Watts AERCO SmartPlate SP23 Installation, Operation & Maintenance Manual
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Watts AERCO SmartPlate SP23 Installation, Operation & Maintenance Manual

Watts AERCO SmartPlate SP23 Installation, Operation & Maintenance Manual

Domestic hot water heaters
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Installation, Operation & Maintenance Manual
SmartPlate Domestic
Hot Water Heaters
Single Wall Heater Models:
SP23, SP33, SP45, SP69, SP150
• SP-100 • 1/30/2020
OMM-0069_0H
Double Wall Heater Models:
SPDW23, SPDW32, SPDW42, SPDW61,
SPDW113

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Summary of Contents for Watts AERCO SmartPlate SP23

  • Page 1 Installation, Operation & Maintenance Manual SmartPlate Domestic Hot Water Heaters Single Wall Heater Models: Double Wall Heater Models: SPDW23, SPDW32, SPDW42, SPDW61, SP23, SP33, SP45, SP69, SP150 SPDW113 • SP-100 • 1/30/2020 OMM-0069_0H...

  • Page 2: Table Of Contents

    SmartPlate Installation, Operation & Maintenance Manual CONTENTS Table Of Contents GENERAL INFORMATION ................5 1.1 INTRODUCTION ........................... 5 1.2 ELECTRONIC CONTROL SYSTEM/SMARTPLATE (ECS/SP) ..............6 1.2.1 Control Box Assembly ........................7 1.2.2 Feed-Forward Temperature Sensors .................... 8 1.2.3 Outlet Temperature Sensors ......................8 1.2.4 Boiler Water Inlet/Outlet Temperature Sensors ................
  • Page 3 SmartPlate Installation, Operation & Maintenance Manual CONTENTS 6.9 PERIODIC CLEANING OF HEAT EXCHANGER ..................46 TROUBLESHOOTING ..................47 7.1 INTRODUCTION ..........................47 7.2 TROUBLESHOOTING PROCEDURES ....................47 CORRECTIVE MAINTENANCE ................57 8.1 INTRODUCTION ..........................57 8.2 SINGLE WALL HEAT EXCHANGER MAINTENANCE ................57 8.3 HEAT EXCHANGER CLEANING &...
  • Page 4 SmartPlate Installation, Operation & Maintenance Manual CONTENTS (This Page Is Intentionally Blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 4 of 134...

  • Page 5: General Information

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION GENERAL INFORMATION 1.1 INTRODUCTION This manual provides detailed coverage for the AERCO SmartPlate line of Water-to-Water Heaters. Each SmartPlate Water Heater model is equipped with AERCO’s Electronic Control System (ECS), specifically designed for SmartPlate (ECS/SP), and an Electronic Control Valve, MXG-461.

  • Page 6: Electronic Control System/Smartplate (Ecs/Sp)

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION CONTROL RELIEF VALVE CONTROL VALVE MXG-461 INTAKE MIXING BOX BOILER WATER COLD WATER OUTLET INLET BOILER WATER DIFFERENTIAL PRESSURE GAUGE BOILER WATER INLET DHW OUTLET BOILER WATER INLET HEAT EXCHANGER STRAINER DOMESTIC (BEHIND SUPPORT ASSY)

  • Page 7: Control Box Assembly

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION If desired, the ECS/SP can be ordered with a Modbus communication option. This option permits the ECS/SP to be externally controlled by an Energy Management System (EMS), Building Automation System (BAS), or a computer supplied by other manufacturers. The ECS/SP assemblies and components are described in the following subordinate sections.

  • Page 8: Feed-Forward Temperature Sensors

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION audible alarm and cuts off power to the Control Valve Actuator thereby closing the Control Valve and shutting off the boiler water flow to the unit. The Boiler Water inlet and outlet temperatures are sensed on the surface of the inlet/outlet pipes and are provided for informational and troubleshooting purposes only.

  • Page 9: Smartplate Piping Assemblies

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION 1.3 SMARTPLATE PIPING ASSEMBLIES The diameter of the piping assemblies furnished with the water heater will depend on the size of the heat exchanger installed in the SmartPlate model ordered. Smaller sized models utilize 1.5” piping assemblies, while the larger sizes utilize 2”...
  • Page 10 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION RELIEF VALVE 3-WAY CONTROL VALVE AIR VENT VALVE ISOLATION BALL VALVE (4 PLCS) INTAKE MIXING BOX BOILER WATER OUTLET COLD WATER HEAT INLET EXCHANGER BOILER WATER DIFFERENTIAL PRESSURE GAUGE RECIRCULATION PUMP BOILER WATER INLET DRAIN VALVE...

  • Page 11: Installation

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION INSTALLATION 2.1 INTRODUCTION All of the SmartPlate Water Heater models are shipped fully assembled and ready for installation. Therefore, installation will consist of the following tasks: • Unpack the SmartPlate Water Heater from its shipping container. •...

  • Page 12: Site Selection And Preparation

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.3 SITE SELECTION AND PREPARATION Ensure that the site selected for installation of the SmartPlate Water Heater includes the following: • Access to AC input power at 120 VAC/60 Hz, 220 VAC/50 Hz or 220 VAC 60 Hz, single phase.

  • Page 13: Setting The Unit

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.3.2 SETTING THE UNIT SmartPlate Single-Wall models contain two lifting tabs at the top of the frame assembly (Figure 2-2 a). Use these tabs to lift and move the unit. Double-Wall models contain two round cutouts on the frame plate and two on the pressure plate of the heat exchanger (Figure 2-2 b).

  • Page 14: Repositioning Ecs/Sp Control Box

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION PRESSURE FRAME PLATE CUTOUTS CUTOUTS Figure 2-2 b. SmartPlate Lifting Provisions – Double-Wall Models 2.3.3 REPOSITIONING ECS/SP CONTROL BOX If required, the front panel displays of the ECS/SP Control Box can be repositioned from the default left-side of the unit (Figure 2-2) to either the right side or rear of the unit to optimize viewing of the panel displays.

  • Page 15: Heating Fluid And Domestic Hot Water (Dhw) Piping

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION REPOSITIONING ECS/SP CONTROL BOX Instructions ECS/SP CONTROL SUPPORT FRAME PHILLIPS HD. SCREWS (4 PLCS) HEAT EXCHANGER (SINGLE-WALL) SMARTPLATE – PARTIAL REAR VIEW Figure 2-3. Repositioning ECS/SP Control Box 2.4 HEATING FLUID AND DOMESTIC HOT WATER (DHW) PIPING The diameter of the heating fluid (hot boiler water) and DHW piping will depend on the model number and size of the unit being installed.

  • Page 16: Smartplate Electrical Wiring Connections

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION IMPORTANT! When SmartPlate Water Heaters are shipped from the factory, all four isolation ball valves and the drain valve (Figure 1-3) are opened. Close all valves during installation. Do not open the valves until instructed to do so in Chapter 5 of this manual.
  • Page 17 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION ELECTRICAL WIRING CONNECTIONS Instructions PANEL CAPTIVE SCREW Figure 2-5. Recessed Panel Behind ECS/SP Control Box Door 3. Swing down the recessed panel to access Terminal Block TB-2 on the bottom interior surface of the Control Box, shown in Figure 2-6.
  • Page 18 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION ELECTRICAL WIRING CONNECTIONS Instructions INSTALL EXTERNAL POWER WIRING THROUGH THIS REAR CUT-OUT TRANSFORMER 120/24 VAC 220/24 VAC NEUTRAL LINE TB-2 POWER SWITCH FROM FUSE INTERIOR BOTTOM SURFACE FOR 220 VAC, WIRE #100 MUST BE CONNECTED TO THIS TERMINAL Figure 2-6.
  • Page 19 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION ELECTRICAL WIRING CONNECTIONS Instructions OVER-TEMPERATURE FAULT RELAY Rated for 2 amps, 260VAC (Energized Upon Fault) Figure 2-7: Remote Relay Option Kit (P/N 69018) Schematic 7. If the ECS was ordered with the Modbus Communication Option, proceed to step 8. However, if this option is not included, no further steps are required.
  • Page 20 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION ELECTRICAL WIRING CONNECTIONS Instructions 8. To permit Modbus control of the ECS/SP, refer to Table 2-2, below, and connect the appropriate wire leads to the Temperature Controller terminals listed. Refer to the Temperature Controller (Eurotherm 2408) pinouts shown in Figure 2-8 to locate the required terminals.

  • Page 21: Additional Component Installation

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.6 ADDITIONAL COMPONENT INSTALLATION A number of SmartPlate Water Heater components are included in an installation kit. These parts must be installed after the unit is setup at the site. There are six installation kits.
  • Page 22 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION ADDITIONAL COMPONENT INSTALLATION Instructions 2. If you have a 200 PSI unit, install the parts as shown in Figure 2-10. Air Vent Valve P/N 92130 Relief Valve P/N 92134-1 Nipple, ¾” P/N 93451 Bushing, 1 ½”...

  • Page 23: Functional Description

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION FUNCTIONAL DESCRIPTION 3.1 INTRODUCTION SmartPlate Water Heaters are equipped with a stainless steel plate heat exchanger, an ECS/SP Electronic Control System, and an MXG-461 Control Valve. This design results in a highly responsive system which provides virtually constant hot water flow at the selected setpoint temperature.

  • Page 24: Electronic Control Overview

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION 3.3 ELECTRONIC CONTROL OVERVIEW The primary control mechanism for the ECS/SP is an Electronic Process Controller which is installed in the Control Box. The Controller utilizes feed forward and PID (Proportional Integral Derivative) algorithms to provide precise control of the unit’s outlet temperature.
  • Page 25 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION DHW OUTLET TEMP CONTROL BOX POWER INPUT 24 VAC XFMR 120 VAC, 60 Hz 120 VAC, 60 Hz WITH 3A, 24 VAC 220 Hz, 50 Hz CKT BRKR OVER-TEMP DHW DUAL OUTLET TEMP POWER 220 VAC, 50 Hz...
  • Page 26 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION (This Page Is Intentionally Blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 26 of 134...

  • Page 27: Adjustment

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT ADJUSTMENT 4.1 INTRODUCTION This chapter provides the adjustment procedures for the 3-Way Control Valve, MXG-461 and the SmartPlate Electronic Control System (ECS/SP). Prior to shipment from AERCO, all MXG-461 Control Valve Actuators are adjusted (auto- stroked) to ensure that they properly position the Control Valve from the fully-open to the fully- closed positions.
  • Page 28 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT CONTROL VALVE CALIBRATION Instructions COVER SCREWS (2) HAND-WHEEL Figure 4-1. Control Valve Electronics Module – Top View 2. Remove the Electronics Module cover from the Valve to access the internal components shown in Figure 4-2 HAND-WHEEL AUTO-...
  • Page 29 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT CONTROL VALVE CALIBRATION Instructions 4. Set the ECS/SP Control Box POWER switch to the ON position to apply 24 VAC power to the Control Valve Actuator (pins 1 (G0) and 2 (G). Ensure the Valve is in the AUTO position, the LED indicator will light green continuously indicating that Valve operation is normal (no faults).

  • Page 30: Manual Control Of 3-Way Valve - Removable Handwheel To Hamper Tampering

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 4.2.2 MANUAL CONTROL OF 3-WAY VALVE – REMOVABLE HANDWHEEL TO HAMPER TAMPERING If desired, the control path (A-to-AB) of the Control Valve, (Siemens, MXG-461) can be opened manually up to 95% of full-stroke. Refer to Figure 4-3 and proceed as follows: MANUAL CONTROL OF 3-WAY VALVE Instructions 1.

  • Page 31: Setpoint Temperature Adjustment

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT OVER TEMPERATURE TEMPERATURE SWITCH CONTROLLER BOILER WATER TEMPERATURE INDICATORS Figure 4-4. Control Box – Front View NOTE: When the Power Switch on the Control Box is set to the ON position, it also energizes the internal 24 VAC Transformer in the Control Box.
  • Page 32 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT SETPOINT TEMPERATURE ADJUSTMENT Instructions 3. If the lower display does not show the desired setpoint temperature, press the ▲ or ▼ arrow button to change the display to the desired value. 4.
  • Page 33 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT SETPOINT TEMPERATURE ADJUSTMENT Instructions TABLE 4-2. Temperature Controller Operating Controls, Indicators & Displays CONTROL or MEANING FUNCTION INDICATOR OP1 lights when a 0 to 10 VDC signal is being Output 1 Indicator supplied to the ECSSP Valve Actuator Output 2 Indicator Not used for the ECS/SP application...

  • Page 34: Over-Temperature Alarm Limit Adjustment

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 4.2.4 OVER-TEMPERATURE ALARM LIMIT ADJUSTMENT The over-temperature alarm limit setting is adjusted using the controls and display on the Over- Temperature Switch. The alarm limit is normally set 20°F above the specified setpoint. The controls and display are illustrated and described in Figure 4-6 and Table 4-3.
  • Page 35 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT REPOSITIONING ECS/SP CONTROL BOX Instructions TABLE 4-3. Over-Temperature Switch Controls and Indicators CONTROL or INDICATOR MEANING FUNCTION Displays current water temperature or LED Display TEMP status setpoint. RESET Button Resets the unit after an alarm condition. UP Button Increases the displayed temperature.
  • Page 36 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT (This Page Is Intentionally Blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 36 of 134...

  • Page 37: Operation

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION OPERATION 5.1 INTRODUCTION This chapter provides the pre-operational checks, initial start-up and operating procedures for SmartPlate Water Heaters. WARNING! FLUIDS MUST BE GRADUALLY INTRODUCED TO THE UNIT. FAILURE TO DO SO CAN CAUSE DAMAGE TO HEAT EXCHANGER PLATES.

  • Page 38: Initial Start-Up

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION 5.3 INITIAL START-UP In order to prevent a possible over-temperature condition during initial start-up, AERCO recommends that the following steps be performed in the order specified: INITIAL START-UP Instructions 1. With the ECS/SP Control Box door open, set the POWER switch on the right side of the box to the ON position.

  • Page 39: Checking Mixed Inlet Temperature

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION CHECKING MIXED INLET TEMPERATURE If desired, the water heater mixed inlet temperature can be monitored using the controls and displays on the Temperature Controller. This is accomplished as follows: Instructions CHECKING MIXED INLET TEMPERATURE 1.
  • Page 40 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION Instructions SHUTTING DOWN THE SYSTEM 4. Next, connect a hose to the Drain Valve on the DHW Side of the piping assembly. Open the Relief Valve to allow air into the pipe during draining. 5.

  • Page 41: Scheduled Maintenance

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE 6.1 INTRODUCTION SmartPlate Water Heaters require regular routine maintenance to keep the unit operating at optimum efficiency. AERCO recommends that the tasks listed in Table 6-1 – Scheduled Maintenance Action, be performed at the periodic intervals specified.

  • Page 42: Boiler Water Differential Pressure Gauge Check

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 6.2 BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK Once each week check the Differential Pressure Gauge on the unit’s Boiler Water Inlet as follows: BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK Instructions 1.

  • Page 43: Plate Pack Leakage Checks (Double-Wall Models Only)

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 6.3 PLATE PACK LEAKAGE CHECKS (DOUBLE-WALL MODELS ONLY) For SmartPlate Double-Wall Water Heater models, check the Plate Pack for leaks as follows: PLATE PACK LEAKAGE CHECKS Instructions 1. Remove the splash guard to access the Plate Pack (see Figure 5-1). 2.

  • Page 44: Strainer Inspection And Cleaning

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE OVER-TEMP SWITCH CHECK Instructions 2. Verify that an Over-Temp Alarm is generated and the following events occur: a) The Control Valve (Siemens MXG-461) closes. b) The Over-Temp Switch generates an audible alarm. 3.

  • Page 45: Recirculation Pump Check

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE TEMPERATURE SENSOR CHECKS Instructions 5. Inspect the Sensors for evidence of scale build-up on the stainless-steel sleeve of the Sensors. If necessary, clean the Sensors using a wire brush. 6.

  • Page 46: Periodic Cleaning Of Heat Exchanger

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 6.9 PERIODIC CLEANING OF HEAT EXCHANGER It may be necessary to de-scale the heat exchanger periodically, depending on water conditions and temperature settings. Section 8.2 describes the descaling process for the Water Heater’s heat exchanger.

  • Page 47: Troubleshooting

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TROUBLESHOOTING 7.1 INTRODUCTION The troubleshooting procedures provided in this chapter are intended to aid service and maintenance personnel in isolating the most probable cause of a fault in a packaged SmartPlate Water Heater.
  • Page 48 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TROUBLESHOOTING PROCEDURES Instructions 3. Perform the corresponding checks and procedures listed in the CORRECTIVE ACTION column for the first PROBABLE CAUSE. 4. Continue checking each additional PROBABLE CAUSE for the existing fault until the fault has been corrected.
  • Page 49 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly Fault Indication Probable Cause Corrective Action System outlet water 1. Boiler water inlet 1. Check the strainer differential pressure temperature is below gauge.
  • Page 50 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly Fault Indication Probable Cause Corrective Action Rapid fluctuations in 1. Temp. Controller is not 1. Refer to Table 7-2 and troubleshoot the heater outlet temperature functioning properly.
  • Page 51 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP) Fault Indication Probable Cause Corrective Action 1. External 120 VAC 1. Ensure external circuit breaker is ON. System not operating. power disconnected. Check for 120 or 240 VAC power across All displays are blank.
  • Page 52 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP) Fault Indication Probable Cause Corrective Action Over-Temp. Alarm 1. Shorted Outlet Temp. 1. Replace Outlet Temp, Sensor. condition cannot be Sensor. cleared. 2.
  • Page 53 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP) Fault Indication Probable Cause Corrective Action Temperature control not Unexpected system See Table 7-3 for Temperature Control within specifications. dynamics. Troubleshooting. Items T1 – T8 check out Outlet Temp Sensor Replace Outlet Temp Dual Sensor at Wide fluctuations in...
  • Page 54 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-3. Troubleshooting Guide for Temperature Control Issues Observation Probable Cause Corrective Action T9-1 Too much valve Low flow condition may Increase the Proportional value (Pb oscillations or too wide be unsteady or at a and/or Pb2).
  • Page 55 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING TABLE 7-3A. Dynamic Temperature Control Settings for SmartPlate Single- Water Heaters Feed Unit Size Boiler Water Proportional Proportional *Gain Schedule Forward *Integral 1 * Derivative 1 *Integral 2 *Derivative 2 (SP or Temp Band 1...
  • Page 56 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING (This Page Is Intentionally Blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 56 of 134...

  • Page 57: Corrective Maintenance

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CORRECTIVE MAINTENANCE 8.1 INTRODUCTION This chapter provides the procedures to correct and repair faults detected during operation or isolated during troubleshooting of SmartPlate Water Heaters. The procedures in this chapter are divided into four sections as follows: •...
  • Page 58 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Instructions HEAT EXCHANGER CLEANING RELIEF VALVE CONTROL ISOLATION BALL VALVES AIR VENT VALVE BOILER WATER INTAKE MIXING INLET COLD WATER INLET ISOLATION BALL VALVES BOILER WATER INLET OUTLET HEAT EXCHANGER (BEHIND SUPPORT ASSY) DRAIN RECIRCULATION...
  • Page 59 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Instructions HEAT EXCHANGER CLEANING TABLE 8-1. Cleaning Solution Required For Heat Exchanger De-Scaling Heat Exchanger Cleaning Solution SmartPlate Model Volume (gallons) Required (Gallons) Single-Wall Heat Exchangers SP23 SP33 SP45 SP69 SP150 11.3...

  • Page 60: Single-Wall Heat Exchanger Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.4 SINGLE-WALL HEAT EXCHANGER REPLACEMENT The heat exchanger used in each SmartPlate Single-Wall model is removed and replaced using the following basic procedure: SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions 1. Turn the POWER switch on the side of the ECS/SP Control Box to OFF. 2.
  • Page 61 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions 7. Using a ratchet wrench with an extension and a 3/4” deep socket, loosen, but do not remove, the four (4) Victaulic couplings (Figure 8-3). Two (2) couplings are located on the Domestic Water Side (Figure 8-3) and two (2) are located on the Boiler Water Side.
  • Page 62 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions SUPPORT FRAME MOUNTING ATTACHMENT HAND HOLE 4 PLACES CUTOUT (VIEW “A - A”) (BOTH SIDES) HEAT EXCHANGER (HX) REAR VIEW HEAT EXCHANGER SUPPORT FRAME HEX HEAD BOLT FLAT...

  • Page 63: Double-Wall Heat Exchanger Maintenance

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE SECTION II SMARTPLATE DOUBLE-WALL HEAT EXCHANGER MODELS 8.5 DOUBLE-WALL HEAT EXCHANGER MAINTENANCE The maintenance procedures for SmartPlate Double-Wall models (Figure 8-5) include procedures for: • Cleaning (in-place or by disassembly) •...

  • Page 64: Double-Wall Heat Exchanger Cleaning

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.6 DOUBLE-WALL HEAT EXCHANGER CLEANING The Double-Wall heat exchanger can be cleaned in-place by circulating cleaning agents through the unit, or by disassembly. 8.6.1 HEAT EXCHANGER CLEANING AND DE-SCALING (IN-PLACE METHOD) If the heat exchanger is not encrusted with hardened scale deposits, it can normally be cleaned by circulating cleaning solution such as Rydlyme Chemical Descaler (available from Apex Engineering Products Corp.) and clean water through the assembly.
  • Page 65 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions 4. Open the valve on the Strainer and drain the boiler water from the unit. It will be necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe during draining.

  • Page 66: Double-Wall Heat Exchanger Opening And Closing

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions TABLE 8-2. Recommended Cleaning Procedures TYPE OF CHEMICAL CAUSE CLEANING METHOD NOTES FOULING CLEANING Nitric Acid Incrustation Calcium 1. Soft brush & running Maximum Scaling Carbonate,...

  • Page 67: Opening Heat Exchanger

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.7.1 OPENING HEAT EXCHANGER Perform the following steps to shut down, drain and open the Double-Wall Heat exchanger: OPENING HEAT EXCHANGER Instructions 1. Ensure that the Water Heater has been shut down and drained using the procedures in section 8.6.1, steps 1 through 7.
  • Page 68 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE OPENING HEAT EXCHANGER Instructions Figure 8-8. Measurement of Plate Pack Dimension "A" – Splash Guard Removed 10. If the unit is a model SPDW113, remove the U-bolt securing the heat exchanger support bar (see section 8.9 and Figure 8-18).

  • Page 69: Removal And Insertion Of Plates

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE OPENING HEAT EXCHANGER Instructions 12. With the tightening bolts removed, the pressure plate can be slid back (Figure 8-10) and channel heat transfer plates can also be slid back for inspection or cleaning. Figure 8-10.

  • Page 70: Closing Heat Exchanger

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE REMOVAL AND INSERTION OF PLATES Instructions Figure 8-11. Insertion of Plates in Heat Exchanger 8.7.3 CLOSING HEAT EXCHANGER Closing the heat exchanger is accomplished as follows: CLOSING HEAT EXCHANGER Instructions 1.
  • Page 71 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CLOSING HEAT EXCHANGER Instructions Figure 8-13. Closing the Heat Exchanger 6. Brush the threads of the bolts clean, using a steel wire brush. 7. Lubricate the threads with a thin layer of grease. 8.
  • Page 72 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CLOSING HEAT EXCHANGER Instructions Figure 8-14. Tightening Plate Pack Bolts 9. Check the plate pack length ("A") during closing in at least four locations close to the bolts being used. 10.

  • Page 73: Double-Wall Heat Exchanger Gasket Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CLOSING HEAT EXCHANGER Instructions 13. Perform the following final checks: a) Inspect the washers. b) When fully tightened. The bolts should all be equally tensioned c) The difference between the plate pack lengths measured at adjacent bolts should not exceed: 0.079 inches.

  • Page 74: Replacing Gaskets On End Plate (First Plate Against Frame Plate)

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Replacing Gaskets on Channel Plates Instructions Figure 8-15. Clip-Type Glueless Gasket Installation 4. When the plates of the heat exchanger are assembled and tightened, the gasket provides a tight seal around the plate. 5.
  • Page 75 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Replacing Gaskets on End Plate Instructions Figure 8-16. Cutting Gaskets For End Plate Figure 8-17. End Plate with Gasket Installed OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 75 of 134...

  • Page 76: Double-Wall Heat Exchanger Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.9 DOUBLE-WALL HEAT EXCHANGER REPLACEMENT The heat exchanger used in each SmartPlate Double-Wall model is removed and replaced using the following basic procedure: DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions 1. Turn OFF the POWER Switch on the side of the ECS/SP Control Box. 2.
  • Page 77 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions HEAT EXCHANGER VICTAULIC COUPLINGS (4 PLACES) “L” BRACKETS (2 PLACES) HEAT EXCHANGER MOUNT Figure 8-18. Domestic Water Side - Double-Wall Partial View 8. For larger SmartPlate units (models SPDW61, SPDW113) remove the U-bolt securing the heat exchanger support bar (not shown above) and, if there is an “L”...
  • Page 78 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions DETAIL “A” DETAIL “A” Figure 8-19. Double-Wall Heat Exchanger Mounting Details - Rear WARNING! DEPENDING ON THE SMARTPLATE MODEL, THE DOUBLE-WALL HEAT EXCHANGER WEIGHS BETWEEN 350 AND 800 POUNDS. YOU MUST THEREFORE USE EXTREME CARE WHEN REMOVING THE HEAT EXCHANGER FROM ITS MOUNT.
  • Page 79 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions LIFTING STRAP THREADED BOLTS PRESSURE PLATE PRESSURE PLATE Figure 8-20. Heat Exchanger Lifting Strap To replace the heat exchanger with a new assembly, simply reverse the previous steps. Support the replacement heat exchanger using a suitable lifting strap (shown in Figure 8-20, above) and lower into position on the heat exchanger mount.

  • Page 80: Control Valve Electronic Module Replacement And Valve Removal

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE SECTION III SMARTPLATE WETTED COMPONENTS - ALL MODELS 8.10 CONTROL VALVE ELECTRONIC MODULE REPLACEMENT AND VALVE REMOVAL The only replaceable item on the 3-Way Control Valve (Siemens MXG-461) is the Electronics Module located at the top of the Valve (Figure 8-21).
  • Page 81 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE ELECTRONICS MODULE REPLACEMENT Instructions socket head screws removed in step 4. 7. Refer to Figure 8-23 and ensure that the three (3) DIP switches on the replacement Module are all in the OFF (down) position. 8.

  • Page 82: Control Valve Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.10.2 CONTROL VALVE REPLACEMENT To remove the complete Control Valve Assembly from the SmartPlate Water Heater: CONTROL VALVE REPLACEMENT Instructions 1. Turn the POWER Switch on the side of the ECS/SP Control Box to OFF. 2.

  • Page 83: Recirculation Pump Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CONTROL VALVE REPLACEMENT Instructions 12. Reconnect the power and control signal wire leads to the Electronics Module of the replacement Control Valve. 13. Turn ON the POWER Switch on the side of the ECS/SP Control Box. 14.
  • Page 84 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE RECIRCULATION PUMP REPLACEMENT Instructions RELIEF VALVE AIR ELIMINATOR (200 PSI SHOWN) INLET STRAINER HEAT EXCHANGER STRAINER BLOW-DOWN VALVE ISOLATION BALL VALVES DHW DRAIN VALVE RECIRCULATION PUMP Figure 8-25. Domestic Water Piping Components OMM-0069_0H •...

  • Page 85: Strainers

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.12 STRAINERS All SmartPlate Water Heater models utilize Combination Strainers and Ball Valve on the boiler side, and a strainer on the DHW side to prevent fouling of the heat exchanger by trapping foreign material before it enters the unit.
  • Page 86 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE DIFFERENTIAL PRESSURE GAUGE REPLACEMENT Instructions DIFFERENTIAL PRESSURE GAUGE GAUGE BODY FITTINGS (2 PLCS) COMPRESSION FITTINGS (2 PLCS) ISOLATION BALL VALVE STRAINER BODY BLOW-DOWN VALVE Figure 8-26. Differential Pressure Gauge/Strainer/Ball Valve Combo – Boiler Side OMM-0069_0H •...

  • Page 87: Ecs/Sp Control Box Assembly And Components

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE SECTION IV SMARTPLATE ELECTRONIC CONTROL SYSTEM (ECS/SP) WARNING! TURN OFF THE CONTROL BOX POWER SWITCH AND DISCONNECT AC POWER PRIOR TO PERFORMING ANY CORRECTIVE MAINTENANCE PROCEDURES IN THE FOLLOWING SECTIONS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS PERSONAL INJURY 8.13 ECS/SP CONTROL BOX ASSEMBLY AND COMPONENTS Corrective maintenance for the Control Box and internally-mounted components consist of...

  • Page 88: Temperature Controller Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CONTROL BOX ASSEMBLY REPLACEMENT Instructions 4. After all Control Box cables have been disconnected, remove the four mounting screws securing the bottom of the Control Box to the mounting bracket. Completely remove the Control Box from the unit.

  • Page 89: Over-Temperature Switch And Temperature Indicators

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.16 OVER-TEMPERATURE SWITCH AND TEMPERATURE INDICATORS The Over-Temperature Switch and Temperature Indicators are actually identical devices, however they perform different functions. As the name implies, the Over-Temperature Switch, performs a switching function and generates an alarm when the preset temperature limit is exceeded.

  • Page 90: Vac Step-Down Transformer Replacement

    SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE OVER-TEMPERATURE SWITCH and TEMPERATURE INDICATOR REPLACEMENT Instructions 8. If the replaced unit is an Over-Temperature switch, set the desired over-temperature alarm limit using the adjustment procedures in Chapter 4, section 4.2.4. 9.
  • Page 91 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE STEP-DOWN TRANSFORMER REPLACEMENT Instructions Figure 8-30. ECS/SP Control Box Assembly 69096 (Sheet 1 of 2) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 91 of 134...
  • Page 92 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE STEP-DOWN TRANSFORMER REPLACEMENT Instructions TEMPERATURE OVERTEMP SWITCH CONTROLLER 7 8 9 10 11 7 8 9 10 11 7 8 9 10 11 BOILER WATER TEMP FRONT PANEL – VIEWED FROM BACK VIEW C –...
  • Page 93 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE STEP-DOWN TRANSFORMER REPLACEMENT Instructions ECS/SP CONTROL BOX ASSEMBLY 69096 PARTS LIST Item Qty. Part No. Description 65082 TRANSFORMER, X075CBA, 120/240 TO 24 VAC 64008 TEMPERATURE INDICATOR CONTROLLER 64056 OVER-TEMP SWITCH/TEMP INDICATOR 60003 ON/OFF SWITCH 65087...
  • Page 94 SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE (This page left intentionally blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 94 of 134...
  • Page 95 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION APPENDIX A MODBUS CONTROL AND COMMUNICATION TEMPERATURE CONTROLLER (Eurotherm 2408) PROCEDURES MODBUS COMMUNICATION INFORMATION & PROCESS / DIAGNOSTIC ALARM MESSAGES OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 95 of 134...
  • Page 96 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION A.1 TEMPERATURE CONTROLLER (EUROTHERM 2408) PROCEDURES The following sections provide the procedures to add a Modbus Communication board to the Temperature Controller and change communication addresses. A.1.1 Adding a Communication Board to the Temperature Controller Parts Needed: a.
  • Page 97 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION ADDING A COMMUNICATION BOARD Instructions 4. Place Temperature Indicating Controller back into Control Box Assembly and power up unit. The following screen will appear. (See Figure A-3) Page Up/Down Arrow Button...
  • Page 98 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION A.1.2 Changing the Temperature Controller Communication Addresses NOTE: Refer to the button map at the bottom of the display, Figure A-4, for all panel navigation instructions. Button Map Figure A-4 The Temperature Controller address is defaulted to 1 from the factory.
  • Page 99 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION 2. Enter 24 using the Up Arrow. The number will flash and display PASS. 3. Scroll to Goto (current value is OPEr) and use the Down Arrow to enter a value of Full.
  • Page 100 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION 8. Go to the home screen by pressing the Page and Scroll buttons at the same time. 9. Page to the ACCS list and change the code to anything other than 24. The codE number you enter will flash off and then on to 0 to confirm that access is now set to the OPEr...
  • Page 101 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION A.2 MODBUS COMMUNICATION INFORMATION NOTE: The Eurotherm 2400 Controller supports the MODBUS RTU mode of transmission. The default settings are as follows: 9600 Baud Rate, one start bit, eight data bits, one stop bit, & no parity bit.
  • Page 102 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION A.3 PROCESS & DIAGNOSTIC ALARMS The Process and Diagnostic Alarms that can appear in the Temperature Controller display are listed in the following Tables. PROCESS ALARMS DISPLAY MEANING _FSL* PV Full Scale Low Alarm.
  • Page 103 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION DIAGNOSTIC ALARMS DISPLAY MEANING WHAT TO DO` Err2 Error 2: RAM self-test fail Return Controller for repair Err3 Error 3: Watchdog fail Return Controller for repair Error 4: Keyboard failure. Switch power off and then on, without touching Err4 Stuck button or button was...
  • Page 104 SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION (This page left intentionally blank) OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 104 of 134...

  • Page 105: Appendix B - Ecs/Sp Wiring Diagram & Terminal Block Connections

    SmartPlate Installation, Operation & Maintenance Manual APPENDIX B – ECS/SP WIRING DIAGRAM APPENDIX B – ECS/SP WIRING DIAGRAM & TERMINAL BLOCK CONNECTIONS Drawing Number: 69008-2 rev F OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 105 of 134...
  • Page 106 SmartPlate Installation, Operation & Maintenance Manual APPENDIX B – ECS/SP WIRING DIAGRAM INTERNAL RECIRC. PUMP TRANSFORMER 120/24 VAC 220/24 VAC 120/240 VAC POWER IN FOR 220 VAC, WIRE #100 MUST BE CONNECTED TO THIS TERMINAL POWER SWITCH FROM FUSE OMM-0069_0H • SP-100 • 1/30/2020 Technical Support •...

  • Page 107: Appendix C - Smart Plate Piping Drawings

    SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS APPENDIX C – SMART PLATE PIPING DRAWINGS Drawing Number: SD-A-772 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 107 of 134...
  • Page 108 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-773 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 108 of 134...
  • Page 109 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-774 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 109 of 134...
  • Page 110 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-775 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 110 of 134...
  • Page 111 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-776 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 111 of 134...
  • Page 112 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-777 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 112 of 134...
  • Page 113 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-796 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 113 of 134...
  • Page 114 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-792 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 114 of 134...
  • Page 115 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-793 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 115 of 134...
  • Page 116 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-794 rev E OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 116 of 134...
  • Page 117 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-783 rev D OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 117 of 134...
  • Page 118 SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-784 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 118 of 134...

  • Page 119: Appendix D - Dimensional Drawings

    SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-846 rev C OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 119 of 134...
  • Page 120 SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-847 rev E OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 120 of 134...

  • Page 121: Appendix E - Part Lists

    SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS APPENDIX E – PART LISTS SmartPlate SINGLE WALL – Base Components Item # Qty Part # Description 34026 BASE: SMARTPLATE SEE TABLE BRAZED PLATE HEAT EXCHANGER PIPING ASSY, 1.5" 120V 60 Hz (See assembly drawings below) SEE TABLE PIPING ASSY, 1.5"...
  • Page 122 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS 3 & 4 AERCO SmartPlate Single Wall Part List 02/27/2017 International, Inc. Blauvelt, NY 10913 29381-TAB rev F Sheet 2 of 2 OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 122 of 134...
  • Page 123 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS SmartPlate DOUBLE-WALL – Base Components Item # Part # Description SEE TABLE DOUBLE WALL HEAT EXCHANGER 34026 BASE, SMARTPLATE PIPING ASSY, 1.5" SPDW – 120V/60 Hz SEE TABLE PIPING ASSY, 1.5" SPDW – 220V/50 Hz PIPING ASSY, 2"...
  • Page 124 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS 3 & 4 AERCO SmartPlate Double Wall Part List 02/22/2017 International, Inc. Blauvelt, NY 10913 29382-TAB rev E Sheet 2 of 2 OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 124 of 134...
  • Page 125 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS SmartPlate Installation Kits SmartPlate Water Heater units are shipped with one of the following installation kits: NYC Option Kit # SmartPlate Models HX Type Pressure SP23, SP33, SP45, SP69, SP150 Single Wall 58128-1 SPDW23, SPDW32, SPDW42, SPDW61,...
  • Page 126 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS P/N 22263-TAB – SmartPlate 1.5 " Piping Assemblies 1.5 inch piping assemblies are used in the following SmartPlate models: Pressure * Piping Assembly P/N SmartPlate Models Type Power 150 PSI 22263-1 SP23, SP33 Single Wall...
  • Page 127 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS SmartPlate 1.5” Piping Assembly AERCO 11/15/2016 International, Inc. Blauvelt, NY 10913 22263-TAB rev D Sheet 2 of 2 OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 127 of 134...
  • Page 128 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS P/N 22264-TAB – SmartPlate 2.0 " Piping Assemblies 2.0 inch piping assemblies are used in the following SmartPlate models: Pressure * Piping Assy. P/N SmartPlate Models Type Power 150 PSI 22264-1 SP45, SP69, SP150 Single Wall...
  • Page 129 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS SmartPlate 2.0” Piping Assembly AERCO 11/15/2016 International, Inc. Blauvelt, NY 10913 22264-TAB rev D Sheet 2 of 2 OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 129 of 134...
  • Page 130 SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – PART LISTS CONTROL BOX ASSEMBLY – SINGLE WALL & DOUBLE WALL Item # Qty Part # Description 65082 TRANSFORMER, X075CBA, 120/240 TO 24 VAC 64028-7 TEMPERATURE INDICATOR CONTROLLER - SP23, SPDW23 64028-8 TEMPERATURE INDICATOR CONTROLLER: SP33, SPDW32 64028-9...

  • Page 131: Appendix F - Recommended Spare Parts

    SmartPlate Installation, Operation & Maintenance Manual APPENDIX F – RECOMMENDED SPARE PARTS APPENDIX F – RECOMMENDED SPARE PARTS NOTE Refer to the SmartPlate Parts List illustrations in Appendix E for the locations of the recommended and optional spare parts listed in the following Tables. TABLE F-1.
  • Page 132 SmartPlate Installation, Operation & Maintenance Manual APPENDIX F – RECOMMENDED SPARE PARTS TABLE F-3. Spare Parts Recommended for Pump Maintenance DESCRIPTION PART NUMBER Pump Flange Gasket Set 89011-1 Pump Casing O-Ring 89011-2 Pump Capacitor (120 VAC) 89011-3 Pump Capacitor (220 VAC) 89011-4 Pump Cartridge Assembly 89011-5...
  • Page 133 SmartPlate Installation, Operation & Maintenance Manual NOTES: OMM-0069_0H • SP-100 • 1/30/2020 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 133 of 134...
  • Page 134 SmartPlate Installation, Operation & Maintenance Manual Change Log Date Description Changed By Rev G Changes: 1320: Added 220 V 60 Hz option, plus various updates 07/14/2017 (reference DIR 393) Chris Blair DIR 17-001: Added recommendation in Section 2.4 to use 2 pipe wrenches when tightening pipe connections Rev H: DIR 18-31: Clarified over-temperature fault relay connections...

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