Gas fired water heating system applicable to serial numbers g-02-530 and above natural gas or propane fired, condensing and forced draft hot water heater 1,000,000 btu/hr input (107 pages)
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• GF-5050 INN Venting Guide • GF-5060 INN Elect. Power Guide • GF-5080 INN Sizing Guide Latest Update: 11/22/2013 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 1 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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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.
2.13 FLUE GAS VENT INSTALLATION ..................33 2.14 COMBUSTION AIR ......................34 2.14.1 Combustion From Outside the Building ..................34 2.14.2 Combustion Air from Inside the Building ..................34 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 3 of 196 Phone: 800-526-0288...
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5.9 SSOV PROOF OF CLOSURE SWITCH ................68 5.10 PURGE SWITCH OPEN DURING PURGE ...............69 5.11 IGNITION SWITCH OPEN DURING IGNITION..............69 5.12 SAFETY PRESSURE RELIEF VALVE TEST ..............70 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 196 OMM-0078_0J Phone: 800-526-0288...
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9.6 WHM MENU SETTINGS ....................114 9.6.1 WHM Mode ..........................114 9.6.2 Comm Address (Located in Setup Menu) ..................114 9.6.3 WHM Setpoint ..........................114 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 5 of 196 Phone: 800-526-0288...
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APPENDIX J – RECOMMENDED SPARES ..................187 APPENDIX K – COMBUSTION CALIBRATION (KOREA ONLY) ..........189 APPENDIX L – WARRANTY ......................193 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 196 OMM-0078_0J Phone: 800-526-0288...
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.
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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 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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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...
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Slave to Slave programming SSOV Safety Shut Off Valve Sequencing Valve (Used with Water Heater Management (WHM) system) TEMP (Temp) Temperature AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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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_0J Page 11 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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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 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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.
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 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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.
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______________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 196 OMM-0078_0J Phone: 800-526-0288...
• 1” Gas Supply Shutoff Valve 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.
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.
If the valve is not already installed on the water inlet of the unit, 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_0J Page 19 of 196...
1. Remove the ball valve from its stowed location within the shipping container. 2. Attached the valve to the cold water inlet of the unit using the pipe union and nipple provided. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 196 OMM-0078_0J...
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 2-3A. 4. AERCO recommends that another pipe nipple and union be attached to the valve inlet prior to connecting the cold water supply piping.
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 196 OMM-0078_0J...
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The maximum working pressure for installations within the Province of Alberta is 87 psig. Therefore, a pressure & temperature relief valve with a setting of 75 psig/210°F is supplied with Alberta shipments. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 23 of 196...
The condensate trap inlet (Figure 2-7) must be level with, or lower than the exhaust manifold drain port. • The base of the condensate trap must be supported to ensure that it is level (horizontal). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 196 OMM-0078_0J Phone: 800-526-0288...
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CHAPTER 2 – INSTALLATION • 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. While observing the above guidelines, install the condensate trap as follows: Condensate Trap Installation 1.
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...
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...
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.
National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code. For electrical power wiring diagrams, see the AERCO Innovation Electrical Power Wiring Guide, (GF-5060). Figure 2-10. AC Terminal Block Configurations 2.12 FIELD CONTROL WIRING...
Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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.
3) When the 4-20mA is selected for the Analog Output, the 0-10VDC is disabled at the VFD/Blower terminals, and the selected output is available at the terminals labeled Analog Output +/-. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 31 of 196...
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.
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"...
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.
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_0J Page 35 of 196...
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This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial-to- USB adaptor for use in modern computer USB ports. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 196 OMM-0078_0J...
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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_0J Page 37 of 196 Phone: 800-526-0288...
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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 38 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 39 of 196...
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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 40 of 196 OMM-0078_0J Phone: 800-526-0288...
RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 41 of 196...
Therefore, the WHM Menu contains only eight (8) user-selectable menu options. These menu options are listed in Table 3-5. Descriptions for each of these menu items are included in Appendix A. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 43 of 196...
Integral Gain 0.00 2.00 Derivative Time 0.0 min 2.00 min 0.10 min Reset Defaults? Yes, No, Are You Sure? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location. GAS INLET MANUAL SSOV SHUTOFF VALVE Figure 3-3. SSOV Location (INN1060 Gas Train) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 45 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Purging and indicate the elapsed time of the purge cycle in seconds. AIR/FUEL VALVE BLOWER PROOF SWITCH OUTLET TO BLOWER Figure 3-5. Blower Proof Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Once the demand for hot water has been satisfied, the Control Box will turn off the SSOV gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will be displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 47 of 196...
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...
The unit contains a 1/8” NPT port at the rear of the exhaust manifold. This port is located above the condensate drain connection as shown in Figure 4-2. Prepare the port for the combustion analyzer probe as follows: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 196 OMM-0078_0J...
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_0J Page 51 of 196...
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.
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0.9” – 1.1” W.C. BRASS HEX HEAD CAP (Remove to access gas pressure adjustment Figure 4-4. Gas Pressure Adjustment Screw Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 53 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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60%, • • 30%, 80%, • • 40%, 100% • 50%, This completes the Natural Gas combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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.
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2.8” – 3.0” W.C. INN600 1.6” – 1.8” W.C. 16. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 196 OMM-0078_0J Phone: 800-526-0288...
1 to 3 degrees. After making an adjustment, the outlet water temperature must be allowed to settle for several minutes prior to making any further adjustments. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 57 of 196...
1. While monitoring the VALVE POSITION bar-graph, create a minimum load on the system that will yield a steady valve position between 25% and 35%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 196...
5. Press the MENU key and select the Tuning Menu. 6. Press the ▲ or ▼ arrow key until Max Load Adj is displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 59 of 196...
Set the automatic over-temperature switch to the desired setting. ADJUSTABLE RESET TEMERATURE LIMIT BUTTON SWITCH Figure 4-5. Over Temperature Limit Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 60 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
7. Fully open the external manual gas shut-off valve and press the CLEAR button on the Control Box. 8. 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_0J Page 61 of 196 Phone: 800-526-0288...
9. The fault message should clear and the FAULT indicator should go off. The unit should restart. 10. 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 Page 62 of 196 OMM-0078_0J Phone: 800-526-0288...
4. Reset the adjustable over-temperature switch to its original setting. 5. 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_0J Page 63 of 196...
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 Page 64 of 196 OMM-0078_0J...
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_0J Page 65 of 196 Phone: 800-526-0288...
The unit will execute a 30 second re-ignition delay and display WAIT RETRY PAUSE. The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 196 OMM-0078_0J Phone: 800-526-0288...
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BLOCKED INLET VALVE 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_0J Page 67 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
10. The unit should shut down and display SSOV FAULT DURING PURGE. 11. 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 68 of 196...
3. Remove the Air/Fuel Valve cover (see Figure 5-7) by rotating the cover counterclockwise to unlock and lift up to remove. 4. 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_0J Page 69 of 196...
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 70 of 196 OMM-0078_0J...
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.
Refer to Chapter 4 for combustion calibration procedures. 6. Prior to reinstalling the igniter, a high temperature, conductive, anti-seize compound must be applied to the threads. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 196 OMM-0078_0J Phone: 800-526-0288...
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Figure 6-2. Igniter & Flame Detector Mounting Details 9. Reconnect the igniter cable and ground wire. 10. Reinstall the side and rear panels on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 73 of 196...
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 74 of 196...
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9. 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_0J Page 75 of 196...
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Replace the liner if there is evidence of cracking or warping. 17. 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 76 of 196 OMM-0078_0J...
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MANIFOLD SIDE NUTS (2) 5/16-18 STUDS PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED Figure 6-5. Innovation Heater – Partial Cut-Away View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 77 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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15 ft-lbs. 18. Beginning with the exhaust manifold assembly removed in step 14, reinstall all the components in the reverse order that they were removed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 196 OMM-0078_0J...
(See Figure 6-7). 6. Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head. AERCO recommends that NEW gaskets be used when reassembling. 7. Place a shell head gasket on top of the shell ring first, then place the release gasket on top of the shell head gasket.
Figure 6-7. Flat Style Head Configuration 6.8 HEAT EXCHANGER CLEANING AERCO recommends that the heat exchanger of the unit be cleaned annually to maintain maximum heat transfer efficiencies 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.
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6. Install a “T”, ball valve and hose connection in the outlet piping of the heater (Figure 6-8). Route the hose back to the top of the circulation bucket. Figure 6-8. Sample Heat Exchanger Cleaning Set-Up AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 81 of 196...
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 Page 82 of 196 OMM-0078_0J...
(older style only) and the float in the condensate trap and replace the trap cover. 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 OMM-0078_0J Page 83 of 196...
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 Page 84 of 196 OMM-0078_0J...
3. Close the water inlet and outlet valves to isolate unit. 4. Close external gas supply valve. 5. Open relief valve to vent water pressure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 85 of 196...
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 Page 86 of 196 OMM-0078_0J...
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 OMM-0078_0J Page 87 of 196...
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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 88 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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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_0J Page 89 of 196...
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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 90 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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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_0J Page 91 of 196 Phone: 800-526-0288...
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Replace the switch if it does not show continuity. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 196 OMM-0078_0J Phone: 800-526-0288...
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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_0J Page 93 of 196...
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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 94 of 196 OMM-0078_0J...
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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_0J Page 95 of 196...
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Check control signal type set in type (voltage or current). Configuration Menu. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 196 OMM-0078_0J Phone: 800-526-0288...
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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_0J Page 97 of 196...
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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 98 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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_0J Page 99 of 196 Phone: 800-526-0288...
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INTAKE FLAME DETECTOR MANIFOLD GASKET FLAME DETECTOR OBSERVATION IGNITOR PORT Figure 7-2. Blower-Side Intake Manifold (Shown removed from Heater) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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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 OMM-0078_0J Page 101 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
(if your computer has more than one) and what speed (baud rate) to use when transferring data. For further configuration options (data bits, stop bits, parity, flow AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J...
Figure 8-2: PuTTY GUI: Basic SSH Options for Running Remote Commands 4. Into the textbox titled, Remote command type the full command line you wish to have executed on the remote machine. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 196 OMM-0078_0J...
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: M = Display next Menu...
Enter (i.e. T0 <Enter>). To view earlier records in reverse chronological order, enter T and press Enter. To go back 200 or 1000 records, enter T200 or T1000, etc. and press Enter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 196 OMM-0078_0J...
The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu. The log interval can vary from once every minute to once every day. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J...
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OPEN OPEN OPEN OPEN OPEN 1/15/02 5:16pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
The C-More Water Heater Management (WHM) feature is designed for use with multiple AERCO Water Heaters equipped with C-More Controllers. The software code required to operate the WHM resides in each of the C-Mores that are part of the system. The WHM can control up to eight (8) water heaters in parallel.
Setback End 12:00am 11:59pm 12:00am WHM Auto Mstr Yes or No WHM Auto Timer 10 sec. 120 sec. 30 sec. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 9-2. 4. AERCO recommends that another pipe nipple and union be attached to the valve inlet prior to connecting the cold water supply piping.
At the end unit in the chain, activate the DIP switch labeled “MODBUS TERM” by placing it in the up position. This will ensure that the termination resistors are activated at both ends of the loop. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 196 OMM-0078_0J...
LAST unit on the chain, turn the DIP switches labeled BIAS1, TERM and BIAS2 to the “ON” position. Figure 9-4 WHMS Network Wiring Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 113 of 196 Phone: 800-526-0288 GF-128...
9.6.7 Setback Setpoint This menu item specifies the setpoint temperature that the WHM system will maintain during time periods of low DHW demand. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 196 OMM-0078_0J Phone: 800-526-0288...
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).
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24. If the WHM Auto Mstr option was set to Yes (enabled) in step 23, proceed to step 25. If this option remains set to No (disabled), skip step 25 and go to step 27. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 196...
Defective valve actuator. Replace valve actuator. Following replacement, the actuator stroke will have to be calibrated to ensure it fully opening and closing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 117 of 196 Phone: 800-526-0288 GF-128...
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 118 of 196...
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3. 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_0J Page 119 of 196...
(0°) position. Conversely, a control signal above 14 mA will rotate the valve to the fully closed (90°) position. The valve position can be observed on the scale provided on the Actuator Linkage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 196 OMM-0078_0J...
Allows communications Baud Rate to be set (2400 to 19.2K). (Default = 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 OMM-0078_0J Page 121 of 196 Phone: 800-526-0288 GF-128...
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Setpoint is equal to Active Setpoint + DEADBAND HIGH. Setting range is from 0 to 100. (Default = 30) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 196 OMM-0078_0J...
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PID LOOP will again attempt Valve Position corrections. Setting range is 0 to 25. (Default = 0 for both Deadband High and Deadband Low) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 123 of 196 Phone: 800-526-0288...
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A narrow difference between Nxt On VP and WHM Nxt Off VP will make the system more responsive to load changes. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 196 OMM-0078_0J...
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Protonode with Slave –Slave (SSD) programming. Otherwise leave it at zero (0). (Default = 0) * Only displayed when Heater Tuning Display is enabled by factory authorized personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 125 of 196...
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Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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_0J Page 127 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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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 128 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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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_0J Page 129 of 196 Phone: 800-526-0288...
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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 130 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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_0J Page 131 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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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 132 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
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 OMM-0078_0J Page 133 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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94°F Breakpoint At 30% 103°F Breakpoint At 20% 118°F Breakpoint At 10% 134°F Breakpoint At 0% 136°F Reset Defaults? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
Innovation Parts List 09/15/2013 International, Inc. Blauvelt, NY 10913 29184-TAB rev G, 29293 rev D Page 1 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 137 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation Parts List AERCO 09/15/2013 International, Inc. Blauvelt, NY 10913 29184-TAB rev G, 29293 rev D Page 2 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation Parts List 09/15/2013 International, Inc. Blauvelt, NY 10913 29184-TAB rev G, 29293 rev D Page 3 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 139 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation Parts List AERCO 09/15/2013 International, Inc. Blauvelt, NY 10913 29184-TAB rev G, 29293 rev D Page 4 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation 600-800-1060 FM Gas Train 08/12/2013 International, Inc. Blauvelt, NY 10913 22122 rev E (AP-A-896) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 141 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation 1350 FM Gas Train AERCO 08/02/2013 International, Inc. Blauvelt, NY 10913 22168 rev A (AP-A-905) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation 600-800-1060 DBB Gas Train 08/12/2013 International, Inc. Blauvelt, NY 10913 22122-1 rev F (AP-A-897) Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 143 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation 600-800-1060 DBB Gas Train 08/12/2013 International, Inc. Blauvelt, NY 10913 22122-1 rev F (AP-A-897) Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation 600P-800P PROPANE Gas Train 08/02/2013 International, Inc. Blauvelt, NY 10913 22179 rev B (AP-A-922) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 145 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation 1060P-1350P PROPANE Gas Train 11/05/2013 International, Inc. Blauvelt, NY 10913 22180 rev B (AP-A-923) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation 1350 DBB Gas Train 08/12/2013 International, Inc. Blauvelt, NY 10913 22168-1 rev A (AP-A-906) Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 147 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation 1350 DBB Gas Train 08/12/2013 International, Inc. Blauvelt, NY 10913 22168-1 rev A (AP-A-906) Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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AERCO 11/13/2013 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_0J Page 149 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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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 150 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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Innovation Intake Manifold, Burner & Shield 08/02/2013 International, Inc. Blauvelt, NY 10913 24345 rev B & 24233 rev B (PL-A-175) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 151 of 196 Phone: 800-526-0288 GF-128 PRI: 11/22/2013...
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Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX F – PARTS LIST DRAWINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – C-MORE CONTROL PANEL VIEWS APPENDIX H – C-MORE CONTROL PANEL VIEWS C-MORE CONTROL PANEL EXPLODED VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 177 of 196 Phone: 800-526-0288...
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Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX H – 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 178 of 196 OMM-0078_0J Phone: 800-526-0288...
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_0J Page 187 of 196 Phone: 800-526-0288...
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Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX J – RECOMMENDED SPARES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013 GF-128...
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.
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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 190 of 196 OMM-0078_0J Phone: 800-526-0288...
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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_0J Page 191 of 196 Phone: 800-526-0288...
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Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX K – COMBUSTION CALIBRATION (KOREA ONLY) (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 196 OMM-0078_0J Phone: 800-526-0288 PRI: 11/22/2013...
Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX L – WARRANTY APPENDIX L – WARRANTY INNOVATION WATER HEATER LIMITED WARRANTY AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0J Page 193 of 196 Phone: 800-526-0288 GF-128...
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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.
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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.