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Aerco Innovation 600 User Manual

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See also: User Manual
Innovation Water Heaters Installation, Operation & Maintenance Manual
Natural Gas or Propane
Modulating, Condensing
Water Heater Models
Applicable to Serial Numbers
G-14-1450 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 Gas Supply Guide
• GF-5050
INN Venting Guide
• GF-5060
INN Elect. Power Guide
• GF-5080
INN Sizing Guide
Latest Update: 08/05/2014
OMM-0078_0K
GF-128
USER MANUAL
Installation, Operation and Maintenance
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
Benchmark 3000
INNOVATION Series
Gas-Fired Water Heaters
Page 1 of 208
PRI: 08/05/2014

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Summary of Contents for Aerco Innovation 600

  • Page 1 • GF-5050 INN Venting Guide • GF-5060 INN Elect. Power Guide • GF-5080 INN Sizing Guide Latest Update: 08/05/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 1 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • 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. AERCO International is not liable for errors appearing in this manual.

  • Page 3: Table Of Contents

    2.13 FLUE GAS VENT INSTALLATION ..................34 2.14 COMBUSTION AIR ......................35 2.14.1 Combustion From Outside the Building ..................35 2.14.2 Combustion Air from Inside the Building ..................35 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 3 of 208 Phone: 800-526-0288...
  • Page 4 5.9 SSOV PROOF OF CLOSURE SWITCH ................72 5.10 PURGE SWITCH OPEN DURING PURGE ...............73 5.11 IGNITION SWITCH OPEN DURING IGNITION..............73 5.12 SAFETY PRESSURE RELIEF VALVE TEST ..............74 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 5 9.4.7 Quick Re-Flash Feature – As of 3.08.05 ..................115 9.4.8 WHM Auto Mstr ........................... 116 9.4.9 Run Hours and Run Cycles ......................116 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 5 of 208...
  • Page 6 APPENDIX J – RECOMMENDED SPARES ..................199 APPENDIX K – COMBUSTION CALIBRATION (KOREA ONLY) ..........201 APPENDIX L – WARRANTY ......................205 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 208 OMM-0078_0K 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...
  • 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 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • 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_0K Page 11 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • 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 208 OMM-0078_0K 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

    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_0K Page 19 of 208...

  • Page 20: Water Inlet And Outlet Piping

    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 208 OMM-0078_0K...

  • Page 21: Test Hose Bib Connection

    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.

  • 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 208 OMM-0078_0K...
  • Page 23 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_0K Page 23 of 208...

  • Page 24: Pressure & Temperature Relief Valve Installation

    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 SUPPORT HOUSEKEEPING PAD Housekeeping pad should not extend under the condensate assembly LEFT SIDE VIEW Figure 2-7. Sample Condensate Trap Installation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 25 of 208 Phone: 800-526-0288 GF-128...

  • Page 26: Gas Supply Piping

    CHAPTER 2 – INSTALLATION NOTE As a general guideline, AERCO recommends use of its Neutralizer Kit to raise the pH level of the condensate prior to drainage. At a minimum, the installation must be designed in accordance with local codes that specify acceptable pH limits.

  • Page 27: Manual Gas Shutoff Valve

    NATURAL GAS SUPPLY 1” MANUAL SHUTOFF VALVE GAS PRESSURE DIRT TRAP REGULATOR Figure 2-8. Manual Gas Shut-Off Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 27 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...

  • 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

    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...
  • Page 30 Figure 2-11. Input/Output (I/O) Box Location – Partial Front View 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 31: Outdoor Air In Terminal

    Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the set- point or air/fuel valve position. The factory default setting is for 4 to 20 mA / 1 to 5 VDC, AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K...

  • Page 32: Valve Feedback Terminals

    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 Page 32 of 208 OMM-0078_0K...

  • Page 33: 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 34: 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 35: Combustion Air

    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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 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_0K Page 37 of 208...
  • Page 38 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 38 of 208 OMM-0078_0K...
  • 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_0K Page 39 of 208 Phone: 800-526-0288...
  • 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • Page 41: Control Panel Menus

    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_0K Page 41 of 208...
  • 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 208 OMM-0078_0K Phone: 800-526-0288...

  • Page 43: Operating Menu

    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_0K Page 43 of 208...

  • Page 44: Configuration Menu

    600, 800, 1060 or (Only if Unit Type is 1350 MBH Innovation WH) Fuel Type Natural Gas, Propane Natural Gas AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 45 Spark Current Display CAUTION DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 45 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...

  • Page 46: Water Heater Management (Whm) Menu

    23. WHM Warmup Time 300 sec 30 sec 24. WHM On Timeout 15 Sec 300 Sec 30 Sec 25. WHM Valve State AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 47: Tuning Menu

    The Tuning Menu items in Table 3-6 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K...
  • Page 48 GOV Limit-8 PID Output P Output I Output D Output Valve Debug Reset Defaults? Yes, No, Are You Sure? AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 49: Start Sequence

    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_0K Page 49 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 50 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 50 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 51 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_0K Page 51 of 208...

  • 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 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 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

    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 54 of 208 OMM-0078_0K...

  • Page 55: Connecting Multimeter To Flame Detector

    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_0K Page 55 of 208...

  • Page 56: 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 57 1.2” – 1.4” W.C. BRASS HEX HEAD CAP (Remove to access gas pressure adjustment screw) Figure 4-4. Gas Pressure Adjustment Screw Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 57 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 58 Over-Temp condition. 18. Valve Positions to be checked: • • • • • • 100% • AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • 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 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 60 of 208 OMM-0078_0K Phone: 800-526-0288...

  • Page 61: Reassembly

    Adjustments to these settings are made at minimum and maximum load conditions and should be made in small increments from 1 to 3 degrees. After making an adjustment, the outlet water AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K...

  • Page 62: Setting The Outlet Water Temperature Setpoint

    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 62 of 208...

  • Page 63: Maximum Load Adjustment

    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_0K Page 63 of 208...

  • Page 64: Over-Temperature Limit Switches

    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 64 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 65: Chapter 5. Safety Device Testing

    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_0K Page 65 of 208 Phone: 800-526-0288...

  • Page 66: High Gas Pressure Fault Test

    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 66 of 208 OMM-0078_0K Phone: 800-526-0288...

  • Page 67: Low Water Level Fault Test

    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_0K Page 67 of 208...

  • Page 68: Interlock Tests

    4. The unit should shut down and display INTERLOCK OPEN. 5. Once the interlock connection is reconnected, the INTERLOCK OPEN message should automatically clear and the unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 208 OMM-0078_0K...

  • Page 69: 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_0K Page 69 of 208 Phone: 800-526-0288...

  • Page 70: Air Flow Fault Tests

    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 70 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 71 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_0K Page 71 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...

  • Page 72: Ssov Proof Of Closure Switch

    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 72 of 208...

  • Page 73: Purge Switch Open During Purge

    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_0K Page 73 of 208...

  • Page 74: 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 74 of 208 OMM-0078_0K...

  • Page 75: 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 76: Igniter

    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 76 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 77 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_0K Page 77 of 208...

  • Page 78: 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 78 of 208...
  • Page 79 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_0K Page 79 of 208...
  • Page 80 15. Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as necessary. 16. This completes the fireside inspection of the unit. Proceed to step 17 and reassemble the unit as indicated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 81 If the unit contains a Combustion Chamber Liner (p/n 161151) it can be removed and discarded. This part has been eliminated from all Innovation Water heaters. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 81 of 208...
  • Page 82 15 ft-lbs. 17. Beginning with the exhaust manifold assembly removed in step 14, reinstall all components in the reverse order in which they were removed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 208 OMM-0078_0K...

  • Page 83: Waterside Inspection

    (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.

  • Page 84: Heat Exchanger Cleaning

    Figure 6-7. Flat Style Head Configuration 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). It provides an economical, maintenance free treatment of hard water without the use of salt or any chemicals.
  • Page 85 PREVENTOR COLD WATER PUMP CLOSE COLD CIRCULATION WATER INLET BUCKET DRAIN VALVE Figure 6-8. Sample Heat Exchanger Cleaning Set-Up AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 85 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...

  • Page 86: 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 Page 86 of 208 OMM-0078_0K...

  • Page 87: Condensate Drain Trap

    (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_0K Page 87 of 208...

  • Page 88: Air Filter Replacement

    5/16” nut driver. 6. Replace the side panels on the unit and return heater to service use. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 208 OMM-0078_0K...

  • Page 89: Shutting The Water Heater Down For An Extended Period Of Time

    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_0K Page 89 of 208...

  • Page 90: Placing The Heater Back In Service After A Prolonged Shutdown

    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 90 of 208 OMM-0078_0K...

  • Page 91: Chapter 7. Troubleshooting Guide

    If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 91 of 208...
  • Page 92 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 92 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 93 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_0K Page 93 of 208...
  • Page 94 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 94 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...
  • Page 95 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_0K Page 95 of 208 Phone: 800-526-0288...
  • Page 96 Replace the switch if it does not show continuity. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 97 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_0K Page 97 of 208...
  • Page 98 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 98 of 208 OMM-0078_0K...
  • Page 99 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_0K Page 99 of 208...
  • Page 100 Check control signal type set in type (voltage or current). Configuration Menu. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 101 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_0K Page 101 of 208...
  • Page 102 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 102 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 103: 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_0K Page 103 of 208 Phone: 800-526-0288...
  • Page 104 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 104 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 105 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_0K Page 105 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 106 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 106 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 107: Chapter 8. Rs232 Communication

    (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_0K...

  • Page 108: Running A Command On A Remote Machine Using Putty

    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 108 of 208 OMM-0078_0K...

  • Page 109: Rs232 Communication Setup

    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...

  • Page 110: Data Logging

    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 110 of 208 OMM-0078_0K...

  • Page 111: Operation Time Log

    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_0K...
  • Page 112 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 112 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 113: Chapter 9. Water Heater Management

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

  • Page 114: Whm Principles Of Operation

    Critical valve positioning (On or Off) is assured by the development of two independent valve control functions with one function monitoring the results of the first AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 208...

  • Page 115: Modbus Header Sensor And Outdoor Sensor

    9.4.5 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 Example: If all available heaters are turned off, the C-More display will alternate the display above (MASTER-STANDBY) with the All Heaters Off status message as follows: Alternating status message All Heaters Off 8:58am 3/05/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 117 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...

  • Page 118: Whm Menu

    30 sec 300 sec 60 sec Over WHM Under WHM Min Units WHM Warmup Time 300 sec 30 sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 119: 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 120: Whm Modbus Network Wiring

    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.

  • Page 121: Control And Power Wiring

    WHM unit is accomplished by simply ensuring that the 3-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_0K Page 121 of 208...

  • Page 122: Whm Menu Settings

    The required settings for WHM Menu items will vary depending on the number of units connected to the Modbus network and required setpoint and operating conditions to be AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 208...

  • Page 123: Whm Mode

    The start and end times can be set from 12:00am (mid-night) to 11:59pm. To disable the setback feature, leave the start and end times set to 12:00am (midnight). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K...

  • Page 124: Whm Auto Mstr

    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 125 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 OMM-0078_0K...

  • Page 126: Troubleshooting

    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 Page 126 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • Page 127: Sequencing Valve Description & Operation

    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 OMM-0078_0K Page 127 of 208...
  • Page 128 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 Page 128 of 208 OMM-0078_0K...

  • Page 129: 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 9-7. Sequencing Valve Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 129 of 208...
  • Page 130 Innovation Water Heaters Installation, Operation & Maintenance Manual CHAPTER 9 – WATER HEATER MANAGEMENT This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 131: Appendix A - Innovation Menu Item Descriptions

    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_0K Page 131 of 208 Phone: 800-526-0288 GF-128...
  • Page 132 Specifies the timeout value (seconds) before a Modbus fault is declared. Available settings range from 5 to 999 seconds. (Default = 30 seconds) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 133 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_0K Page 133 of 208 Phone: 800-526-0288...
  • Page 134 WHM Min Addr master. The WHM Min Addr and WHM Max Addr must differ by no more than 7. (Default = 1) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 135 Specifies the time the WHM Master waits for a slave unit to turn WHM On Timeout 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_0K Page 135 of 208 Phone: 800-526-0288 GF-128...
  • Page 136 Max allowable comm errors before a comm. fault is invoked. Set the Comm Address for the unit (This option also available in setup Comm Address menu) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 137 PID timer during Warmup FDback Start Pos Start of Feedback Position Fdback End Pos End of Feedback Position Max Feedback Max Feedback AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 137 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 138 Allows Tuning Menu options to be reset to their Factory Reset Defaults? Default values. * Only displayed when Heater Tuning Display is enabled by factory authorized personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 208 OMM-0078_0K Phone: 800-526-0288...

  • Page 139: 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_0K Page 139 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 140 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 140 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...
  • Page 141 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_0K Page 141 of 208 Phone: 800-526-0288...
  • Page 142 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 142 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • Page 143: 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_0K Page 143 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 144 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 144 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • Page 145: Appendix D - Innovation Default Settings

    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_0K Page 145 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 146 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 146 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 147: Appendix E - Dimensional Drawings

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX E – DIMENSIONAL DRAWINGS APPENDIX E – DIMENSIONAL DRAWINGS Drawing Number: AP-A-888 rev H AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 147 of 208 Phone: 800-526-0288...
  • Page 148 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX E – DIMENSIONAL DRAWINGS Drawing Number: AP-A-902 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 149: Appendix F - Parts List Drawings

    Innovation Parts List 05/15/2014 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_0K Page 149 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 150 Innovation Parts List AERCO 05/15/2014 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 150 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 151 Innovation Parts List 05/15/2014 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_0K Page 151 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 152 Innovation Parts List AERCO 05/15/2014 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 152 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 153 Innovation 600-800-1060 FM Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22122 rev F (AP-A-896) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 153 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 154 Innovation 1350 FM Gas Train AERCO 12/06/2013 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 154 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 155 Innovation 600-800-1060 DBB Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22122-1 rev G (AP-A-897) Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 155 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 156 Innovation 600-800-1060 DBB Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22122-1 rev G (AP-A-897) Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 157 Innovation 600P-800P PROPANE Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22179 rev C (AP-A-922) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 157 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 158 Innovation 1060P-1350P PROPANE Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22180 rev C (AP-A-923) Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 159 Innovation 1350 DBB Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22168-1 rev B (AP-A-906) Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 159 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 160 Innovation 1350 DBB Gas Train 12/06/2013 International, Inc. Blauvelt, NY 10913 22168-1 rev B (AP-A-906) Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 161 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_0K Page 161 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 162 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 162 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 163 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_0K Page 163 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 164 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 164 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 165: Appendix G - Piping Drawings

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-829 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 165 of 208 Phone: 800-526-0288...
  • Page 166 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-830 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 167 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-831 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 167 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 168 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-832 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 169 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-833 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 169 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 170 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-836 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 171 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-837 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 171 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 172 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-838 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 173 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-841 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 173 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 174 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-842 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 175 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-843 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 175 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 176 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-844 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 177 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-845 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 177 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 178 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-848 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 179 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-849 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 179 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 180 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-850 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 181 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-851 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 181 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 182 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-852 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 183 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-853 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 183 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 184 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-854 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 185 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-855 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 185 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 186 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-856 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 187 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-939 rev A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 187 of 208 Phone: 800-526-0288 GF-128 PRI: 08/05/2014...
  • Page 188 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 189: Appendix H - C-More Control Panel Views

    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_0K Page 189 of 208 Phone: 800-526-0288...
  • Page 190 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 190 of 208 OMM-0078_0K Phone: 800-526-0288...

  • Page 191: Appendix I - C-More Wiring Diagrams

    Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68039 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 191 of 208 Phone: 800-526-0288...
  • Page 192 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 192 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 193 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68039 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 193 of 208 Phone: 800-526-0288...
  • Page 194 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 194 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 195 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68042 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 195 of 208 Phone: 800-526-0288...
  • Page 196 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 196 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...
  • Page 197 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68042 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0K Page 197 of 208 Phone: 800-526-0288...
  • Page 198 Innovation Water Heaters Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 198 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 199: Appendix J - 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_0K Page 199 of 208 Phone: 800-526-0288...
  • Page 200 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 200 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014 GF-128...

  • Page 201: Appendix K - 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 202 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 202 of 208 OMM-0078_0K Phone: 800-526-0288...
  • Page 203 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_0K Page 203 of 208 Phone: 800-526-0288...
  • Page 204 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 204 of 208 OMM-0078_0K Phone: 800-526-0288 PRI: 08/05/2014...

  • Page 205: Appendix L - Warranty

    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_0K Page 205 of 208 Phone: 800-526-0288 GF-128...
  • Page 206 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 207 AERCO shall at its option modify, repair or exchange the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation. In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges.
  • Page 208 3-2, 3-3 and 3-4, added/removed WHM menu options to Appendix A, added new options to Chapter 9 - Water Heater Management © AERCO International, Inc., 2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 208 of 208 OMM-0078_0K Phone: 800-526-0288...

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