Aerco INN600 User Manual
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Aerco INN600 User Manual

Natural gas or propane modulating, condensing water heater
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Natural Gas or Propane
Modulating, Condensing
Water Heater Models
Applicable to Serial Number
G-14-2265 and above
This guide applies to the
following Innovation models
•
Innovation 600
•
Innovation 800
•
Innovation 1060
•
Innovation 1350
Other documents for this
product include:
• GF-5030
INN-Recon Gas Supply Guide
• GF-5050
INN-Recon Venting Guide
• GF-5060
INN-Recon Elect. Power Guide
• GF-5080
INN Sizing Guide
Latest Update: 11/25/2014
OMM-0078_0L
GF-128
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
USER MANUAL
Installation, Operation and Maintenance
INNOVATION Series
Gas-Fired Water Heaters
Page 1 of 206
PRI: 11/25/2014

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  • Page 1 • GF-5050 INN-Recon Venting Guide • GF-5060 INN-Recon Elect. Power Guide • GF-5080 INN Sizing Guide Latest Update: 11/25/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 1 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • 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.

  • Page 3: Table Of Contents

    2.12.14 AUX RELAY Terminals ......................... 33 2.13 FLUE GAS VENT INSTALLATION ..................33 2.14 COMBUSTION AIR ......................34 2.14.1 Combustion From Outside the Building ..................34 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 3 of 206 Phone: 800-526-0288...
  • Page 4 5.6.1 Remote Interlock ..........................70 5.6.2 Delayed Interlock ........................... 71 5.7 FLAME FAULT TESTs ......................71 5.8 AIR FLOW FAULT TESTS ....................72 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 5 8.3.9 Run Hours and Run Cycles ......................116 8.3.10 High Temperature Governor ...................... 116 8.4 WHM STATUS DISPLAYS ....................116 8.5 BST ALTERNATING STATUS DISPLAYS ................ 117 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 5 of 206 Phone: 800-526-0288...
  • Page 6 APPENDIX I – RECOMMENDED SPARES ................197 APPENDIX J – COMBUSTION CALIBRATION (KOREA ONLY) ..........199 APPENDIX K – WARRANTY ....................203 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 7: Foreword

    FORWARD FOREWORD The AERCO Innovation Series Potable Water Heaters are modulating units which represent a true industry advance that meets the needs of today's energy efficiency and environmental concerns. Designed for use in any domestic water heating system, each Innovation model provides precisely-controlled potable water within ±2°F of setpoint, regardless of flow rate.
  • Page 8 Input, Natural Gas or Propane, Double Block & Bleed INN1350SVPDBB (Formerly IRI) Gas Train with WHM Sequencing Valve 1,205 lbs. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 9 British Thermal Unit. A unit of energy approximately equal to the heat required to raise 1 pound of water 1°F. Combustion Control Panel C-More Controller A control system developed by AERCO and currently used in all (or Control Box) Benchmark, Innovation and KC1000 Series product lines. Carbon Monoxide...
  • Page 10 A resistor placed at each end of a daisy-chain or multi-drop network in order to prevent reflections that may cause invalid data in the communication AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 206 OMM-0078_0L...
  • Page 11 Vacuum Fluorescent Display, or Variable Frequency Drive Watt W.C. Water Column Water Heater Management µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 11 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 12 Innovation Water Heaters Installation, Operation & Maintenance Manual FORWARD (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 13: Chapter 1. Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired heaters and ANSI/NFPASB for LP gas-fired heaters.

  • Page 14: Emergency Shutdown

    MANUAL GAS SHUT-OFF VALVE VALVE OPEN VALVE CLOSED Figure 1-1. Manual Gas Shutoff Valve AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 15: Prolonged 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 of the unit. The installer must identify the emergency shut-off device.
  • Page 16 ______________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 17: Chapter 2. Installation

    • Condensate Drain Trap If the Innovation Water Heater is equipped for use with the AERCO Water Heater Management (WHM) system, an actuator-controlled ball valve will also be included with the unit. When optional accessories are ordered, they may be packed within the unit’s shipping container, factory installed on the unit, or packed and shipped in a separate container.

  • Page 18: Site Preparation

    Figure 2-1 (shown with optional Sequencing Valve). 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.

  • Page 19: Setting The Unit

    Heater Management (WHM) system, then an actuator-controlled ball valve will be included with the shipment. Refer to section 2.5.1 for installation instructions prior to connecting inlet piping. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 19 of 206...

  • Page 20: Water Inlet And Outlet Piping

    Attached the valve to the cold water inlet of the unit using the pipe union and nipple provided. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 2-3b. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 21: Test Hose Bib Connection

    CHAPTER 2 – INSTALLATION WHM Ball Valve Installation – Continued AERCO recommends that another pipe nipple and union be attached to the valve inlet prior to connecting the cold water supply piping. Tighten all pipe connections after the valve is properly positioned.

  • Page 22: System Recirculation Loop

    C-More Control System. The Control System utilizes this data to modulate the fire rate (Air/Fuel Valve position) to precisely maintain the hot water outlet temperature at the selected setpoint temperature. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 206 OMM-0078_0L...

  • Page 23: Pressure & Temperature Relief Valve Installation

    12 inches of the floor to prevent injury in the event of a discharge. The relief outlet piping must be equal to the outlet size of the relief valve without reduction. No valves, restrictions, or other AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L...

  • Page 24: Condensate Drain & Piping

    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 25 For more information, see Technical Instruction Document TID-0029, Condensate Neutralization Kit and TID-0074 Condensate Neutralization Tank. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 25 of 206 Phone: 800-526-0288...

  • Page 26: Gas Supply Piping

    Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.10 GAS SUPPLY PIPING The AERCO Innovation Gas Components and Supply Design Guide, GF-5030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF...

  • Page 27: External Gas Supply Regulator

    However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact AERCO for more information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 28: Ac Electrical Power Wiring

    Figure 2-9. Power Box Location – Partial Front View, Front Panel Removed 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 2-10. In addition, a wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.

  • Page 29: Field Control Wiring

    Refer to the wiring diagram provided on the cover of the I/O Box (Figure 2-12) when making all wiring connections. 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 30: Outdoor Air In Terminal

    The controller will attempt up to three ignition cycles. If no spark is present by the third try, the controller will shut down and display a fault message. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 206...

  • Page 31: Analog In Terminals

    NOTE When driving an isolation valve, shorting jumper #JP2 MUST be installed on the I/O Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 31 of 206 Phone: 800-526-0288...

  • Page 32: Rs485 Comm Terminals

    Heaters are being controlled by an Energy Management System (EMS) or the C-More Water Heater Management (WHM) system using Modbus (RS485) communication. The WHM software required to control up to 8 AERCO Innovation Water Heaters is included in the C-More Control System used with each Innovation unit.

  • Page 33: Fault Relay Terminals

    2.13 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-5050 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 34: Combustion Air

    The more common methods of combustion air supply are outlined in the following sections. For combustion air supply from ducting, consult the AERCO Innovation Venting and Combustion Air Guide, GF-5050. 2.14.1 Combustion From Outside the Building Air supplied from outside the building must be provided through two permanent openings.

  • Page 35: Ducted Combustion

    In a ducted combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. See the AERCO Innovation Venting and Combustion Air Guide, GF-5050. When using the heater in a ducted combustion air configuration, each unit must have a minimum 6 inch diameter connection at the unit.
  • Page 36 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 37: Chapter 3. Operation

    Table 3-1. Additional information on these items is provided in the individual operating procedures provided in this Chapter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 37 of 206...
  • Page 38 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-1. Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 39 Low Water Level alarm. TEST/RESET Switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 39 of 206 Phone: 800-526-0288 GF-128...
  • Page 40 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 Page 40 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 41: Control Panel Menus

    The menu option choices do not wrap around. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 41 of 206...
  • Page 42 Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 43: Operating Menu

    The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 43 of 206...

  • Page 44: Setup Menu

    Factory-Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 45 0°F 10°F Network Timeout 5 Sec 999 Sec 30 Sec Shutoff Dly Temp Demand Offset Deadband High Deadband Low AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 45 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...

  • Page 46: Tuning Menu

    103°F Breakpt at 20% 30°F 240°F 118°F Breakpt at 10% 30°F 240°F 134°F Breakpt at 0% 30°F 240°F 136°F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 47: Calibration Menu

    Outlet Tmp Dsply Enabled or Disabled Inlet Tmp Dsply Enabled or Disabled Valv Pos Out Dsp Enabled or Disabled AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 47 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 48 Depends on unit type/size Min Spark Amps 0 Amps 2.5 Amps 0.1 Amps Max Spark Amps 0 Amps 2.5 Amps 0.4 Amps AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 49: Start Sequence

    Also, if the required conditions are not observed at any point during the start sequence, appropriate messages will be displayed and the unit will go into fault mode. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 49 of 206...
  • Page 50 AIR IN STEPPER PURGE MOTOR VALVE POSITION DIAL AT 100% TO BLOWER Figure 3-4. Air/Fuel Valve In Purge Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 51 STEPPER IGNITION VALVE MOTOR POSITION DIAL AT 25% to 35% TO BLOWER Figure 3-6. Air/Fuel Valve In Ignition Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 51 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...

  • Page 52: Start/Stop Levels

    416,000 665,000 306,000 424,000 520,000 870,000 370,000 486,000 715,000 1,001,000 483,000 615,000 845,000 1,203,000 100% 600,000 800,000 1,060,000 1,350,000 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 53: Chapter 4. Initial Start-Up

    Safety Device 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. 100 Oritani Drive...

  • Page 54: Installing Gas Supply Manometer

    (Install manometer here) MANUAL SHUTOFF SSOV VALVE AIR/FUEL Figure 4-1. 1/4 Inch Gas Plug Location (INN600-1060 Gas Train Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 55: Accessing The Analyzer Probe Port

    µA scale. The flame detector is mounted on the flange of the blower side intake manifold as shown in Figure 4-3. Proceed as follows to set up the multimeter to measure the flame strength current: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 55 of 206...

  • Page 56: Recommendations For Temperature Calibration

    In case of DHW pre-heat systems, the required temperature rise through an individual unit can be much lower to ensure that flow per unit does not exceed 50 GPM at any time. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 206...

  • Page 57: Natural Gas Combustion Calibration

    BTU content, gas supply piping and supply regulators. Start-Up & Registration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
  • Page 58 25% higher than the listed calibration range shown in the table. Record the increased O value on the Combustion Calibration sheet. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 206 OMM-0078_0L...

  • Page 59: Propane Combustion Calibration

    BTU content, gas supply piping and supply regulators. Start-Up & Registration Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
  • Page 60 Combustion Oxygen Level at 16% Valve Position Oxygen % ± 0.5 Carbon Monoxide Flame Strength 6.0 % <50 ppm <15 ppm >2.0 µA AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 61: Reassembly

    This completes the PROPANE combustion calibration procedure. 4.5 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 61 of 206 Phone: 800-526-0288...

  • Page 62: Temperature Control Calibration

    Upon completion of calibration, set the Outlet Feedback back to ENABLE. Temperature control calibration is accomplished by performing the Minimum and Maximum Load Adjustment procedures in sections 4.6.2 and 4.6.3, respectively. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 206 OMM-0078_0L...

  • Page 63: Setting The Outlet Water Temperature Setpoint

    Repeat steps 5 through 9 as needed until the temperature is stabilized at no more than 2 to 3 degrees above the unit’s setpoint. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 63 of 206...

  • Page 64: Maximum Load Adjustment

    After performing Temperature Calibration and prior to placing the water heater into service, be sure to set the Outlet Feedback option in the Tuning Menu back to ON. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 206 OMM-0078_0L...

  • Page 65: Over-Temperature Limit Switches

    MANUAL RESET (NON- AUTOMATIC RESET ADJUSTABLE) OVER- (ADJUSTABLE) OVER- TEMPERATURE LIMIT TEMPERATURE LIMIT SWITCH SWITCH Figure 4-6. Over-Temperature Limit Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 65 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 66 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 67: Chapter 5. Safety Device Testing

    Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box. The fault message should clear and the FAULT indicator should go off. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 67 of 206 Phone: 800-526-0288...

  • Page 68: High Gas Pressure Fault Test

    SSOV VALVE TO AIR/FUEL VALVE Figure 5-1. Low & High Gas Pressure Testing (INN600-1060 Gas Train) 5.3 HIGH GAS PRESSURE FAULT TEST To simulate a high gas pressure fault, refer to Figure 5-1 and proceed as follows: High Gas Pressure Fault Remove the 1/8“...

  • Page 69: Low Water Level Fault Test

    Reset the adjustable over-temperature switch to its original setting. 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 OMM-0078_0L Page 69 of 206...

  • Page 70: Interlock Tests

    The unit should shut down and display INTERLOCK OPEN. 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 Page 70 of 206 OMM-0078_0L...

  • Page 71: Delayed Interlock

    The unit will execute a 30 second re-ignition delay and display WAIT RETRY PAUSE. c) The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 71 of 206 Phone: 800-526-0288...

  • Page 72: Air Flow Fault Tests

    SHUTOFF SSOV VALVE AIR/FUEL Figure 5-3. Manual Gas Shut-Off Valve Location (INN600-1060 Gas Train) 5.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 5-4. Air Flow Fault Tests Disable the blower output drive voltage as follows: Press the MENU key until CONFIGURATION MENU is displayed.
  • Page 73 VALVE INLET SWITCH BLOWER PROOF SWITCH BLOWER PARTIAL FRONT VIEW Figure 5-4. Blower Proof & Blocked Inlet Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 73 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...

  • Page 74: Ssov Proof Of Closure Switch

    The unit should shut down and display SSOV FAULT DURING PURGE. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 206...

  • Page 75: Purge Switch Open During Purge

    Remove the Air/Fuel Valve cover (see Figure 5-7) by rotating the cover counterclockwise to unlock and lift up to remove. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 5-8). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 75 of 206...

  • Page 76: Safety Pressure Relief Valve Test

    Figure 5-8. Air/Fuel Valve Purge and Ignition Switch Locations 5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code, Section AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 206 OMM-0078_0L...

  • Page 77: Chapter 6. Maintenance

    6.1 MAINTENANCE SCHEDULE 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 78: 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 Page 78 of 206 OMM-0078_0L...
  • Page 79 Reconnect the igniter-injector cable and ground wire. Reinstall the side and rear panels on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 79 of 206...

  • Page 80: Flame Detector

    Such deposits can be influenced by the extent of the condensing operation and the chloride and sulfur levels that can vary significantly from application to application. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 206...
  • Page 81 Refer to Figure 6-3. Loosen and remove the four (4) 1/4-20 cap screws securing the blower side of the intake manifold (44106). DO NOT REMOVE the two 1/4-20 screws and nuts securing the manifold support bracket. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 81 of 206...
  • Page 82 Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as necessary. This completes the fireside inspection of the unit. Proceed to step 18 and reassemble the unit as indicated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 206 OMM-0078_0L Phone: 800-526-0288...
  • Page 83 EXHAUST MANIFOLD SIDE NUTS 5/16-18 STUDS (6) PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED Intake and Exhaust Manifolds Figure 6-5. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 83 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 84 Reinstall the exhaust vent onto the exhaust manifold using a High Temp Red RTV silicon sealant, such as sealants available from Permatex or Loctite. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 206 OMM-0078_0L...

  • Page 85: Waterside Inspection

    Pull the baffle assembly out of the chamber, exposing the heat exchanger tubes. Inspect and clean the heat exchanger tubes of scale and clean all gasket surfaces thoroughly before reassembling the upper head. AERCO recommends that NEW gaskets be used when reassembling.

  • Page 86: Anode Replacement

    Remove any hardware or debris that may have fallen on the cardboard shield installed in step 1 and then remove the shield from the chamber. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 206...

  • Page 87: Heat Exchanger Cleaning

    Figure 6-8. Anode Assembly and Combustion Chamber Head 6.8 HEAT EXCHANGER CLEANING For hard water installations, AERCO high recommends use of its Scale Reducer system. The Scale Reducer, Model SR300, is strongly recommended for installations in areas with hard water (>3.5 grains/gal).

  • Page 88: Pumping System Set-Up Instructions

    PREVENTOR COLD WATER PUMP CLOSE COLD CIRCULATION WATER INLET BUCKET DRAIN VALVE Figure 6-9. Sample Heat Exchanger Cleaning Set-Up AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 89: Cleaning Procedure

    There are two methods of testing the effectiveness of HydroSkrub during cleaning: the calcium carbonate spot test of the circulating solution and the charting of a trend in the pH of the cleaning solution. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 89 of 206...

  • Page 90: Condensate Drain Trap

    (older style only) and the float in the condensate trap and replace the trap cover. 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 Page 90 of 206 OMM-0078_0L...

  • Page 91: Air Filter Replacement

    5/16” nut driver. Replace the side panels on the unit and return heater to service use. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 91 of 206...

  • Page 92: Low Water Cutoff (Lwco) Capacitor Integrity Test

    On the Innovation series, the LWCO probe is located on the heat exchanger body on the left side of the unit. Refer to Figure 6-12 for an illustration of the LWCO probe assembly and its installation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 206 OMM-0078_0L...

  • Page 93: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    Serious personal injury or death may occur if this warning is not observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 93 of 206...
  • Page 94 Ohmmeter 19-Pin Shell Harness Cable Connector LWCO Probe Assembly Figure 6-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 95: Low Water Cutoff (Lwco) - Standard C-More Test

    Close external gas supply valve. Open relief valve to vent water pressure. Open the drain valve and drain all water from the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 95 of 206 Phone: 800-526-0288...

  • Page 96: Placing The Heater Back In Service After A Prolonged Shutdown

    Perform initial startup per Chapter 4. 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 Page 96 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 97: Chapter 7. Troubleshooting Guide

    The front panel of the C-More Control Box contains an RS232 port. This port is used only by factory-trained personnel to monitor OnAER communications via a portable computer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 97 of 206...
  • Page 98 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 99 Check Air/Fuel Valve position at 0%, 50% and 100% open 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 OMM-0078_0L Page 99 of 206...
  • Page 100 See CORRECTIVE ACTIONS from 3 to 16 for AIRFLOW AIRFLOW FAULT DURING IGNITION FAULT DURING IGNITION. applies for this fault AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 101 Carbon or other debris on Burner. Remove the burner and inspect for any carbon or debris. Clean and reinstall. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 101 of 206 Phone: 800-526-0288...
  • Page 102 Replace the switch if it does not show continuity. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 206 OMM-0078_0L Phone: 800-526-0288...
  • Page 103 N.O. and COM terminals. If the switch shows continuity when not in contact with the cam replace the switch. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 103 of 206...
  • Page 104 Check that proving switch for any device hooked to the interlocks is not closed. interlock circuit is closing and that the device is operational. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 206 OMM-0078_0L...
  • Page 105 If the switch shows continuity when not in contact with the cam, check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 105 of 206...
  • Page 106 Check control signal type set in type (voltage or current). Configuration Menu. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 206 OMM-0078_0L Phone: 800-526-0288...
  • Page 107 Incorrectly wired switch. Ensure that the SSOV Proof of Closure switch is correctly wired. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 107 of 206 Phone: 800-526-0288...
  • Page 108 Poor combustion calibration TEMP HIGH Heat exchanger has scale. (Flashing WARNING) Clean heat exchanger using procedures in Chapter 6. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 109: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 80% Valve Position in Control Box are outdated. are Rev. E or higher. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 109 of 206 Phone: 800-526-0288...
  • Page 110 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 111 FLAME DETECTOR (Kit P/N 24356-2) IGNITION IGNITER-INJECTOR SOLENOID (Kit P/N 58023) Figure 7-2. Blower-Side Intake Manifold (Shown removed from Heater) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 111 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 112 COVER OPEN/CLOSED ACTUATOR INDICATOR WINDOW COVER SCREW Figure 7-3. SSOV Actuator With Gas Pressure Adjustment & Damping Orifice AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 113: Chapter 8. Water Heater Management

    The On-Board-Water-Heater Management system II (WHM II) is an integrated C-MORE feature designed to stage and coordinate multiple AERCO Innovation water heaters while maximizing operational efficiency. The WHM software code resides in each C-More that is part of the system.

  • Page 114: Whm Principles Of Operation

    (On or Off) is assured by the development of two independent valve control functions, with one function monitoring the results of the other. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 206 OMM-0078_0L...

  • Page 115: Modbus Header Sensor

    8.3.5 Automatic Temperature Sensor Calibration This feature allows the user to automatically calibrate the temperature sensors to achieve optimal system performance and efficiency. This feature requires an AERCO Temperature Calibration dongle (fixed resistor set) and a password level to access the calibration menu.

  • Page 116: Whm Auto Mstr

    Only AERCO personnel are permitted to change this menu item. To increase the Run Hours/Cycles, go the “Run Cycles” or “Run Hours” items in the Diagnostic menu.

  • Page 117: Bst Alternating Status Displays

    In addition to the WHM Menu items listed in Table 8-1, the Setup Menu contains a Comm Address option which must be entered for each unit to enable WHM control of the system. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 117 of 206...
  • Page 118 ValveFdbk Status Close Open Fdbk state MB Head Temp En Enable or Disable Disable WHM Header Temp Header Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 119: Whm Menu Item Descriptions

    WHM Master. This will simplify the number of required entries since most of the settings will be “pushed” to the appropriate Slaves. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 119 of 206...
  • Page 120 Yes (Enabled), the WHM Auto Timer option allows the user to select the elapsed time interval between failure of the WHM Master and switch-over to a new WHM Master. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 206 OMM-0078_0L...
  • Page 121 Specifies the time the WHM Master waits for a slave unit to turn On. Displays the status of the WHM Sequencing Valve. WHM Valve State (1 = ON, 0 = OFF) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 121 of 206 Phone: 800-526-0288...
  • Page 122 Where: Unit 1 & 3 = On, Unit 2 = Off, Unit 4 = Not available, Unit 5 = Lead On, Unit 6 = Lag Off AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 206...

  • Page 123: Whm Hardware Installation & Set-Up Instructions

    The following sections provide the basic installation and set-up instructions for implementing a Water Heater Management System (WHM) to control up to eight (8) AERCO Innovation Water Heaters. Some of the descriptions and procedures included in Chapter 2 may be repeated here to avoid unnecessary referencing.

  • Page 124: Whm Modbus Network Wiring

    SLAVE NOTE: The WHMS Master does not necessarily have to be on either end of the Daisy-Chain loop Figure 8-3. Typical Daisy-Chain Modbus/RS485 Network AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 206 OMM-0078_0L...

  • Page 125: Control And Power Wiring

    WHM unit is accomplished by simply ensuring that the 4-pin Molex connectors on the units are connected to the corresponding connectors on the valves. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 125 of 206...
  • Page 126 C-More Control Panel of the last unit on the chain, turn the DIP Figure 8-4 WHMS Network Wiring Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 127: Whm Programming & Start-Up

    AERCO recommends that the WHM Master be set up first. By doing so, the Master will “push” most of the required menu entries to each WHM Slave as each unit is brought on-line. The following steps assume that the WHM Master and Slaves will be consecutively numbered, starting at 1 (WHM Master).
  • Page 128 The WHM Auto Mstr and WHM Auto Timer options will be automatically “pushed” to the WHM Slaves on the network. This completes all programming for the WHM. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 206 OMM-0078_0L...

  • Page 129: Troubleshooting

    The Actuator-Controlled Sequencing Valve shown in Figure 8-5 is comprised of the following main components: • 2” Brass Ball Valve • Actuator Linkage • Actuator Housing • Valve Shaft Handle AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 129 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 130 The components on the PC board include DIP switches which are preset at the factory and should not be changed unless instructed to do so. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 206...
  • Page 131 Press and hold the brass CLUTCH button shown in Figure 8-6. With the CLUTCH button depressed, the ball valve can be manually rotated from the fully open (90°) to the fully closed (0°) position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 131 of 206...

  • Page 132: Sequencing Valve Operating Characteristics

    Valve (open/close) as a feedback signal (2 – 10Vdc) to the C-More. The valve position can be observed on the scale provided on the Actuator Linkage. Figure 8-7. Sequencing Valve Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 206 OMM-0078_0L...

  • Page 133: Appendix A - Innovation Menu Item Descriptions

    Displays total run time of unit in hours from 0 to 9,999,999. Fault Log Displays information on the last 20 faults (0 – 19). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 133 of 206...

  • Page 134: Table A-2: Setup Menu Item Descriptions

    Sets the Number portion of a unit serial number Identifies the current software version of the control box (Ver Software Version 0.0 to Ver 9.9). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 135: Table A-3: Configuration Menu Item Descriptions

    N/A for Water Heaters Setpt Limiting Setpt Limit Band N/A for Water Heaters AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 135 of 206 Phone: 800-526-0288 GF-128...
  • Page 136 Displays the IGST Board Version Installed in the C-More Displays the active Ignition Time setting (4sec or 7sec) as IGN Time Setting defined by the P4 Harness AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 137: Table A-4: Tuning Menu Item Descriptions

    Start of Feedback Position Fdback End Pos End of Feedback Position Max Feedback Max Feedback Fdback Value Monitor Feedback Value AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 137 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 138 For Factory Personnel ONLY NOTE: Feedback Gain (Item 8) is only displayed when Heater Tuning Display is enabled by factory authorized personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 139: Table A-5: Calibration Menu Item Descriptions

    1% to 5% in 1% increments. Power Reset Allows the Power Reset Option to be set to Auto or Manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 139 of 206...
  • Page 140 Range = -20ºF to +20ºF – Inlet Wtr Offset Range = -20ºF to +20ºF – Outlet Wtr Offset Range = -20ºF to +20ºF AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 141 Min Spark Amps spark transformer input. Allows the adjustment of the maximum spark current required at the Max Spark Amps spark transformer input. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 141 of 206 Phone: 800-526-0288 GF-128...
  • Page 142 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 143: Appendix B - Startup, Status And Fault Messages

    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 OMM-0078_0L Page 143 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 144 The Low Water Cutoff board is indicating low water level. LEVEL NETWORK COMM The RS-485 network information is not present or is corrupted. FAULT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...
  • Page 145 TEMP HIGH (Flashing) Level #1: 180ºF, Flash WARNING Level #2: 190ºF, Govern fire rate/flash WARNING Level #3. 200ºF, Shut down unit (requires manual reset) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 145 of 206 Phone: 800-526-0288...
  • Page 146 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 147: Appendix C - Temperature Sensor Resistance/Voltage Chart

    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 OMM-0078_0L Page 147 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 148 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 149: Appendix D - Dimensional Drawings

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-888 rev H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 149 of 206 Phone: 800-526-0288...
  • Page 150 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-902 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 151: Appendix E - Parts List Drawings

    EXHAUST MANIFOLD SEAL AERCO International, Innovation Parts List 10/30/2014 Inc. Blauvelt, NY 10913 Top Level Page 1 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 151 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 152 PLATED HEAT EXCHANGER KIT AERCO International, Innovation Parts List 10/30/2014 Inc. Blauvelt, NY 10913 Top Level Page 2 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 153 RIGHT-SIDE VIEW – EXPLODED AERCO International, Innovation Parts List 10/30/2014 Inc. Blauvelt, NY 10913 Top Level Page 3 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 153 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 154 RIGHT-FRONT VIEW LEFT-REAR VIEW AERCO International, Innovation Parts List 10/30/2014 Inc. Blauvelt, NY 10913 Top Level Page 4 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 155 AERCO International, Innovation 600-800-1060 FM 1” Gas Train 09/19/2014 Inc. Blauvelt, NY 10913 22122 rev G Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 155 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 156 AERCO Innovation 600-800-1060 DBB Gas Train 10/23/2014 International, Inc. Blauvelt, NY 10913 22122-1 rev J Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 157 AERCO Innovation 600-800-1060 DBB Gas Train 10/23/2014 International, Inc. Blauvelt, NY 10913 22122-1 rev J Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 157 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 158 AERCO Innovation 1350 FM Gas Train 09/19/2014 International, Inc. Blauvelt, NY 10913 22168 rev B Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 159 AERCO Innovation 600P-800P PROPANE Gas Train 09/19/2014 International, Inc. Blauvelt, NY 10913 22179 rev D Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 159 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 160 AERCO 09/19/2014 1/2" Propane DBB Gas Train International, Inc. Blauvelt, NY 10913 22179-1 rev A Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 161 AERCO 09/19/2014 1/2" Propane DBB Gas Train International, Inc. Blauvelt, NY 10913 22179-1 rev A Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 161 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 162 Innovation 1060P-1350P AERCO 09/19/2014 3/4"PROPANE Gas Train International, Inc. Blauvelt, NY 10913 22180 rev D Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 163 09/19/2014 3/4 Inch Propane DBB Gas Train International, Inc. Blauvelt, NY 10913 22180-1 rev A Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 163 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 164 09/19/2014 3/4 Inch Propane DBB Gas Train International, Inc. Blauvelt, NY 10913 22180-1 rev A Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 165 AERCO Innovation 1350 DBB Gas Train 11/17/2014 International, Inc. Blauvelt, NY 10913 22168-1 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 165 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 166 AERCO Innovation 1350 DBB Gas Train 11/17/2014 International, Inc. Blauvelt, NY 10913 22168-1 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 167 Innovation 1350K 1" Gas Train AERCO 11/17/2014 International, Inc. Blauvelt, NY 10913 22182-1 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 167 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 168 Innovation 1350PK 3/4" Propane DB Gas AERCO 11/17/2014 Train International, Inc. Blauvelt, NY 10913 22182-4 rev C Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 169 AERCO 11/14/2013 Air Fuel Delivery System International, Inc. Blauvelt, NY 10913 24295 rev K (PL-A-164) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 169 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 170 AERCO 11/13/2013 Air Fuel Delivery System International, Inc. Blauvelt, NY 10913 24346 rev F (PL-A-174) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 171 Innovation Intake Manifold, Burner & Shield 09/18/2014 International, Inc. Blauvelt, NY 10913 24234 rev C & 24233 rev C Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 171 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 172 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 173: Appendix F - Piping Drawings

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-829 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 173 of 206 Phone: 800-526-0288...
  • Page 174 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-830 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 175 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-831 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 175 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 176 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-845 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 177 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-848 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 177 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 178 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-849 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 179 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-850 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 179 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 180 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-851 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 181 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-852 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 181 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 182 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-853 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 183 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-854 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 183 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 184 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-855 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 185 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-856 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 185 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 186 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-939 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 187: Appendix G - C-More Control Panel Views

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – C-MORE CONTROL PANEL VIEWS APPENDIX G – C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL EXPLODED VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 187 of 206 Phone: 800-526-0288...
  • Page 188 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL REAR VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 206 OMM-0078_0L Phone: 800-526-0288...

  • Page 189: Appendix H - C-More Wiring Diagrams

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68039 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 189 of 206 Phone: 800-526-0288...
  • Page 190 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 191 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68039 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 191 of 206 Phone: 800-526-0288...
  • Page 192 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 193 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68042 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 193 of 206 Phone: 800-526-0288...
  • Page 194 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 194 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...
  • Page 195 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS Drawing Number: 68042 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 195 of 206 Phone: 800-526-0288...
  • Page 196 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 196 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 197: Appendix I - Recommended Spares

    NOTE 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 OMM-0078_0L Page 197 of 206 Phone: 800-526-0288...
  • Page 198 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – RECOMMENDED SPARES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 198 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014 GF-128...

  • Page 199: Appendix J - Combustion Calibration (Korea Only)

    BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
  • Page 200 Allow the combustion analyzer to stabilize following each adjustment. Clockwise rotation reduces the oxygen level, while counterclockwise rotation increases the oxygen level. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 200 of 206 OMM-0078_0L Phone: 800-526-0288...
  • Page 201 16. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed. 17. This completes the combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 201 of 206 Phone: 800-526-0288...
  • Page 202 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX J – COMBUSTION CALIBRATION (KOREA ONLY) (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 202 of 206 OMM-0078_0L Phone: 800-526-0288 PRI: 11/25/2014...

  • Page 203: Appendix K - Warranty

    Operation of the heater using contaminated air will void the warranty. The heat exchangers combustion chamber shall not be warranted from failure due to scaling, liming, corrosion, or erosion due to water or installation conditions. AERCO will repair, rebuild or exchange, at its option the heat exchanger/combustion chamber according to the following...
  • Page 204 An Officer of AERCO must do any modifications to this warranty in writing. AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES.
  • Page 205 Innovation Water Heaters Installation, Operation & Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0L Page 205 of 206 Phone: 800-526-0288 GF-128 PRI: 11/25/2014...
  • Page 206 1118: Removed vent gasket 81148, expanded section 2-13 Flue Gas Vent Installation; use Red RTV when installing flue vent International Inc. © AERCO International, Inc., 2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 206 of 206 OMM-0078_0L Phone: 800-526-0288...

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