Released: 05/26/2011 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 141 of 200...
  • Page 142 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.

  • Page 143: Gas Pressure Requirements

    TAG-0044_0A General AERCO Innovation Low NOx gas fired water heaters are modulating input devices that require an adequate volume of natural gas at constant pressure for proper operation. The gas requirements specified in this document must be satisfied to ensure efficient combustion. Designers and installers must adhere to the AERCO specifications and those of the local authorities having jurisdiction.
  • Page 144 Some utilities, insurance carriers, and industrial customers have special requirement gas components on high input devices beyond that which are normally supplied with AERCO heaters. Secondary shutoffs, high or low pressure operators, and external regulators are typical of the requirements of gas utilities. It is mandatory that a designer or installer comply with these requirements.

  • Page 145: Gas Piping

    DRIP heater. Sufficient clearances for maintenance are required. Diagram 3 Typical Multiple Heater Manifold Construction Pg. 5 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 145 of 200...
  • Page 146 47082 37809 32359 28680 25986 22240 19711 6.00 6.065 110924 76237 61221 52397 46439 42077 36012 31917 Pg. 6 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 146 of 200 07/21/11...
  • Page 147 AERCO’s general guidelines for venting of gas regulators are listed below. AERCO recommends that these guidelines be followed to ensure the most reliable and proper operation of AERCO gas fired equipment. It is also recommended that you consult local codes and the gas regulator manufacturer for additional details.
  • Page 148 GF-5030 Gas Supply Design Guide TAG-0044_0A This Page Is Intentionally Blank Pg. 8 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 148 of 200 07/21/11...
  • Page 149 ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Pg. 9 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 149 of 200...
  • Page 150 Gas Supply Design Guide TAG-0044_0A AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913 Visit Us at www.aerco.com Pg. 10 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 150 of 200 07/21/11...

  • Page 151: Appendix K: Gf-5050: Venting & Combustion Air Guide

    Innovation Series Water Heaters Appendix K GF-5050 Venting Guide USER MANUAL OMM-0078_0B APPENDIX K: GF-5050 INNOVATION WATER HEATER VENTING & COMBUSTION AIR GUIDE 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 151 of 200...
  • Page 152 Innovation Series Water Heaters Appendix K USER MANUAL GF-5050 Venting Guide OMM-0078_0A This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 152 of 200 07/21/11...
  • Page 153 VENTING & COMBUSTION AIR INNOVATION Series Natural Gas Modulating, Condensing Water Heater Gas-Fired Water Heaters Models: · INN600 · INN800 · INN1060 Released: 07/21/2011 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 153 of 200...
  • Page 154 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.
  • Page 155 Gas Code - ANSI Z223.1, or Sections 7.2, 7.3, or 7.4 of CAN/CSA B149, Installation Codes, or applicable provisions of the local building codes. Pg 3 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 155 of 200...
  • Page 156 1. PVC · ASTM F891 · ASTM D2665 · ASTM D1785 · ASTM D2241 Pg 4 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 156 of 200 07/21/11...
  • Page 157 6" EXHAUST CONNECTION KIT (24287) FOR INN600 (24286) FOR INN800 & INN1060 Figure 1. Air Inlet & Vent Connection Components Pg 5 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 157 of 200...

  • Page 158: Combustion Air System

    · Non-motorized louvers and grilles must be fixed in an open position. · Minimum screens mesh size shall not be smaller than ¼ inch mesh. Pg 6 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 158 of 200 07/21/11...
  • Page 159 Figure 2. Combustion Air From Outside the building COMBUSTION AIR FROM EQUIPMENT ROOM Figure 3. Combustion Air From Inside and Outside the Building Pg 7 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 159 of 200...
  • Page 160 (305 CM), TERMINATION MUST BE A MIN. OF 2 FT ABOVE RIDGE. Figure 4. Roof-Mounted Combustion Air Inlet & Vent Outlet Installations Pg 8 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 160 of 200 07/21/11...
  • Page 161 (102 mm) (152 mm) (152 mm) Maximum Combustion Air Equivalent Feet (Meters) (42.7 m) (42.7 m) (42.7 m) Pg 9 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 161 of 200...
  • Page 162 Individual Connector plus Common Combustion Air (42.7 m) (42.7 m) (42.7 m) (42.7 m) (42.7 m) Equivalent Feet (Meters) Pg 10 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 162 of 200 07/21/11...
  • Page 163 135 equivalent ft is LESS than 400 equivalent feet: OK to use 8” Common air intake piping and 6” individual connectors. Pg 11 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 163 of 200...
  • Page 164 Figure 6. Roof-Mounted Combustion Air Inlet & Vent Installation Figure 7. Wall-Mounted Combustion Air Inlet & Vent Installation Pg 12 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 164 of 200 07/21/11...

  • Page 165: Vent System

    7, Venting Systems and Air Supply for Appliances, of the CAN/CSA B149, Installation Codes, or applicable provisions of the local building codes. The vent system for the Innovation heaters must be installed in accordance with AERCO’s installation instructions described in this guide.
  • Page 166 See the National or Canadian Codes listed at the beginning of these instructions for additional information on termination location. Pg 14 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 166 of 200 07/21/11...
  • Page 167 GF-5050 TAG-0043_0C Venting and Combustion Air Guide Pg 15 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 167 of 200...
  • Page 168 (305 CM), TERMINATION MUST BE A MIN. OF 2 FT ABOVE RIDGE. Figure 9. Acceptable Combustion Air Inlet & Vent Outlet Configuration AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 168 of 200 07/21/11...
  • Page 169 2. A 30 foot (10.4 m) length of vent pipe and 2 sharp 90° elbows plus a termination rain add up to 30 ft + (2 x 10 ft) + 10 ft = 50 equivalent ft (18.3 m). Pg 17 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 169 of 200...
  • Page 170 This will ensure the least amount of pressure drop. DO NOT use a TEE, 90°, or 45° elbow. Pg 18 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 170 of 200...
  • Page 171 60 equivalent ft is LESS than 140 equivalent feet: OK to use 8” Common vent piping and 6” individual connectors. Pg 19 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 171 of 200...
  • Page 172 5050 Venting and Combustion Air Guide TAG-0043_0C This Page Is Intentionally Blank Pg 20 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 172 of 200 07/21/11...
  • Page 173 ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Pg 21 of 22 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 173 of 200...
  • Page 174 Venting and Combustion Air Guide TAG-0043_0C AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913 Visit Us at www.aerco.com Pg 22 of 22 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 174 of 200 07/21/11...

  • Page 175: Appendix L: Gf-5060: Electrical Power Guide

    Innovation Series Water Heaters Appendix L GF-5060 Power Guide USER MANUAL OMM-0079_0B APPENDIX L: GF-5060 INNOVATION WATER HEATER ELECTRICAL POWER GUIDE 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 175 of 200...
  • Page 176 Innovation Series Water Heaters Appendix L USER MANUAL GF-5060 Power Guide OMM-0079_B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 176 of 200 07/21/11...
  • Page 177 ELECTRICAL POWER GUIDE INNOVATION Series Natural Gas Modulating, Condensing Water Heater Gas-Fired Water Heaters Models: · INN600 · INN800 · INN1060 Released: 05/26/2011 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 177 of 200...
  • Page 178 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.
  • Page 179 Service Disconnect Switch Control Panel Knock-Out for alternate electrical conduit to Service Switch Figure 1. Service Switch Typical Location Pg. 3 of 6 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 179 of 200...
  • Page 180 120 VAC, 1 PHASE 120V/1/60Hz 1 POLE 20 AMP CIR UIT BREAKER Figure 3. 120V/1Æ/60 Hz Wiring Schematic Pg. 4 of 6 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 180 of 200 07/21/11...
  • Page 181 ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Pg. 5of 6 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 181 of 200...
  • Page 182 Electrical Power Guide TAG-0045_0A AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913 Visit Us at www.aerco.com Pg. 6 of 6 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 182 of 200 07/21/11...

  • Page 183: Appendix M: Gf-5080: Commercial Laundry Sizing Guide

    Innovation Series Water Heaters Appendix M GF-5080 Sizing Guide USER MANUAL OMM-0079_0A APPENDIX M: GF-5080 INNOVATION WATER HEATER COMMERCIAL LAUNDRY SIZING GUIDE AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 183 of 200 PR1 - 07/21/11...
  • Page 184 Innovation Series Water Heaters Appendix M USER MANUAL GF-5080 Sizing Guide OMM-0079_0A This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 184 of 200 07/21/11...
  • Page 185 COMMERCIAL LAUNDRY SIZING GUIDE INNOVATION Series Natural Gas Modulating, Condensing Water Heater Gas-Fired Water Heaters Models: · INN600 · INN800 · INN1060 Released: 05/26/2011 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 185 of 200...
  • Page 186 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.
  • Page 187 100% usability. Standard practice has shown that the tank is able to deliver between 60% and 80% of its total capacity without excessive temperature degradation. AERCO recommends using 70% of the total capacity of an un-baffled vertical tank piped as shown in Figure 1.
  • Page 188 MID = 0.15GPM • capacity of largest machines in pounds PLUS 0.10GPM • total capacity of all other machines in pounds Pg. 4 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 188 of 200 07/21/11...
  • Page 189 In a small laundry (up to 200 pound total machine capacity, and where fill times of 1 minute or longer are acceptable), it is practical to consider the use of the AERCO Innovation heater without any supplemental storage. Heater capacity is selected equal to the maximum instantaneous demands (MID) as calculated for the standard system above.
  • Page 190 7.22 4.17 11.23 7.78 4.49 12.03 8.33 4.81 12.83 8.88 5.13 13.64 9.44 5.45 14.44 9.99 5.77 Pg. 6 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 190 of 200 07/21/11...
  • Page 191 GF-5080 Commercial Laundry Sizing Guide TAG-0046_0A Pg. 7 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 191 of 200...
  • Page 192 GF-5080 Commercial Laundry Sizing Guide TAG-0046 0A Pg. 8 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 192 of 200 07/21/11...
  • Page 193 _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ ______________________________________________________________________________________ Pg. 9 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 193 of 200...
  • Page 194 Commercial Laundry Sizing Guide TAG-0046 0A AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913 Visit Us at www.aerco.com Pg. 10 of 10 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 194 of 200 07/21/11...

  • Page 195: Appendix N: Limited Warranty

    GF-128 Innovation Series Water Heaters APPENDIX N USER MANUAL OMM--0079_0B WARRANTY APPENDIX N: WARRANTY INNOVATION WATER HEATER LIMITED WARRANTY AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 07/21/11 Page 195 of 200...
  • Page 196 GF-128 Innovation Series Water Heaters USER MANUAL OMM--0079_0B This Page Is Intentionally Blank AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph.: 800-526-0288 Page 196 of 200 07/21/11...
  • Page 197 The sale of the product is specifically conditioned upon acceptance of these terms. 07/21/11 AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 197 of 200...
  • Page 198 AERCO shall at its option modify, repair or exchange the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation. In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges.
  • Page 199 ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ __________________________________________________________________________ AERCO International, Inc. · 100 Oritani Dr. · Blauvelt, NY 10913 · Ph: 800-526-0288 Page 199 of 200 07/21/11...

  • Page 200: Aerco International, Inc. · 100 Oritani Dr. · Blauvelt, Ny 10913 · Ph: 800-526-0288

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

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