Watts Aerco INN 1060N Installation, Operation And Maintenance Manual

Watts Aerco INN 1060N Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
Innovation Water Heaters
With Edge [i] Controller
Applies to models:
INN 600N
INN 800N
INN 1060N
INN 1350N
Other documents for this product include:
GF-5036 Gas Supply Design Guide
GF-5056 Venting & Combustion Air Design Guide
GF-5066 Electric Power Design Guide
GF-5086 Sizing Guide
This manual applies to serial numbers:
G-19-2230 and above
U.S. Patent No. 9,243,848
Disclaimer
The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or consequential
damages occurring in connection with the furnishing, performance, or use of
these materials.
OMM-0143_A
GF-216 • 9/6/2019
AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913
USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST
Heating and Hot Water Solutions
© 2019 AERCO

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Summary of Contents for Watts Aerco INN 1060N

  • Page 1 Installation, Operation and Maintenance Manual Innovation Water Heaters With Edge [i] Controller Applies to models: • INN 600N • INN 800N • INN 1060N • INN 1350N Other documents for this product include: • GF-5036 Gas Supply Design Guide • GF-5056 Venting &...
  • Page 2: Table Of Contents

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CONTENTS TABLE OF CONTENTS FOREWORD ........................7 CHAPTER 1. SAFETY PRECAUTIONS ..............11 1.1 WARNINGS & CAUTIONS ....................11 1.2 EMERGENCY SHUTDOWN ....................12 1.3 PROLONGED SHUTDOWN ....................12 1.4 FOR MASSACHUSETTS INSTALLATIONS ...............13 CHAPTER 2. INSTALLATION ..................15 2.1 INTRODUCTION.........................15 2.2 RECEIVING THE UNIT .......................15 2.3 UNPACKING ........................15...
  • Page 3 Innovation - Edge [i] Installation, Operation, Maintenance Manual CONTENTS 2.15 DUCTED COMBUSTION AIR ...................34 CHAPTER 3. OPERATION ..................35 3.1 INTRODUCTION.........................35 3.2 EDGE CONTROLLER DESCRIPTION ................35 3.2.1 Touchscreen Button Functionality .................37 3.2.2 Logging In ........................38 3.3 MENU STRUCTURE ......................38 3.3.1 Unit Status Menu ......................39 3.3.2 Calibration Menu ......................40 3.3.3 Diagnostics Menu ......................41 3.3.4 Main Menu →...
  • Page 4 Innovation - Edge [i] Installation, Operation, Maintenance Manual CONTENTS 6.1 MAINTENANCE SCHEDULE ....................77 6.2 Water Quality Guideline ......................78 6.3 IGNITER-INJECTOR ......................78 6.4 FLAME DETECTOR ......................81 6.5 COMBUSTION CALIBRATION ...................81 6.6 SAFETY DEVICE TESTING ....................81 6.7 FIRESIDE INSPECTION .....................82 6.8 WATERSIDE INSPECTION AND CLEANING ..............86 6.8.1 Waterside Inspection-Cleaning Schedule ..............86 6.8.2 Waterside Inspection ....................87 6.8.3 Waterside Heat Exchanger Cleaning ................88...
  • Page 5 Innovation - Edge [i] Installation, Operation, Maintenance Manual CONTENTS 8.10.1 Sequencing Valve Description .................. 132 8.10.2 Sequencing Valve Operating Characteristics ............134 APPENDIX A – Startup, Status and Fault Messages .............. 135 APPENDIX B – Temperature Sensor Resistance/Voltage Chart ..........136 APPENDIX D –...
  • Page 6 Innovation - Edge [i] Installation, Operation, Maintenance Manual CONTENTS (This Page Is Intentionally Blank) OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 6 of 170...
  • Page 7: Foreword

    Innovation - Edge [i] 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 - Edge [i] Installation, Operation, Maintenance Manual FORWARD Phrases, abbreviations and acronyms used in this manual are listed in the following table: AERCO Technical Terminology Meanings TERMINOLOGY MEANING A (Amp) Ampere ADDR Address AGND Analog Ground ALRM Alarm ANSI American National Standards Institute ASME American Society of Mechanical Engineers...
  • Page 9 Innovation - Edge [i] Installation, Operation, Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING Innovation Water Heater Input/Output Input/Output (I/O) Box currently used on Benchmark, Innovation and I/O Box KC1000 Series products Internet Protocol Industrial Risk Insurers. Used to define gas trains containing two SSOVs and a solenoid operated vent valve (See DBB above) International Organization for Standardization Lbs.
  • Page 10 Innovation - Edge [i] Installation, Operation, Maintenance Manual FORWARD AERCO Technical Terminology Meanings TERMINOLOGY MEANING RS422 A standard for serial, full-duplex (FDX) transmission of data based on (or EIA-422) the RS422 Standard RS485 A standard for serial, half-duplex (HDX) transmission of data based on (or EIA-485) the RS485 Standard SETPT (Setpt)
  • Page 11: Chapter 1. Safety Precautions

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS CHAPTER 1. SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.
  • Page 12: Emergency Shutdown

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS CAUTION! • Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean water after leak checks have been completed. •...
  • Page 13: For Massachusetts Installations

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS 1.4 FOR MASSACHUSETTS INSTALLATIONS Water heater Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Heater must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 14 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2.
  • Page 15: Chapter 2. Installation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION CHAPTER 2. INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install AERCO Innovation Water Heaters. 2.2 RECEIVING THE UNIT Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight is shown in Table F1 in the Forward to this manual.
  • Page 16: Site Preparation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.4 SITE PREPARATION Ensure that the site selected for installation of the Innovation Water Heater includes: • Access to AC Input Power at either: o 110 VAC, Single-Phase, 60 Hz @ 20 Amps o 220 VAC, Single-Phase, 50/60 Hz @ 20 Amps –...
  • Page 17: Setting The Unit

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION CAUTION! While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY. FOR MASSACHUSETTS ONLY For Massachusetts installations, the unit must be installed by a plumber or gas-fitter who is licensed within the Commonwealth of Massachusetts.
  • Page 18: Water Inlet And Outlet Piping

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.5 WATER INLET AND OUTLET PIPING The locations of the 2" (5.08 cm) NPT cold water inlet and hot water outlet piping connections are shown in Figure 2.5. Flow rates through the unit are limited to 50 gallons (189 Liters) per minute continuous.
  • Page 19: Whm Actuator-Controlled Ball Valve Installation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.5.1 WHM Actuator-Controlled Ball Valve Installation If the Innovation Water Heater was ordered for use with the Water Heater Management (WHM) system and the actuator-controlled ball valve is not already installed on the unit, as shown in Figure 2.5.1, it will be packed separately within the shipping container.
  • Page 20: Automatic Float Vent Installation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.5.2 Automatic Float Vent Installation All Innovation Water Heaters require an Automatic Float Vent connected to a Safety Check valve. Both must be installed on all units, on the top of the heat exchanger dome, as shown below.
  • Page 21: Internal Recirculation Loop

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.7 INTERNAL RECIRCULATION LOOP The internal Recirculation Loop Assembly is located inside the unit enclosure at the rear of the unit. In order to access this assembly, the right-rear panel must be removed, as shown in Figure 2.7.
  • Page 22: Pressure & Temperature Relief Valve Installation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION An ASME rated Pressure & Temperature (P&T) Relief Valve must be installed on each Innovation water heater, on the hot water outlet at the top of the Recirculation Loop Assembly as shown in Figure 2.7, above.
  • Page 23 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION While observing the guidelines above, install the condensate trap as follows: CONDENSATE TRAP INSTALLATION Instructions Attach the 3/4” NPT nipple (P/N 94136) to the exhaust manifold’s drain port. Loosen the condensate trap’s cap, then install it on the open end of the 3/4“...
  • Page 24: Gas Supply Piping

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.10 GAS SUPPLY PIPING The minimum, nominal and maximum allowable gas pressures are listed in the Innovation-Edge Gas Supply Design Guide (TAG-0091, GF-5036). This guide must be consulted prior to designing or installing any gas supply piping.
  • Page 25: Manual Gas Shutoff Valve

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.10.2 Manual Gas Shutoff Valve A manual shut-off valve is factory-installed in the gas supply line at the unit, as shown in Figure 2.5. Additionally, if a gas regulator is installed upstream of the unit, refer to Figure 2.10.3.2 to determine the location of the manual shut-off valve installation in relation to the regulator.
  • Page 26: Ac Electrical Power Wiring

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 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.
  • Page 27: Electrical Power Requirements

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 220 VAC TRANSFORMER Figure 2.11-3: 220 VAC Transformer – Front and Side Panels Removed 2.11.1 Electrical Power Requirements AERCO Innovation Heater built for the International market require the following input voltage: •...
  • Page 28: Field Control Wiring

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.12 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the Edge Controller used with all Innovation water heaters does allow for some control and monitoring features.
  • Page 29: Outdoor Air In Terminal

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION Outdoor Air Remote Intl’k OUT Air Sensor Common Remote Intl’k IN Air Temp Sensor O2 Sensor – NOT USED Not Used Delayed Intl’k OUT Spark Signal + Delayed Intl’k IN Spark Signal –...
  • Page 30: Analog In Terminals

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.12.5 ANALOG IN Terminals The ANALOG IN terminals (+ & -) are used when an external signal is used to change the unit’s setpoint or air/fuel valve position. There are four signal types: •...
  • Page 31: Rs485 Comm Terminals

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2. If “On Board” Water Heater Management is enabled, the Analog Output terminals are used to drive the isolation valve, open and closed. NOTE: When driving an isolation valve, shorting jumper #JP2 MUST be installed on the I/O Board. 2.12.9 RS485 Comm Terminals The RS485 communication terminals (+, GND, &...
  • Page 32: Aux Relay Terminals

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed. The Fault Relay connections are shown in Figure 2.12-2. 2.12.14 AUX RELAY Terminals Each unit is equipped with a single pole double throw (SPDT) auxiliary relay that is energized when there is a demand for heat and de-energized after the demand for heat is satisfied.
  • Page 33: Combustion Air

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION equivalent length. For a natural draft installation, the draft must not exceed - 0.10” W.C. (-24.9 Pa). These factors must be planned into the vent installation. If the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate properly or reliably.
  • Page 34: Ducted Combustion Air

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 2 – INSTALLATION 2.15 DUCTED COMBUSTION AIR See the Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056). 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 35: Chapter 3. Operation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION CHAPTER 3. OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Innovation Water Heater using the Edge Controller mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • Page 36 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Multi-Function Bar, shows either: • Fire Rate • Valve Position Parameter Indicator for both temperature read-outs: • LEFT: Inlet temperature or Setpoint temperature • RIGHT: Outlet temperature or System Header temperature Temperature scale indicator: Fahrenheit or Celsius...
  • Page 37: Touchscreen Button Functionality

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION This button allows you to finalize a selection (for instance, a selected from a menu or from a pop-up (for example, password entry input completion). Enter Note, all alphanumeric data entry is entered in the touchscreen. Fault A red light Indicates that the Controller is in a Fault condition.
  • Page 38: Logging In

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.2.2 Logging In The Edge Controller user interface is protected by password levels to prevent unauthorized use. The Level 1 password, which allows some basic setting changes, is 159. Higher level passwords (appropriate for AERCO Trained Technicians), are distributed on an individual, as needed, basis.
  • Page 39: Unit Status Menu

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.3.1 Unit Status Menu The Unit Status menu contains the following sections and parameters. Unlike other Edge menus, navigation starts at the Unit Status screen and proceeds from there by scrolling to the right.
  • Page 40: Calibration Menu

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.3.2 Calibration Menu The Calibration menu contains the following sections and parameters: Main Menu → Calibration → Combustion Calibration Select the unit’s NOx requirement: None, <= 20 or <= 9 NOx Requirement Select PPM.
  • Page 41: Diagnostics Menu

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Spark Monitor Enabled/Disabled Enables/Disables the Spark Monitor. Min Spark Numeric Entry Minimum spark. (0.00 to 0.29 amps) Max Spark Numeric Entry Maximum spark. (0.30 to 2.50 amps) 3.3.2.3 Main Menu → Calibration → Combustion Summary Main Menu →...
  • Page 42 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.3.3.4 Main Menu → Diagnostics → Subsystems Main Menu → Diagnostics → Subsystems → Air Fuel Valve Stepper Motor Auto Stroke Toggle Initiates A/F cycle, 0 to 100 to 0% Valve Position In Adjust Manual adjustment of A/F Valve 0 to 100%.
  • Page 43: Main Menu → Advanced Setup

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Main Menu → Diagnostics → Comm & Network → BAS Read Only The Building Automation System protocol. Communication The unit’s BAS address. Read Only Address The unit’s Device Instance within BAS. Device Instance Read Only The unit’s IP address on the network.
  • Page 44 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.3.4.1 Main Menu → Advanced Setup → Unit Main Menu → Advanced Setup → Unit → Unit Settings The unit’s factory-set serial number. Do NOT change Unit Serial # Entry except when replacing the Controller.
  • Page 45 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Power Reset Toggle Choose if power fault reset mode, Manual or Automatic. Choose water temperature fault reset mode, Manual or Water Temp Reset Toggle Automatic. Choose if gas pressure fault reset mode, Manual or Gas Pressure Reset Toggle Automatic.
  • Page 46 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION The maximum address in the WHM cascade (1 to 16, Max Address Numeric Entry WHM Unit Mode = WHM Manager). Cascade Baud Rate Select The communication baud rate in the cascade. The timeout before a Modbus Fault is declared (5 to 999 Network Timeout Numeric Entry...
  • Page 47 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Specifies the amount of time full shut down will be Off Delay Numeric Entry delayed (Slow Shutdown = Enabled). The threshold fire rate above which Slow Shutdown will Off Delay Threshold Numeric Entry take effect (Slow Shutdown = Enabled).
  • Page 48 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Subnet Numeric Entry The subnet address of the network (DHCP = Disabled). Gateway Numeric Entry The IP address of the Gateway (DHCP = Disabled). DNS1 Numeric Entry The IP address of DNS Server 1 (DHCP = Disabled). DNS2 Numeric Entry (The IP address of DNS Server 2 DHCP = Disabled).
  • Page 49 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Main Menu → Advanced Setup → Performance → Temperature Control → Setpoint Range Setpoint Low Limit Numeric Entry Determines the upper and lower limit within which the setpoint can vary. Setpoint High Limit Numeric Entry Setpoint Limiting...
  • Page 50 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION Allows adjustment of the pre-ignition purge time (5 to 60 Purge Timer Numeric Entry sec.). Allows adjustment of the post purge time before the unit Post Purge Timer Numeric Entry shuts down (0 to 60 sec.).
  • Page 51: Start Sequence

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.4 START SEQUENCE When the Edge Controller’s Enable/Disable switch is set to the Enable position, it checks all pre-purge safety switches to ensure they are closed. These switches include: •...
  • Page 52 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION START SEQUENCE Instructions b. The Air/Fuel Valve rotates to the full-open purge position and closes purge position switch. The dial on the Air/Fuel Valve (Figure 3.4-2) will read 100 to indicate that it is full-open (100%).
  • Page 53 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION START SEQUENCE Instructions Figure 3.4-4: 25% Air/Fuel Valve Ignition Position Up to 7 seconds will be allowed for ignition to be detected. The igniter-injector relay will be turned off one second after flame is detected. After 2 seconds of continuous flame, FLAME PROVEN will be displayed and the flame strength will be indicated.
  • Page 54: Start/Stop Levels

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 3 – OPERATION 3.5 START/STOP LEVELS The ignition position (start) and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows: Fuel Model Stop Level...
  • Page 55: Chapter 4. Initial Start-Up

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Innovation Water Heater consists of the following: • Complete installation (Chapter 2) •...
  • Page 56: Required Tools & Instrumentation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP 4.2.1 Required Tools & Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit: • Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1 PPM.
  • Page 57: Accessing The Analyzer Probe Port

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Check that the manometer reading is within the allowable gas pressure range, 4.0” W.C. and 14” W.C. If it is outside that range, you must take whatever steps necessary to correct this issue.
  • Page 58: Recommendations For Temperature Calibration

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP CONNECTING MULTIMETER TO MEASURE FLAME STRENGTH Instructions Refer to Figure 4.2.4 and remove the right-side panel from the unit to access the flame detector. Disconnect the flame detector wire lead #135 from the detector and connect the multimeter in series with the wire lead using alligator clips as shown in Figure 4.2.4.
  • Page 59: Combustion Calibration

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP 4.3 COMBUSTION CALIBRATION Innovation Water Heaters are combustion calibrated at the factory prior to shipping. However, recalibration is necessary as part of initial start-up due to changes in the local altitude, gas BTU (kW) content, gas supply piping and supply regulators.
  • Page 60 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Combustion Calibration Instructions 7. Choose the Nitrogen Oxide NOx requirement for the unit, None or <= 20 PPM. Figure 4.3-2: Choose NOx Requirement 8. The main Combustion Calibration screen now appears. It provides two methods to ramp the unit’s valve position up or down: •...
  • Page 61 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Combustion Calibration Instructions TABLE 4.3-1: Gas Pressure Downstream of SSOV 1.9 ± 0.2” W.C. INN 600N 473 ± 50 Pa 1.7 ± 0.2” W.C. INN 800N 423 ± 50 Pa 1.9 ±...
  • Page 62 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Combustion Calibration Instructions • Verify that the gas supply conforms to the requirements in the Innovation-Edge Gas Supply Design Guide (TAG-0091, GF-5036). • Verify that the regulator (if one is used) is properly sized. •...
  • Page 63: Reassembly

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Combustion Calibration Instructions Main Menu → Calibration → Combustion Summary. This screen will remain accessible and unchanged until the next time combustion calibration is performed. Figure 4.3-6: Combustion Calibration Complete Screen 4.4 REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation.
  • Page 64: Setting The Outlet Water Temperature Setpoint

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP temperature must be allowed to settle for several minutes prior to making any further adjustments. When calibrating temperature controls, observe the following: • The unit must be in the Auto mode of operation. •...
  • Page 65: Minimum Load Adjustment

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP 4.5.2 Minimum Load Adjustment With the unit in operation, check the temperature control at minimum load as described below. Minimum Load Adjustment Go to: Main Menu → Advanced Setup → Performance → Temperature Control → FFWD Settings.
  • Page 66: Over-Temperature Limit Switches

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 4 – INITIAL START-UP Maximum Load Adjustment yield a steady valve position between 80% and 90%. Wait several minutes to allow the outlet water temperature to stabilize under load conditions. Once stabilized, the outlet temperature displayed on the Controller should read no more than 2 to 3 °F (1.1 to 1.65 °C) below the unit’s setpoint.
  • Page 67: Chapter 5. Safety Device Testing

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING CHAPTER 5. SAFETY DEVICE TESTING 5.1 INTRODUCTION Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The unit control system comprehensively monitors all combustion- related safety devices before, during and after the start sequence.
  • Page 68: High Gas Pressure Fault Test

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING Low Gas Pressure Fault Test Instructions LOW GAS PRESSURE SWITCH 1/4" NPT PLUG (Install manometer here for SSOV LOW gas pressure test) HIGH GAS PRESSURE 1/4" NPT PLUG SWITCH (Install manometer here for HIGH gas pressure test)
  • Page 69: Low Water Level Fault Test

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING 5.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault: Low Water Level Fault Test Instructions Set the Controller’s Enable/Disable switch to the Disable position. Close the water shut-off valves in the supply and return piping to the unit.
  • Page 70: Interlock Tests

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING NOTE: The (non-adjustable) Manual Reset Over-Temperature Limit switch is calibrated to trip if the discharge water exceeds 190° F (87.8° C). Testing of this device must be done by authorized personnel only.
  • Page 71: Delayed Interlock

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING 5.6.2 Delayed Interlock Delayed Interlock Instructions Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals (see Figure 2.12-2). Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.
  • Page 72: Air Flow Fault Tests

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING Flame Fault Tests Instructions Open the valve closed in step 8. Press the CLEAR button. The unit should restart and fire. GAS INLET LOW GAS PRESSURE SWITCH SSOV HIGH GAS...
  • Page 73 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING Air Flow Fault Tests Instructions DEFAULT MODE MANUAL MODE Figure 5.8-1: Analog Outputs Screen The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps: The unit will execute a 30 second re-ignition delay and display WAIT RETRY PAUSE.
  • Page 74: Ssov Proof Of Closure Switch

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING Air Flow Fault Tests Instructions BLOWER PROOF SWITCH BLOCKED INLET SWITCH BLOWER AIR/FUEL VALVE PARTIAL FRONT VIEW Figure 5.8-2: Blower Proof & Blocked Inlet Switch Locations AIR INLET COLD WATER INLET DRAIN VALVE...
  • Page 75: Purge Switch Open During Purge

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING SSOV Proof of Closure Switch Instructions Disconnect wire #148 from the SSOV to “open” the Proof Of Closure switch circuit. The unit should fault and display SSOV Switch Open. Replace wire #148 and press the CLEAR button.
  • Page 76: Safety Pressure Relief Valve Test

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 5 – SAFETY DEVICE TESTING Ignition Switch Open During Ignition Instructions Set the Controller’s Enable/Disable switch to the Disable position. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.
  • Page 77: Chapter 6. Maintenance

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 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 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 78: Water Quality Guideline

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.2 WATER QUALITY GUIDELINE To keep your water heater operating efficiently over a long lifetime, it is critical to make sure the chemical composition of incoming water is not harmful to the heater. To prevent corrosion, fouling, and other harmful effects on the heater, the following water quality guideline should be adhered to: TABLE 6-2: Water Quality Guideline...
  • Page 79 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE FLAME IGNITER-INJECTOR DETECTOR BURNER FLANGE GASKET (P/N GP-18899) INTAKE MANIFOLD FLANGE FLAME DETECTOR GASKET (Kit P/N 24356-2) OBSERVATION FLAME DETECTOR PORT (Kit P/N 24356-2) IGNITER-INJECTOR IGNITION (Kit P/N 58023) SOLENOID Figure 6.3-1: Intake Manifold with Igniter-Injector &...
  • Page 80 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Igniter-Injector Inspection/Replacement Instructions DO NOT POSITION THE GAS INJECTOR TUBE WITHIN THIS ARC FLAME DETECTOR GAS INJECTOR TUBE FLAME OBSERVATION PORT VIEWED FROM BELOW, LOOKING UP Figure 6.3-2: Igniter-Injector & Flame Detector Mounting Details Torque the ignitor-injector to 15 ft-lbs.
  • Page 81: Flame Detector

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.4 FLAME DETECTOR Flame detector (Kit P/N 24356-2) is used on ALL Innovation Water Heater models. The flame detector is also located on the flange of the intake manifold as shown in Figures 6-1 and 6-2. The flame detector may be hot.
  • Page 82: Fireside Inspection

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.7 FIRESIDE INSPECTION Fireside inspection of the Innovation Water Heater includes removing the exhaust manifold, intake manifold, and the burner assembly from the unit. The purpose of this inspection is to check for the formation of deposits on the inside of the heat exchanger tubes, exhaust manifold, and/or the burner assembly.
  • Page 83 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Fireside Inspection Instructions HEAT EXCHANGER EXHAUST MANIFOLD 5/16-18 HEX NUTS (6) INTAKE MANIFOLD CAP SCREWS (4) 1/4-20 X 7/8” (22.2 mm) Long 1/4-20 SCREWS (2) DO NOT REMOVE PARTIAL RIGHT-SIDE VIEW –...
  • Page 84 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Fireside Inspection Instructions EXHAUST MANIFOLD TO COMBUSTION CHAMBER GASKET (P/N 122537) BURNER ASSEMBLY BURNER MOUNTING BURNER FLANGE PLATE GASKETS (P/N GP-18899) INTAKE MANIFOLD FLANGE INTAKE GASKET MANIFOLD (P/N 81198) Figure 6.7-2: Intake Manifold and Burner –...
  • Page 85 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Fireside Inspection Instructions BURNER FLANGE GASKET (P/N GP-18899) BLOWER SIDE INTAKE MANIFOLD INTAKE MANIFOLD INTAKE MANIFOLD FLANGE GASKET (P/N 81198) BURNER, INTAKE AND EXHAUST MANIFOLDS Figure 6.7-4: Combustion Chamber Gasket Locations IMPORTANT! During reassembly, apply high-temperature, anti-seize lubricant to the threads of the igniter- injector and grounding screw.
  • Page 86: Waterside Inspection And Cleaning

    For units installed at sites with hard water (>3.5 grains/gal, >59.9 mg/L), AERCO strongly ® recommends use of Watts OneFlow anti-scaling system (note, this system does not protect against orthophosphates, which can also cause scale deposits). It provides an economical, chemical free treatment of hard water, allowing the water heater to perform at its peak heat transfer efficiency, thereby reducing heating cost.
  • Page 87: Waterside Inspection

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.8.2 Waterside Inspection Inspection of the heat exchanger tubes and tubesheet area is done using the two 2” NPT inspection ports, in the upper and lower sections of the shell, as shown in Figure 6.8.2. Waterside Inspection Instructions Disconnect the electrical power to the unit.
  • Page 88: Waterside Heat Exchanger Cleaning

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.8.3 Waterside Heat Exchanger Cleaning If the inspection of the waterside components revealed sediment and/or scale buildup, complete the instructions below to flush the shell with a cleaning solution. To clean the heat exchanger, AERCO recommends using a cleaning solution of Rydlyme Chemical Descaler (or equivalent) and clean water.
  • Page 89 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Set-Up Instructions Instructions UNION CLOSE HOT WATER OUTLET HOSE CONNECTION UPPER DRAIN VALVE BACK-FLOW PREVENTER COLD WATER CLOSE COLD PUMP WATER INLET CIRCULATION BUCKET LOWER DRAIN VALVE Figure 6.8.3.1: Sample Heat Exchanger Cleaning Set-Up Install a hose to the upper drain valve and route it back to the top of the circulation bucket.
  • Page 90: Condensate Drain Trap

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Cleaning Procedure Instructions Upon completion of the cleaning process, begin flushing the solution by adding clean water to the circulation bucket, then disconnect the return valve and hose connection from the top of the circulating bucket and thoroughly flush.
  • Page 91: Air Filter Replacement

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE Run water through the body of the trap to thoroughly clean the inside of the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap.
  • Page 92: Low Water Cutoff (Lwco) Capacitor Integrity Test

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST If the LWCO capacitor has failed, order the LWCO capacitor Kit, P/N 69126, from AERCO, and consult the Innovation 24 Month Maintenance Technical Instructions Document (TID-0094) for replacement instructions.
  • Page 93 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE LWCO Capacitor Electrical Short Test Instructions Unplug Shell Harness Cable from P5 Connector Figure 6.11.1-1: Removing Shell Harness Cable from P5 Connector on Rear Panel 3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure 6.11.1-2.
  • Page 94: Low Water Cutoff (Lwco) - Standard Test

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.11.2 Low Water Cutoff (LWCO) - Standard Test Perform the standard Low Water Cutoff test using the Edge Controller as described below. Standard Low Water Cutoff Edge Test Instructions 1.
  • Page 95: Spark Monitor (Ac Current Transducer)

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE 6.14 SPARK MONITOR (AC CURRENT TRANSDUCER) The spark monitor (P/N 61034) evaluates the strength of the current between the ignition transformer (P/N 65085) and igniter or igniter-injector (see Figure 6.14-2). SPARK MONITOR WIRE 140 IGNITION...
  • Page 96 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 6 – MAINTENANCE (This Page Is Intentionally Blank) OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 96 of 170...
  • Page 97: Chapter 7. Troubleshooting Guide

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE CHAPTER 7. TROUBLESHOOTING GUIDE 7.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in an Innovation Water Heater. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
  • Page 98 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 98 of 170...
  • Page 99 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blower stopped running due to thermal Check combustion blower for signs of excessive heat or high or current overload.
  • Page 100 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blower not running or running too Start the unit. If the blower does not run check the blower solid state relay for input and output voltage.
  • Page 101 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Delayed Interlock Jumper not installed Check for a jumper properly installed across the delayed or removed. interlock terminals in the I/O box.
  • Page 102 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Worn Flame Detector or cracked Remove and inspect the Flame Detector for signs of wear or ceramic.
  • Page 103 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Faulty Water temperature switch. Test the temperature switch to insure it trips at its actual water temperature setting.
  • Page 104 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Switch wired incorrectly. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). If the switch is wired correctly, replace the switch.
  • Page 105 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Line and Neutral switched in AC Check hot and neutral in AC Power Box to ensure they are not Power Box.
  • Page 106 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Switch wired incorrectly. If the switch is wired correctly, replace the switch. PRG SWITCH Defective Power Supply Board or fuse. Check DS1 &...
  • Page 107 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV not fully closed. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.
  • Page 108 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Air/Fuel Valve out of calibration. Perform Stepper Test per GF-112 (section 6.3.5) to ensure stepper motor rotates properly from 0% (fully closed) to 100% (fully open) positions.
  • Page 109: Additional Faults Without Specific Fault Messages

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE 7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 7-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 7-2. WATER HEATER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION...
  • Page 110 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 7 – TROUBLESHOOTING GUIDE FLAME IGNITER-INJECTOR DETECTOR BRASS HEX HEAD CAP (Remove to access gas BURNER FLANGE pressure adjustment screw) GASKET (P/N GP-18899) INTAKE MANIFOLD FLAME DETECTOR SSOV ACTUATOR GASKET COVER (Kit P/N 24356-2) OBSERVATION PORT...
  • Page 111: Chapter 8. Water Heater Management

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT CHAPTER 8. WATER HEATER MANAGEMENT NOTE: Some of the descriptions and procedures provided in this Chapter may duplicate information provided in previous Chapters of this manual. This is done to organize all WHM related information into a single Chapter, thus minimizing referencing back to these descriptions and procedures.
  • Page 112: Whm Principles Of Operation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.2 WHM PRINCIPLES OF OPERATION The WHM system communicates with the plant water heaters via a RS485 network utilizing Modbus RTU protocol (8-bit, 9600 baud, no parity). All Modbus networks are implemented using a “Manager”...
  • Page 113: Modbus Header Sensor

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.3.4 Modbus Header Sensor This optional feature allows users to monitor the combined system outlet temperature or the system Tank temperature via Modbus. This feature requires a Modbus Temperature sensor Module to read and transmit the temperature to the Manager unit.
  • Page 114: Auto-Manager Transfer

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.3.7 Auto-Manager Transfer The Auto-Manager Transfer feature, once enabled, automatically transfers WHM Manager functionality to a new unit if the current WHM Manager fails or loses power. To use this feature (default = Disabled), go to: Main Menu →...
  • Page 115: Whm Status Displays

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.4 WHM STATUS DISPLAYS The following WHM status information will be displayed to inform the user of critical WHM real- time operating conditions: Once a unit is defined as the WHM Manager, the green Manager light appears on the Controller’s front face.
  • Page 116: Whm Parameters

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.6 WHM PARAMETERS The WHM parameters are all in the various screens under Main Menu → Advanced Setup → WHM Cascade. However, these parameters can only be viewed if the Unit Type option in the Main Menu →...
  • Page 117 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT TABLE 8-6b: WHM Cascade → Cascade Communication Parameters Available Choices or Limits Menu Item Display Default Minimum Maximum Unit Address The address in the WHM Cascade of the current unit. Min Address WHM Manager only –...
  • Page 118 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT TABLE 8-6b: WHM Cascade → Cascade Communication Parameters Max Address) WHM On Timeout 15 Sec 300 Sec 60 Sec WHM Manager only – Specifies the time the WHM Manager must wait for a Client unit to turn WHM CLIENT SCREEN WHM MANAGER SCREEN Figure 8.6-2: Cascade Communication Screens...
  • Page 119 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT Figure 8.6-3: Application Configuration Screen The remaining WHM parameters are in Main Menu → Advanced Setup → WHM Cascade → Operating Controls. TABLE 8-6d: Operating Controls → Sequencing Control Parameters Available Choices or Limits Menu Item Display Default...
  • Page 120 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT WHM Client screen WHM Manager screen Figure 8.6-4: Operating Controls: Sequencing Controls Screens TABLE 8-6e: Operating Controls → Anti-Cycling Parameters Available Choices or Limits Menu Item Display Default Minimum Maximum...
  • Page 121 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT Figure 8.6-5: Operating Controls: Anti-Cycling Control Screen TABLE 8-6f: Operating Controls → Valve Configuration Parameters Available Choices or Limits Menu Item Display Default Minimum Maximum Select Output Standard Setup Read Only Select the output you want to configure.
  • Page 122: Whm Hardware Installation & Set-Up Instructions

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT TABLE 8-6g: Operating Controls → Lead/Lag Control Parameters Available Choices or Limits Menu Item Display Default Minimum Maximum Run Hours, Unit Size, Lead/Lag Setting Select Lead/Lag Select Lead/Lag Determines how the Lead and Lag units will be selected.
  • Page 123: Installation Notes

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.7.1 Installation Notes AERCO requires a WHM sequencing valve in multi-unit Innovation configurations. When WHM is employed, Modbus communication with BAS is available via Modbus TCP (go to Main Menu →...
  • Page 124: Whm Modbus Network Wiring

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT BALL VALVE WITH ACTUATOR COLD WATER INLET 2” (5.1 cm) NPT NIPPLE 2” (5.1 cm) NPT UNION HEATER DRAIN VALVE Figure 8.7: Innovation Water Heater Equipped with Sequencing Valve 8.7.3 WHM Modbus Network Wiring As previously mentioned, all units being controlled by the WHM will be connected to a RS485 Modbus Network.
  • Page 125: Control And Power Wiring

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT the last unit on the daisy-chain prior to performing the wiring connections. This will simplify wiring connections and Modbus address assignments. Modbus network wiring connections must be made using shielded twisted-pair wiring, (18 – 24 AWG) such as Belden #9841, #3105A, #8760, or equivalent.
  • Page 126 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-1192 rev A Figure 8.7.4-1: WHM Network Wiring Diagram OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 126 of 170...
  • Page 127 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-1190 rev A Figure 8.7.4-2: WHM Network Wiring Diagram OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 127 of 170...
  • Page 128 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-1191 rev A Figure 8.7.4-3: WHM Network Wiring Diagram OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 128 of 170...
  • Page 129: Whm Programming & Start-Up

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.8 WHM PROGRAMMING & START-UP All required hardware installation and network wiring must be completed before configuring the WHM parameters into the WHM Manager and Client units. In addition, the required menu entries must be determined based on the descriptions in the previous sections.
  • Page 130 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT WHM Manager Programming & Start-Up Procedure e. Check that the Manager LED is lit on the Controller’s front face. 5. Go to: Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Sequencing Control.
  • Page 131: Troubleshooting

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.9 TROUBLESHOOTING Faults which may occur during WHM operation include the items listed in Table 8-9. TABLE 8-9: WHM Troubleshooting FAULT INDICATION PROBABLE CAUSE CORRECTIVE ACTION Outlet Temperature Edge Controllers...
  • Page 132: Sequencing Valve Description & Operation

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.10 SEQUENCING VALVE DESCRIPTION & OPERATION Brief descriptions of Actuator-Controlled Sequencing Valve (P/N 92123) and its operating characteristics are provided below in Sections 8.11.1 and 8.11.2, respectively. The installation of the valve itself is described in Chapter 2, Section 2.5.1.
  • Page 133 Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT POTENTIOMETER CLUTCH (See Note 2) TERMINALS (5) AUTO-STROKE (RESET) BUTTON DIP SWITCHES (4) DO NOT PRESS 1–OFF (DOWN) (See Note 1) 2–OFF (DOWN) 3–ON (UP) 4–OFF (DOWN) NOTES: 1.
  • Page 134: Sequencing Valve Operating Characteristics

    Innovation - Edge [i] Installation, Operation, Maintenance Manual CHAPTER 8 – WATER HEATER MANAGEMENT 8.10.2 Sequencing Valve Operating Characteristics The Sequencing Valve is powered by 24 VAC which is supplied from a step-down transformer located in the Power Box of the Innovation Water Heater. The 24 VAC power output and a 2 to 10 VDC control signal from the I/O Box of the Water Heater are routed to the Sequencing Valve via a 4-pin Molex connector.
  • Page 135: Appendix A - Startup, Status And Fault Messages

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX A – STARTUP, STATUS AND FAULT MESSAGES APPENDIX A – Startup, Status and Fault Messages All Startup, Status and Fault messages are included in Section 8 of the Edge [i] Controller Manual for Benchmark Boilers and Innovation Water Heaters, OMM-0141, GF-213.
  • Page 136: Appendix B - Temperature Sensor Resistance/Voltage Chart

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX B – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART APPENDIX B – Temperature Sensor Resistance/Voltage Chart TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART (BALCO) TEMPERATURE °F °C RES (OHMS) VOLTS* 779.0 1.93 -34.4 797.5 1.96 -28.9 816.3 1.99 -23.3 835.4...
  • Page 137: Appendix D - Dimensional Drawings

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS APPENDIX D – Dimensional Drawings Drawing Number: AP-A-1053 rev A OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 137 of 170...
  • Page 138 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-1054 rev A OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 138 of 170...
  • Page 139: Appendix E - Parts List Drawings

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS APPENDIX E – Parts List Drawings Innovation 600N/800N/1060N/1350N Parts List – Page 1 Item Qty. Part # Description Item Qty. Part # Description 22246 DYNAMIC LOAD ANTICIPATOR ASSY 34061 BASE FORMED 26 X 40 80090...
  • Page 140 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N/800N/1060N/1350N Parts List – Page 2 Item Qty. Part # Description Item Qty. Part # Description 65175 THERMOSTAT, JUMO 22332 GAS TRAIN, FM ¾” SSOV, INN 600/800N 122843 LOW WATER, CUTOFF 22353...
  • Page 141 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N/800N/1060N/1350N Parts List – Page 3 Item Qty. Part # Description Item Qty. Part # Description 25074 ENCLOSURE, FRAME ASSY 37095 FRONT PANEL 59133 LATCH, COMPRESSION 37098 TOP PANEL OMM-0143_A...
  • Page 142 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS INTAKE MANIFOLD – BURNER – EXHAUST MANIFOLD CROSS-SECTION VIEW Innovation 600N/800N/1060N/1350N Parts List – Page 4 Item Qty. Part # Description Item Qty. Part # Description 44106 INTAKE MANIFOLD GP-18899...
  • Page 143 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N/800N/1060N/1350N Parts List – Page 5 Item Qty. Part # Description Item Qty. Part # Description 37101 REAR PANEL, UPPER RIGHT 37097 PANEL, LEFT REAR 37099 PANEL, SIDE 80107...
  • Page 144 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N/800N/1060N/1350N Parts List – Page 6 Item Qty. Part # Description Item Qty. Part # Description 64163 POWER BOX 120/220 VAC INNOVATION 69245 I/O BOX WITH ONAER & SEQ VALVE CABLES 30090 PANEL, ELECTRICAL 72082...
  • Page 145 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N, 800N 3/4” Gas Train – P/N 22332 rev A Item Qty Part # Description Part # Description Item 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4"...
  • Page 146 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 1060N 1” Gas Train – P/N 22353 rev A Item Qty Part # Description Part # Description Item 95026 1.25"NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE (CLOSED) 92006-5 VALVE: BALL 1"...
  • Page 147 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 1350 Gas Train – P/N 22363 rev A Item Qty Part # Description Item Qty Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4"...
  • Page 148 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Innovation 600N, 800N 1060N, 1350N Air Fuel Delivery System – P/N 24648 rev A Item Qty Part # Description Item Part # Description 43101 BLOWER INTAKE MANIFOLD 61002-4 HIGH GAS PRESSURE SWITCH 4.0”...
  • Page 149 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS Intake Manifold Assembly P/N 24234 rev E Innovation Burner Assembly P/N 24233-2 Item Qty Part # Description Item Qty Part # Description 44106 INTAKE MANIFOLD 44179 BURNER PLATE 59104 OBSERVATION PORT...
  • Page 150 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX E – PARTS LIST DRAWINGS (This Page Is Intentionally Blank) OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 150 of 170...
  • Page 151: Appendix F - Piping Drawings

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS APPENDIX F – Piping Drawings Drawing Number: SD-A-829 rev C OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 151 of 170...
  • Page 152 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-830 rev C OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 152 of 170...
  • Page 153 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-831 rev C OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 153 of 170...
  • Page 154 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-845 rev C OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 154 of 170...
  • Page 155 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-848 rev D OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 155 of 170...
  • Page 156 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-851 rev D OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 156 of 170...
  • Page 157 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-852 rev D OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 157 of 170...
  • Page 158 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-854 rev G OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 158 of 170...
  • Page 159 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-856 rev D OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 159 of 170...
  • Page 160 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-939 rev B OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 160 of 170...
  • Page 161: Appendix G - Edge [I] Controller Views

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX G – EDGE [i] CONTROLLER VIEWS APPENDIX G – Edge [i] Controller Views Figure G-1 – Edge Controller (P/N 64134) - Exploded View OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 161 of 170...
  • Page 162 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX G – EDGE [i] CONTROLLER VIEWS INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) BOX SHELL HARNESS CONNECTOR (19 PIN) GAS TRAIN HARNESS CONNECTOR (9 PIN) A/F VALVE HARNESS CONNECTOR (16 PIN) EXT.
  • Page 163: Appendix H - Wiring Diagrams

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX H – – Wiring Diagrams APPENDIX H – Wiring Diagrams Drawing Number: 68056 rev D Sheet 1 of 2 OMM-0143_A • GF-216 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 163 of 170 •...
  • Page 164 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX H – – Wiring Diagrams Drawing Number: 68056 rev D Sheet 2 of 2 OMM-0143_A • GF-216 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 164 of 170 •...
  • Page 165 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX H – – Wiring Diagrams Drawing Number: 68057 rev D Sheet 1 of 2 OMM-0143_A • GF-216 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 165 of 170 •...
  • Page 166 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX H – – Wiring Diagrams Drawing Number: 68057 rev D Sheet 2 of 2 OMM-0143_A • GF-216 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 166 of 170 •...
  • Page 167: Appendix I - Recommended Spares

    Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX I – RECOMMENDED SPARES APPENDIX I – Recommended Spares For the locations of the recommended and optional spare parts listed below, refer to the Parts List Illustrations in Appendix E. TABLE I-1. Recommended Emergency Spare Parts DESCRIPTION PART NO.
  • Page 168 Innovation - Edge [i] Installation, Operation, Maintenance Manual APPENDIX I – RECOMMENDED SPARES TABLE I-3. Optional Spare Parts DESCRIPTION PART NO. QUANTITY Circulator Pump, for Dynamic Load Anticipator: 22246 One per site Stock one if site has Edge Controller 64134 difficulty getting parts Stock one if site has Burner...
  • Page 169 Innovation - Edge [i] Installation, Operation, Maintenance Manual NOTES: OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 169 of 170...
  • Page 170 Innovation - Edge [i] Installation, Operation, Maintenance Manual Change Log: Date Description Changed By 9/6/2019 Rev A: Initial release (internal reference DIR 19-43) © AERCO International, Inc., 2019 OMM-0143_A • GF-216 • 9/6/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 170 of 170...

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