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Aerco innovation 600 User Manual

Natural gas and propane gas modulating, condensing water heaters
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Innovation Installation, Operation & Maintenance Manual
OPERATION & MAINTENANCE MANUAL
Natural Gas and Propane Gas Modulating, Condensing Water heaters
600, 800, 1060, 1350 MBH Water Heaters
Latest Release: 08/10/2017
OMM-0078_0O
GF-128
USER MANUAL
This Guide Applies to the Following Models:
• Innovation 600
• Innovation 800
• Innovation 1060
• Innovation 1350
Other documents for this product include:
• GF-5030
• GF-5050
• GF-5060
• GF-5080
Applies to Serial Numbers:
G-17-1700 and above
U.S. Patent No. 9,243,848
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Phone: 800-526-0288
Natural Gas:
• Innovation 600P
• Innovation 800P
• Innovation 1060P
• Innovation 1350P
INN Gas Supply Guide
INN Venting Guide
INN Electric Power Guide
INN Sizing Guide
GF-128
Propane:
Page 1 of 194
08/10/2017

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  • Page 1 INN Electric Power Guide • GF-5080 INN Sizing Guide Applies to Serial Numbers: G-17-1700 and above U.S. Patent No. 9,243,848 Latest Release: 08/10/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078_0O Page 1 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 2: Table Of Contents

    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 Page 2 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 3 5.7 FLAME FAULT TESTs ......................73 5.8 AIR FLOW FAULT TESTS ....................74 5.9 SSOV PROOF OF CLOSURE SWITCH ................76 5.10 PURGE SWITCH OPEN DURING PURGE ...............77 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 3 of 194 Phone: 800-526-0288...
  • Page 4 8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS ........128 8.8.1 Installation Notes ......................... 128 8.8.2 Hardware Installation ........................129 8.8.3 WHM Modbus Network Wiring ....................130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 5 APPENDIX G – C-More Control Panel Views................179 APPENDIX H – C-More Wiring Diagrams ................181 APPENDIX I – Recommended Spares ..................189 APPENDIX J – Warranty ......................191 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 5 of 194 Phone: 800-526-0288...
  • Page 6 Innovation Installation, Operation & Maintenance Manual (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 7: Foreword

    Innovation Installation, Operation & Maintenance Manual FORWARD FOREWORD The AERCO Innovation Series Potable Water Heaters are tankless modulating units which represent a true industry advance that meets the needs of today's energy efficiency and environmental concerns. Innovation’s compact size and robust venting capabilities allow maximum installation flexibility.
  • Page 8 Innovation’s advanced electronic controls offer simplified integration with today’s Energy Management Systems. For service or parts, contact your local sales representative or AERCO International, Inc. IMPORTANT! Unless otherwise specified, the descriptions and procedures provided in this Installation, Operation &...
  • Page 9 AERCO’s on-line remote system monitoring system Printed Circuit Board Primary Micro-Controller (PMC) board, contained in the C-More PMC Board Controller Part Number AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 9 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 10 W.C. Water Column, a unit of pressure (1 inch W.C. = 249 Pa) µA Micro amp (1 million of an ampere) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 11: 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 12: Emergency Shutdown

    Chapter 5 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 13 248 CMR 5.08(2)(a)1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 13 of 194...
  • Page 14 ______________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 194 OMM-0078_0O Phone: 800-526-0288...

  • Page 15: 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 16: 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 17: Setting The Unit

    All piping must include ample provisions for expansion. LIFTING LUGS Figure 2-2. Partial Top View Showing Installed Lifting Lugs AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 17 of 194 Phone: 800-526-0288...

  • Page 18: Water Inlet And Outlet Piping

    The use of dielectric unions is recommended. When connecting the hot water outlet and cold water inlet to building piping, first make sure the threads are thoroughly clean. AERCO recommends using Teflon tape followed by RectorSeal® T+2 when plumbing the inlet and outlet water connections.

  • Page 19: Whm Actuator-Controlled Ball Valve Installation

    Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 2-3b. AERCO recommends that another pipe nipple and union be attached to the valve inlet prior to connecting the cold water supply piping. Tighten all pipe connections after the valve is properly positioned.

  • Page 20: Test Hose Bib Connection

    The Test Hose Bib cannot be omitted. TEST HOSE BIB TEST HOSE WATER TO DRAIN Figure 2-4. Test Hose Bib Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 21: Internal Recirculation Loop

    HEAT EXCHANGER COLD WATER INLET DRAIN VALVE REAR VIEW – REAR PANEL & EXHAUST VENT REMOVED Figure 2-5. Recirculation Loop AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 21 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 22: 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 (see Section 6.9 for instructions). AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port. •...
  • Page 23 SUPPORT HOUSEKEEPING PAD Housekeeping pad should not extend under the condensate assembly Figure 2-7a. Sample Condensate Trap Installation – Left Side View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 23 of 194 Phone: 800-526-0288...

  • Page 24: Gas Supply Piping

    Figure 2-7b. Sample Condensate Trap Installation – Left Side View NOTE: As a general guideline, AERCO recommends use of its Condensate 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 25: Gas Supply Specifications

    The maximum allowable gas pressure to the Heater is 14” W.C. (3.49 kPa). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 25 of 194...

  • Page 26: External Gas Supply Regulator

    It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. 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.

  • Page 27: Ac Electrical Power Wiring

    CHAPTER 2 – INSTALLATION 2.11 AC ELECTRICAL POWER WIRING The AERCO Innovation Electrical Power Wiring Guide, GF-5060, must be consulted prior to connecting any AC power wiring to the unit. External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front door of the unit to access the Power Box mounted directly above the C-More Controller.

  • Page 28: Electrical Power Requirements

    220 VAC TRANSFORMER Figure 2-11. 220 VAC Transformer – Front and Side Panels Removed 2.11.1 Electrical Power Requirements AERCO Innovation Heater built for the Korea market require the following input voltage: • 120 VAC, single-phase, 50/60 Hz @ 20A •...

  • Page 29: Field Control Wiring

    Refer to the wiring diagram provided on the cover of the I/O Box (Figure 2-13) when making all wiring connections. Since identical I/O Boxes are used with both AERCO gas-fired boilers and water heaters, some of the input and output connections apply only to boilers while others are common to both boilers and heaters.

  • Page 30: Outdoor Air In Terminal

    The ANALOG IN terminals (+ & -) are used when an external signal is used to change the setpoint (Remote Setpoint mode) of the heater. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 30 of 194...

  • Page 31: Valve Feedback Terminals

    NOTE: When driving an isolation valve, shorting jumper #JP2 MUST be installed on the I/O Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 31 of 194 Phone: 800-526-0288...

  • Page 32: Rs485 Comm Terminals

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

  • Page 33: Aux Relay Terminals

    2.13 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-5050 must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification. Because the unit is capable of discharging low temperature exhaust gases, the flue must be pitched back towards the unit a minimum of 1/4"...

  • Page 34: Combustion Air

    2.14 COMBUSTION AIR The AERCO Gas-Fired Heater Venting and Combustion Air Guide, GF-5050 MUST be consulted before any flue or inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.

  • Page 35: Ducted Combustion

    Innovation Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.15 DUCTED COMBUSTION AIR The AERCO Innovation Water Heater is UL listed for 100%-ducted combustion air. For ducted combustion air installations, the inlet air ductwork must then be attached directly to the unit’s air inlet.
  • Page 36 Innovation Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 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-OA Page 37 of 194...
  • Page 38 Innovation Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Figure 3-1. Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 39 • Pressing RESET resets the water level monitor circuit. switches • Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 39 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 40 20 segment red LED bargraph continuously shows the Air/Fuel Valve VALVE POSITION position in 5% increments from 0 to 100% Bargraph AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 41: Control Panel Menus

    The menu option choices do not wrap around. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 41 of 194...
  • 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 194...

  • Page 43: Operating Menu

    The Outdoor Temp setting (Item 5) will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration menu (Table 3-4). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 43 of 194...

  • Page 44: Setup Menu

    A full description of each item appears in Table A-3 of Appendix A – Innovation Menu Item Descriptions. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 45 Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0°F (0°C) 10°F (5.5°C) Network Timeout 5 Sec 999 Sec 30 Sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 45 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 46 Displays current reading CAUTION! * DO NOT CHANGE the Analog Output menu item from its Default setting, Valve Pos 0- 10V. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 47: Tuning Menu

    20 sec. The following items appear only with password level 3 or higher FDback Start Pos 100% Fdback End Pos 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 47 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 48: Calibration Menu

    Outlet Tmp Dsply Enabled or Disabled Disabled Inlet Tmp Dsply Enabled or Disabled Disabled Valv Pos Out Dsp Enabled or Disabled Enabled AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 49 -3.0 +3.0 O2 Sensor Enabled or Disabled Depends on unit type/size Cal Temp Sensors Off or Start FFWD Temp Offset AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 49 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 50: Start Sequence

    Also, if the required conditions are not observed at any point during the start sequence, appropriate messages will be displayed and the unit will go into fault mode. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 194 OMM-0078_0O...
  • Page 51 The VALVE POSITION bargraph will show 100%. AIR IN PURGE VALVE POSITION STEPPER DIAL AT 100% MOTOR TO BLOWER Figure 3-4: Air/Fuel Valve in Purge Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 51 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 52 AIR IN IGNITION STEPPER VALVE MOTOR POSITION DIAL AT 25% to 35% TO BLOWER Figure 3-6: Air/Fuel Valve in Ignition Position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 53: Start/Stop Levels

    715,000 (209.5) 1,001,000 (293.3) 483,000 (141.5) 615,000 (180.2) 845,000 (247.6) 1,203,000 (352.5) 100% 600,000 (175.8) 800,000 (234.4) 1,060,000 (310.6) 1,350,000 (395.6) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 53 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 54 Innovation Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 55: 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 56: Required Tools & Instrumentation

    1/4" (6.35 mm) NPT PLUG (Install manometer here) TO AIR/FUEL VALVE Figure 4-1. 1/4 Inch Gas Plug Location (INN600 – 1060 Gas Train Shown) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 194 OMM-0078_0O Phone: 800-526-0288...

  • Page 57: Accessing The Analyzer Probe Port

    µA scale. The flame detector is mounted on the intake manifold flange 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-OA Page 57 of 194...

  • Page 58: Recommendations For Temperature Calibration

    In case of DHW pre-heat systems, the required temperature rise through an individual unit can be much lower to ensure that flow per unit does not exceed 50 gal. (189 L) per minute at any time. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 194...

  • Page 59: Natural Gas Combustion Calibration

    BTU (kW) 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 Navigate to the SET Stdby V Out (Standby Voltage) setting and verify that it is set to 2.0 V. AERCO recommends that it be kept at 2.0 volts to prevent flue gas recirculation. Press the ▲ arrow key until Set Valve Position reads 100%, then press the ENTER key.
  • Page 61 (TAC valve). TAC VALVE Figure 4-6. TAC Valve (Idle Screw) Adjustment This completes the NATURAL GAS combustion calibration procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 61 of 194 Phone: 800-526-0288...

  • Page 62: 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 63 Navigate to the SET Stdby V Out (Standby Voltage) setting and verify that it is set to 2.0 V. AERCO recommends that it be kept at 2.0 volts to prevent flue gas recirculation. Press the ▲ arrow key until Set Valve Position reads 100%, then press the ENTER key.

  • Page 64: Reassembly

    Remove the combustion analyzer probe from the 1/8” (3.18 mm) vent hole in the exhaust manifold. Replace the 1/8” NPT plug in the manifold. Replace the unit’s side panels and front door. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 194 OMM-0078_0O...

  • Page 65: Temperature Control Calibration

    To change the setpoint, press the CHANGE key. The display will begin to flash. Press the ▲ or ▼ arrow key until the desired setpoint is displayed. Press the ENTER key to save the change. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 65 of 194...

  • Page 66: Minimum Load Adjustment

    5. Press the MENU key and select the Tuning Menu. Press the ▲ or ▼ arrow key until MAX LOAD ADJ is displayed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 194 OMM-0078_0O...
  • Page 67 After performing Temperature Calibration and prior to placing the water heater into service, be sure to set the Outlet Feedback option in the Tuning Menu back to ON. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA...

  • Page 68: Over-Temperature Limit Switches

    Over-Temperature Limit switch to the desired setting. MANUAL RESET AUTOMATIC RESET OVER-TEMPERATURE OVER-TEMPERATURE LIMIT SWITCH LIMIT SWITCH (NON-ADJUSTABLE) (ADJUSTABLE) Figure 4-9. Over-Temperature Limit Switch Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 69: Chapter 5. Safety Device Testing

    Fully open the external manual gas shut-off valve and press the CLEAR button on the C- More Controller. 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-OA Page 69 of 194 Phone: 800-526-0288...

  • Page 70: High Gas Pressure Fault Test

    The fault message should clear and the FAULT indicator should go off. The unit should restart. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4“ plug removed in step 1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 194 OMM-0078_0O Phone: 800-526-0288...

  • Page 71: Low Water Level Fault Test

    Reset the adjustable over-temperature switch to its original setting. The unit should start once the Automatic Reset Over-Temperature Limit switch setting is above the actual outlet water temperature. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 71 of 194...

  • Page 72: Interlock Tests

    The unit should shut down and display INTERLOCK OPEN. Once the interlock connection is reconnected, the INTERLOCK OPEN message should automatically clear and the unit should restart. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 194 OMM-0078_0O...

  • Page 73: Delayed Interlock

    LOSS DURING IGNITION following the IGNITION RETRY cycle. Open the valve closed in step 8. Press the CLEAR button. The unit should restart and fire. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 73 of 194...

  • Page 74: Air Flow Fault Tests

    The unit should perform two IGNITION RETRY cycles and then shut down on the third successive ignition attempt. The unit will display AIRFLOW FAULT DURING PURGE. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 194...
  • Page 75 BLOCKED VALVE INLET SWITCH BLOWER PROOF SWITCH BLOWER PARTIAL FRONT VIEW Figure 5-4. Blower Proof & Blocked Inlet Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 75 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 76: Ssov Proof Of Closure Switch

    Replace the wire on the SSOV and press the CLEAR button. The unit should restart. SSOV ACTUATOR COVER ACTUATOR COVER SCREW Figure 5-6. SSOV Actuator Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 77: Purge Switch Open During Purge

    Replace the wire on the Ignition switch and press the CLEAR button. The unit should restart. AIR/FUEL VALVE COVER (Rotate CCW to remove) Figure 5-7. Typical Air/Fuel Valve Cover Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 77 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 78: 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 78 of 194 OMM-0078_0O...

  • Page 79: Chapter 6. Maintenance

    The Innovation Water Heater requires regular routine maintenance to ensure continued reliable operation throughout the service life of the unit. For optimum operation, AERCO requires that the following routine maintenance procedures be performed in the time periods specified in Table 6- Appendix I contains a list of the recommended spare parts for maintenance of the Innovation Heater.

  • Page 80: Igniter-Injector

    Refer to Chapter 4 for combustion calibration procedures. Prior to reinstalling the igniter-injector, apply a high temperature, conductive, anti-seize com- pound to the threads. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 81 Reconnect the igniter-injector cable and ground wire. Reinstall the side and rear panels on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 81 of 194...

  • Page 82: Flame Detector

    Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a log book. See Chapter 5 for Safety Device Test Procedures. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 194...

  • Page 83: Fireside Inspection

    Refer to Figure 6-3. Loosen and remove the four (4) 1/4-20 cap screws securing the blower side of the intake manifold (P/N 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-OA Page 83 of 194...
  • Page 84 Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as necessary. This completes the fireside inspection of the unit. Proceed to step 18 to reassemble the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 194 OMM-0078_0O...
  • Page 85 NUT (1) EXHAUST MANIFOLD SIDE NUTS 5/16-18 STUDS (6) PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED Figure 6-5. Intake and Exhaust Manifolds AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 85 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 86 Step 19, re-torqueing the six 5/16 hex nuts attaching the intake manifold to the exhaust manifold to 146 in/lbs. (16.5 Nm). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 194...

  • Page 87: Waterside Port Inspection

    INSPECTION PORT, 2” NPT PIPE PLUG (shown with plug removed) DRAIN VALVE Figure 6-7: Lower Waterside Inspection Port Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 87 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 88: Waterside Heat Exchanger Inspection And Cleaning

    Inspect and clean the heat exchanger tubes of scale and clean all gasket surfaces thoroughly before reassembling the upper head. Refer to Section 6.8.1 for heat exchanger cleaning instructions. AERCO recommends that a new gasket be used when reassembling. Place two Baffle Spacer strips (P/N...

  • Page 89: Heat Exchanger Cleaning

    Table 6-2, below, 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.
  • Page 90 Install a “T”, ball valve and hose connection in the outlet piping of the heater (Figure 6-9). Route the hose back to the top of the circulation bucket. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 194...
  • Page 91 Continue water flushing the equipment for a minimum of 10 minutes or until discharge runs clear. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 91 of 194...
  • Page 92 10-15 minute intervals. Once the solution’s pH reads 6.0-7.0 on three or more consecutive readings, the solution is expended. If the pH reads below 6.0 after the circulating time, the application is clean. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 194 OMM-0078_0O...

  • Page 93: Condensate Drain Trap

    Trap O-Ring (P/N 84017) INLET Float 3/4" NPT Port O-Rings OUTLET CROSS-SECTION EXPLODED VIEW Figure 6-10a. Original Condensate Trap P/N 24441 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 93 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 94 Reassemble all piping and hose connections to the condensate trap inlet and outlet. Top Cap INLET OUTLET Bottom Cap Figure 6-10b. New Condensate Trap P/N 99259 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 95: Air Filter Replacement

    AIR FILTER FILTER CLAMP AIR/FUEL VALVE BLOWER MOTOR BARE HEATER – PARTIAL FRONT VIEW Figure 6-11. Air Filter Mounting Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 95 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 96: Low Water Cutoff (Lwco) Capacitor Integrity Test

    2. Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the rear panel of the C-More Controller (see Figure 6-13). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 194 OMM-0078_0O...
  • Page 97 LWCO Probe Assembly Figure 6-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable 5. Confirm that the ohmmeter does NOT read a short. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 97 of 194...

  • Page 98: Low Water Cutoff (Lwco) - Standard C-More Test

    Close external gas supply valve. Open relief valve to vent water pressure. Open the drain valve and drain all water from the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 194 OMM-0078_0O Phone: 800-526-0288...

  • Page 99: Placing The Heater Back In Service After Aprolonged Shutdown

    I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA...
  • Page 100 Innovation Installation, Operation & Maintenance Manual CHAPTER 6 – MAINTENANCE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 101: Chapter 7. Troubleshooting Guide

    The front panel of the C-More Controller contains an RS232 port. This port is used only by factory-trained personnel to monitor OnAER communications via a portable computer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 101 of 194...
  • Page 102 Innovation Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 103 Defective Air-Fuel Valve positions. The positions on the VALVE POSITION bargraph should potentiometer. match the dial readings on the Air/Fuel Valve dial. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 103 of 194 Phone: 800-526-0288...
  • Page 104 PROBABLE CAUSES from AIRFLOW IGNITION above, items 3 to 12. FAULT DURING IGNITION above, items 3 to 12, applies to this fault. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 105 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-OA Page 105 of 194 Phone: 800-526-0288...
  • Page 106 Replace the switch if it does not show continuity. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 107 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-OA Page 107 of 194...
  • Page 108 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 108 of 194 OMM-0078_0O...
  • Page 109 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-OA Page 109 of 194...
  • Page 110 Check control signal type set in correct signal type (voltage or Configuration Menu. current). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...
  • Page 111 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-OA Page 111 of 194...
  • Page 112 Check combustion calibration using procedures in Chapter 4. Poor combustion calibration. TEMP HIGH Clean heat exchanger using procedures in Chapter 6. Heat exchanger has scale. (Flashing WARNING) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 113: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards the 80% Valve Position in C-More Controller are are Rev. E or higher. outdated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 113 of 194 Phone: 800-526-0288 GF-128...
  • Page 114 PRESSURE SWITCH LEAK DETECTION BALL VALVE SSOV MANUAL SHUTOFF VALVE TO AIR/FUEL VALVE Figure 7-1. Innovation 600/800/1060 Gas Train Component Locations (P/N 22122 Shown) HIGH GAS PRESSURE SWITCH LOW GAS GAS INLET PRESSURE SWITCH LEAK DETECTION BALL VALVE MANUAL SHUTOFF VALVE...
  • Page 115 SSOV ACTUATOR COVER ACTUATOR OPEN/CLOSED COVER SCREW INDICATOR WINDOW Figure 7-4. SSOV Actuator with Gas Pressure Adjustment AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 115 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 116 Innovation Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 117: Chapter 8. Water Heater Management

    More Controller’s menu processing procedures used throughout this manual. The On-Board-Water-Heater Management system II (WHM II) is a feature integrated in the C- More Controller, designed to stage and coordinate multiple AERCO Innovation water heaters while maximizing operational efficiency. The WHM software code resides in each C-More Controller that is part of the system.

  • Page 118: Whm Principles Of Operation

    (On or Off) is assured by the development of two independent valve control functions, with one function monitoring the results of the other. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 194 OMM-0078_0O...

  • Page 119: Modbus Header Sensor

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

  • Page 120: High Temperature Governor

    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 121: Water Heater Management Alternating Status Displays

    Example: If all available heaters are turned off, the C-More display will alternate the display above (MANAGER-STANDBY) with the All Heaters Off status message as follows: Alternating status All Heaters Off message 8:58am 3/05/14 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 121 of 194 Phone: 800-526-0288 GF-128 08/10/2017...

  • Page 122: Whm Menu

    Degrees or Points Degrees 1 Valve Status 8 1 Comm Errors 8 WHM On Delay 30 sec 300 sec 60 sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 123 The Level 2 Password (6817) in the Setup Menu must be entered to view or change the WHM Auto Mstr and WHM Auto Timer options (items 11 and 12, above). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA...

  • Page 124: Whm Menu Item Descriptions

    Setpoint Setback Setpoint is entered into the Setback Setpoint item and the time is entered in the Setback Start and Setback End items. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 125 1= valve open 2= valve stuck closed 3= valve stuck open 1 Comm Errors 8 Display Comm Errors of all the units. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 125 of 194 Phone: 800-526-0288 GF-128...
  • Page 126 Enable or disable the Modbus Header Temp sensor WHM Header Temp Display the Header Sensor Modbus temp unit format (˚F or ˚C) Mdbus Temp Units AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...
  • Page 127 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 OMM-0078-OA Page 127 of 194...

  • Page 128: 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 are repeated here to avoid unnecessary referencing.

  • Page 129: Hardware Installation

    Ensure that the valve is positioned with the actuator enclosure position as shown in Figure 8-2. AERCO recommends that another pipe nipple and union be attached to the valve inlet prior to connecting the cold water supply piping. Tighten all pipe connections after the sequencing valve is properly positioned.

  • Page 130: Whm Modbus Network Wiring

    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 130 of 194 OMM-0078_0O...

  • Page 131: Control And Power Wiring

    3. On the CPU board inside the C-More Controller of the last unit on the chain, Figure 8-4 WHMS Network Wiring Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 131 of 194 Phone: 800-526-0288...

  • Page 132: Whm Programming & Start-Up

    AERCO recommends that the WHM Manager be set up first. By doing so, the Manager will “push” most of the required menu entries to each WHM Client as each unit is brought on-line.
  • Page 133 The WHM Auto Mstr and WHM Auto Timer options will be automatically “pushed” to the WHM Clients on the network. This completes all programming for the WHM. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 133 of 194...

  • Page 134: Troubleshooting

    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 Page 134 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 135: 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-OA Page 135 of 194...
  • Page 136 Press and hold the brass CLUTCH button shown in Figure 8-6. With the CLUTCH button depressed, the ball valve can be manually rotated from the fully open (90°) to the fully closed (0°) position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 194 OMM-0078_0O...

  • Page 137: Sequencing Valve Operating Characteristics

    (0°) position. The sequencing valve will send a status of the Valve (open/close) as a feedback signal (2 – 10 VDC) to the C-More Controller. Figure 8-7. Sequencing Valve Wiring AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 137 of 194...
  • Page 138 Innovation Installation, Operation & Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 139: Appendix A - Innovation Menu Item Descriptions

    Fault Log Displays information on the last 20 faults (0 – 19). Manual Valve Pos Selects Valve Position in Manual mode. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 139 of 194 Phone: 800-526-0288 GF-128...

  • Page 140: Table A-2: Setup Menu Item Descriptions

    Sets the Number portion of a unit serial number Identifies the current software version of the C-More Software Version Controller (Ver 0.0 to Ver 9.9). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 194 OMM-0078_0O Phone: 800-526-0288...

  • Page 141: Table A-3: Configuration Menu Item Descriptions

    Setpt Limiting N/A for Water Heaters Setpt Limit Band N/A for Water Heaters AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 141 of 194 Phone: 800-526-0288 GF-128...
  • Page 142 First diagnostic valve position Diag Valve Pos 2 Second diagnostic valve position Diag Valve Pos 3 Third diagnostic valve position AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 143 Enable or disable diagnostic run VP Loop Time Monitor VP, loop count, time of current VP Highest Ign Time Highest time to ignite in diagnostic AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 143 of 194 Phone: 800-526-0288 GF-128...

  • Page 144: Table A-4: Tuning Menu Item Descriptions

    Range = 0.00 – 2.00 Default = 0.50 Warmup PID Timer Range = 0 - 240 seconds Default = 20 seconds AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...
  • Page 145 Reset Defaults? values. NOTE: Feedback Gain (Item 8) is only displayed when Heater Tuning Display is enabled by factory authorized personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 145 of 194 Phone: 800-526-0288 GF-128...

  • Page 146: Table A-5: Calibration Menu Item Descriptions

    Allows adjustment of the analog input from -5.0% to +5.0%. Allows adjustment of the water Flow Rate Input from Flow In Adj -5.0% to +5.0%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 194 OMM-0078_0O Phone: 800-526-0288...
  • Page 147 Range = -3.0 to +3.0. – O2 Sensor Enables the O2 Sensor Cal Temp Sensors Allows calibration of the temperature sensor AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 147 of 194 Phone: 800-526-0288 GF-128...
  • Page 148 Allows the adjustment of the maximum spark current required at Max Spark Amps the spark transformer input. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017...

  • Page 149: Appendix B - Startup, Status And Fault Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 149 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 150 The RS-485 network information is not present or is corrupted. FAULT OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out of range. SENSOR FAULT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 151 Level #2: 190ºF (87.8°C), Govern fire rate/flash WARNING TEMP HIGH (Flashing) Level #3. 200ºF (93.3°C), Shut down unit (requires manual reset) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 151 of 194 Phone: 800-526-0288 GF-128...
  • Page 152 Innovation 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 152 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 153: Appendix C - Temperature Sensor Resistance/Voltage Chart

    2.54 104.4 1364.2 2.56 1391.0 2.58 115.6 1418.2 121.1 1445.7 *Voltage at AUX & Common terminals in the I/O Box AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 153 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 154 Innovation 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 154 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 155: Appendix D - Dimensional Drawings

    APPENDIX D – DIMENSIONAL DRAWINGS APPENDIX D – Dimensional Drawings AERCO INNOVATION 600/800/1060/1350 DIMENSIONAL OUTLINE Drawing Number: AP-A-888 rev K AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 155 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 156 Innovation Installation, Operation & Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS AERCO Innovation 600/800/1060/1350 w/SEQUENCING VALVE DIMENSIONAL OUTLINE Drawing Number: AP-A-902 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 157: Appendix E - Parts List Drawings

    80088 EXHAUST MANIFOLD SEAL AERCO International, Innovation Parts List 12/31/2016 Inc. Blauvelt, NY 10913 Top Level Page 1 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 157 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 158 49274 BAFFLE SPACER STRIP AERCO International, Innovation Parts List 12/31/2016 Inc. Blauvelt, NY 10913 Top Level Page 2 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 159 RIGHT-SIDE VIEW – CROSS-SECTION, EXPLODED AERCO International, Innovation Parts List 12/31/2016 Inc. Blauvelt, NY 10913 Top Level Page 3 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 159 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 160 RIGHT-FRONT VIEW LEFT-REAR VIEW AERCO International, Innovation Parts List 12/31/2016 Inc. Blauvelt, NY 10913 Top Level Page 4 of 4 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 161 GAS PRESSURE LABEL (P/N 75003) AERCO Innovation 600-800-1060 1” Gas Train 04/12/2017 International, Inc. Blauvelt, NY 10913 22122 rev M Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 161 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 162 GAS PRESSURE LABEL (P/N 75003) AERCO Innovation 600P-800P PROPANE Gas Train 04/11/2017 International, Inc. Blauvelt, NY 10913 22179 rev J Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 163 Innovation 1060P, 1350P 3/4" PROPANE Gas Train 04/12/2017 International, Inc. Blauvelt, NY 10913 22180 rev J Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 163 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 164 Innovation 1350 1" Natural Gas Gas Train 01/19/2017 International, Inc. Blauvelt, NY 10913 22168 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 165 GAS PRESSURE LABEL (P/N 75003) AERCO Innovation 1350 DBB Gas Train 03/06/2017 International, Inc. Blauvelt, NY 10913 22168-1 rev H Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 165 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 166 Innovation Installation, Operation & Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600, 800, 1060 Air Fuel Delivery System – P/N 24295 Item Qty Part # Description Item Qty Part # Description 44107 BLOWER SIDE INTAKE MANIFOLD 9 ...
  • Page 167 81057, 24220-4 & 88003 ‘O’-Ring #2-339 (not shown) are included in A/F Valve FRU kit: #24311-4 AERCO Innovation 1350 Air/Fuel Delivery System 04/20/2016 International, Inc. Blauvelt, NY 10913 24346 rev J Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 167 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 168 Intake Manifold, Burner & Shield 08/24/2015 International, Inc. Blauvelt, NY 10913 24234 rev E & 24233 rev E Sheet 1 of 1 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 169: Appendix F - Piping Drawings

    Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS APPENDIX F – Piping Drawings Drawing Number: SD-A-829 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 169 of 194 Phone: 800-526-0288 GF-128...
  • Page 170 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-830 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 171 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-831 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 171 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 172 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-845 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 172 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 173 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-848 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 173 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 174 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-851 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 174 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 175 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-852 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 175 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 176 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-854 rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 176 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 177 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-856 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 177 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 178 Innovation Installation, Operation & Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-939 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 178 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 179: Appendix G - C-More Control Panel Views

    FRONT FACE PLATE, BENCHMARK PUSH BUTTON P/N 124949 SWITCHES P/N 124954 VERTICAL OVERLAY, BENCHMARK P/N 124718 Figure G-1. C-More Controller - Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 179 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 180 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure G-2. C-MORE CONTROLLER PANEL REAR VIEW AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 180 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 181: Appendix H - C-More Wiring Diagrams

    APPENDIX H – – C-More Wiring Diagrams APPENDIX H – C-More Wiring Diagrams Drawing Number: 68056 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 181 of 194 Phone: 800-526-0288...
  • Page 182 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 182 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 183 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams Drawing Number: 68056 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 183 of 194 Phone: 800-526-0288...
  • Page 184 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 184 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 185 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams Drawing Number: 68057 rev D Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 185 of 194 Phone: 800-526-0288...
  • Page 186 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 186 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...
  • Page 187 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams Drawing Number: 68057 rev D Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 187 of 194 Phone: 800-526-0288...
  • Page 188 Innovation Installation, Operation & Maintenance Manual APPENDIX H – – C-More Wiring Diagrams This Page Is Intentionally Blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 188 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 189: Appendix I - Recommended Spares

    One kit per unit • Direct Spark with air filter 58036-04 • Direct Spark with filter cleaner (no air filter) 58036-06 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 189 of 194 Phone: 800-526-0288 GF-128...
  • Page 190 • Nat Gas INN600 to INN1350 with Dungs 60032 One per three units switch • Propane INN600 to 1350 with Dungs switch 60032 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 190 of 194 OMM-0078_0O Phone: 800-526-0288 08/10/2017 GF-128...

  • Page 191: Appendix J - Warranty

    Operation of the heater using contaminated air will void the warranty. The heat exchangers combustion chamber shall not be warranted from failure due to scaling, liming, corrosion, or erosion due to water or installation conditions. AERCO will repair, rebuild or exchange, at its option the heat exchanger/combustion chamber according to the following...
  • Page 192 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 193 Innovation Installation, Operation & Maintenance Manual NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0078-OA Page 193 of 194 Phone: 800-526-0288 GF-128 08/10/2017...
  • Page 194 Removed Obsolete Piping Drawings Appendix F. Chris Blair DIR 339: Added New Step 17 To Combustion Cal Instructions (Section 4.3 & 4.4) To Verify AERCO's Recommended Standby Voltage Of 2.0 V. PIR 1285: Updated A/F Valve Assembly Drawings 24295 & 24346 In Appendix E PIR 1307: Updated gas trains 22122, 22122-1, 22179 in Appendix I.

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