Watts AERCO Innovation INN 600N Installation, Operation And Maintenance Manual
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Watts AERCO Innovation INN 600N Installation, Operation And Maintenance Manual

Natural gas, propane, and butane units with edge controller
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  • Page 1 • • • • • • • • •...

  • Page 2: Table Of Contents

    CONTENTS CONTENTS CONTENTS.............................. 2 FOREWORD ............................7 CHAPTER 1. SAFETY PRECAUTIONS ..................10 1.1 Warnings & Cautions ......................10 1.2 Emergency Shutdown ......................11 1.3 Prolonged Shutdown ......................11 1.4 For Massachusetts Installations ..................12 CHAPTER 2. INSTALLATION ......................14 2.1 Introduction .........................14 2.2 Receiving The Unit ......................14 2.3 Unpacking 14 2.4 Site Preparation ........................15 2.4.1 Installation Clearances ........................
  • Page 3 CONTENTS 2.14.1 Combustion Air from Outside the Building .................. 32 2.14.2 Combustion Air from Inside the Building ..................32 2.15 Ducted Combustion Air .....................32 CHAPTER 3. OPERATION ....................... 33 3.1 Introduction .........................33 3.2 Edge Controller Description ....................33 3.2.1 Touchscreen Button Functionality ....................35 3.2.2 Logging In ............................
  • Page 4 CONTENTS 5.11 Ignition Switch Open During Ignition..................74 5.12 Safety Pressure Relief Valve Test ..................75 CHAPTER 6. MAINTENANCE ......................76 6.1 Maintenance Schedule ......................76 6.2 Water Quality Guideline ......................76 6.3 Igniter-Injector ........................77 6.4 Flame Detector ........................80 6.5 Combustion Calibration .......................80 6.6 Safety Device Testing ......................80 6.7 Fireside Inspection ......................81 6.8 Waterside Inspection And Cleaning ..................85 6.8.1 Waterside Inspection-Cleaning Schedule ..................
  • Page 5 CONTENTS 8.7.4 Control and Power Wiring ......................118 8.8 WHM Programming & Start-Up ..................122 8.9 Troubleshooting ........................ 124 8.10 Sequencing Valve Description & Operation ..............125 8.10.1 Sequencing Valve Description ....................125 8.10.2 Sequencing Valve Operating Characteristics................126 APPENDIX A – Startup, Status and Fault Messages .............. 129 APPENDIX B –...

  • Page 7: Foreword

    CHAPTER 1 SAFETY PRECAUTIONS 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 CHAPTER 1 SAFETY PRECAUTIONS 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 Auxiliary Building Automation System, often used interchangeably with EMS (see below) Symbol rate, or number of distinct symbol changes (signaling events) transmitted Baud Rate per second.
  • Page 9 MA (mA) Milliampere (1 thousand of an ampere) Modbus® A serial, half-duplex data transmission protocol developed by AEG Modicon The cloud-based water management software from Watts that offers real-time Nexa equipment monitoring, insight, and alerts. NC (N.C.) Normally Closed NO (N.O.)

  • Page 10: Chapter 1. Safety Precautions

    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 11: Emergency Shutdown

    CHAPTER 1 SAFETY PRECAUTIONS C A U T I O N ! • 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 12: For Massachusetts Installations

    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 13 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. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

  • Page 14: Chapter 2. Installation

    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 15: Site Preparation

    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 – International Models only •...

  • Page 16: Setting The Unit

    CHAPTER 2 INSTALLATION C A U T I O N ! While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY. F O R M A S S A C H U S E T T S O N L Y For Massachusetts installations, the unit must be installed by a plumber or gas-fitter who is licensed within the Commonwealth of Massachusetts.

  • Page 17: Water Inlet And Outlet Piping

    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 18: Whm Actuator-Controlled Ball Valve Installation

    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 19: Automatic Float Vent Installation

    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. Both valves are included in the Accessory Kit shipped with the unit.

  • Page 20: Internal Recirculation Loop

    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. To access this assembly, the right-rear panel must be removed, as shown in Figure 2.7. This assembly contains a recirculation pump that connects the upper hot water outlet to the lower cold-water inlet to the unit’s heat exchanger.

  • Page 21: Pressure & Temperature Relief Valve Installation

    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 22 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“ nipple. Rotate the cap so the outlet faces towards the condensate drain, then tighten it.

  • Page 23: Gas Supply Piping

    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. W A R N I N G ! NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS...

  • Page 24: Manual Gas Shutoff Valve

    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 25: Ac Electrical Power Wiring

    CHAPTER 2 INSTALLATION 2.11 AC Electrical Power Wiring The AERCO Innovation-Edge Electrical Power Design Guide (TAG-0092, GF-5066) must be consulted prior to connecting any AC power wiring to the unit. This guide includes electrical power wiring diagrams. External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front door of the unit to access the Power Box mounted directly above the Edge Controller.

  • Page 26: Electrical Power Requirements

    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 Heaters built for the international market require the following input voltage: • 120 VAC, single-phase, 50/60 Hz @ 20A •...

  • Page 27: Field Control Wiring

    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 current generation water heaters does allow for some control and monitoring features. Wiring connections for these features are made in the Input/Output (I/O) Box.

  • Page 28: Outdoor Air Terminal

    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 Not Used + Delayed Intl’k IN Not Used – Not Used O2 Sensor + Not Used +12 V Out Analog In +...

  • Page 29: Valve Feedback Terminals

    CHAPTER 2 INSTALLATION All supplied signals must be floating (ungrounded) signals. Connections between the source and the Heater’s I/O Box must be made using twisted shielded pair of 18–22 AWG wire such as Belden 9841. Polarity must be maintained, and the shield must be connected only at the source end and must be left floating (not connected) at the unit’s I/O Box.

  • Page 30: Vfd/Blower Terminals

    CHAPTER 2 INSTALLATION 2.12.10 VFD/BLOWER Terminals These terminals (0-10 & AGND) send an analog signal to control the blower speed. When any of the 4-20 mA options is selected for the Analog Outputs (Section 2.12.8), the output from the VFD/Blower terminals is disabled. 2.12.11 Interlock Terminals The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers or other accessories.
  • Page 31 CHAPTER 2 INSTALLATION flue must be pitched back towards the unit a minimum of 1/4" per foot (21 mm per m) to avoid any condensate pooling and to allow for proper drainage. In addition, you must add a bead of high temperature red silicon sealant (such as Permatex Hi-Temp Red RTV or Loctite Superflex Red High Temp RTV) between the exhaust manifold and the mating flange of the exhaust connector, as shown in Figure 2.13.

  • Page 32: Combustion Air

    CHAPTER 2 INSTALLATION 2.14 Combustion Air The Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056) must be consulted before any flue or inlet air venting is designed or installed. Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.

  • Page 33: Chapter 3. Operation

    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 34 CHAPTER 3 OPERATION Figure 3.2: Edge Controller Front Panel Layout The Soft-Keys on the Controller’s front face Multi-Function Bar, shows either: • Fire Rate function as follows: • Valve Position Parameter Indicator for both temperature read-outs: • LEFT: Inlet temperature or Setpoint temperature •...

  • Page 35: Touchscreen Button Functionality

    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 36: Logging In

    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 basis when after technicians have complete AERCO certified training.

  • Page 37: Unit Status Menu

    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. Main Menu → Unit Status Target Fire Rate Read Only The target Fire Rate (0% to 100%).

  • Page 38: Calibration Menu

    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. The unit’s target Valve Position. Valve Position - Target Read Only The unit’s actual Valve Position.

  • Page 39: Diagnostics Menu

    CHAPTER 3 OPERATION Max Spark Numeric Entry Maximum spark. (0.30 to 2.50 amps) 3.3.2.3 Main Menu → Calibration → Combustion Summary Main Menu → Calibration → Combustion Summary Valve Position Read Only Displays combustion calibration valve steps. Read Only Displays combustion calibration O2 results. Read Only Displays combustion calibration NOx results.
  • Page 40 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%. Main Menu →...
  • Page 41 CHAPTER 3 OPERATION 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. Unit IP Address Read Only The unit’s MAC address within BAS.

  • Page 42: Advanced Setup Main

    CHAPTER 3 OPERATION 3.3.4 Advanced Setup Main The Advanced Setup menu contains the following sections: Main Menu → Advanced Setup → Access Numeric Entry Enter 159 or your password, then press Save. Password 3.3.4.1 Main Menu → Advanced Setup → Unit Main Menu →...
  • Page 43 CHAPTER 3 OPERATION Main Menu → Advanced Setup → Unit → Settings Transfer Restore All Settings Select Restores all settings to the factory default. Restore Common Settings Select Restores common settings to the factory default. Save All Settings Select Saves all settings to USB or onboard memory. Main Menu →...
  • Page 44 CHAPTER 3 OPERATION The address of the WHM Manger (0 to 16, WHM Unit Auto-Manager Addr Read Only Mode = WHM Manager). The address of the unit designated as the Backup WHM Backup Manager Addr Numeric Entry Manger (0 to 16) (WHM Unit Mode = WHM Manager). Main Menu →...
  • Page 45 CHAPTER 3 OPERATION The temperature above setpoint the unit may rise to Shutoff Delay Temp Numeric Entry during delay shutdown (0°F to 25°F). Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Valve Configuration Select Output Read Only Displays Standard Setup.
  • Page 46 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 47 CHAPTER 3 OPERATION Setpoint Limiting Enable/Disable Enables/disables Setpoint Limiting functionality. Sets the number of °F below Setpoint High Limit the unit’s outlet temperature must fall before the unit restarts (0 Setpoint Limit Band Numeric Entry to 10°F, Setpoint Limiting = Enable). Setback Schedule Enable/Disable Enables/disables Setback Schedule functionality...
  • Page 48 CHAPTER 3 OPERATION Sets the air fuel valve position at which the unit will operate Ignition Position Numeric Entry during the ignition sequence (5% to 60%). Ignition Blower Voltage Read Only Displays the actual blower voltage during ignition. Allows an adjustment to the blower voltage during ignition Ignition Voltage Offset Numeric Entry (-5.00 to 5.00).

  • Page 49: Start Sequence

    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: • Safety Shut-Off Valve Proof of Closure (POC) switch •...
  • Page 50 CHAPTER 3 OPERATION START SEQUENCE Instructions PURGE VALVE POSITION DIAL AT 100% TO BLOWER AIR IN STEPPER MOTOR Figure 3.4-2: Air/Fuel Valve in Purge Position Next, the Blower Proof switch on the Air/Fuel Valve (Figure 3.4-3) closes. The display will show Purging and indicate the elapsed time of the purge cycle in seconds. BLOWER PROOF BLOCKED SWITCH...

  • Page 51: Start/Stop Levels

    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 52: Chapter 4. Initial Start-Up

    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) • Set proper controls and limits (Chapter 3) •...

  • Page 53: Installing Gas Supply Manometer

    CHAPTER 4 INITIAL START-UP 4.2.2 Installing Gas Supply Manometer The gas supply manometer is used to verify that the upstream gas pressure is within the allowable range, and it is then installed on the downstream side of the SSOV to measure gas pressure during the combustion calibration process.

  • Page 54: Accessing The Analyzer Probe Port

    CHAPTER 4 INITIAL START-UP 4.2.3 Accessing the Analyzer Probe Port The unit contains a 1/8” NPT port at the rear of the exhaust manifold. This port is located above the condensate drain connection as shown in Figure 4.2.3. Prepare the port for the combustion analyzer probe as follows: ACCESSING ANALYZER PROBE PORT Instructions Refer to Figure 4.2.3 and remove the 1/8”...

  • Page 55: Recommendations For Temperature Calibration

    CHAPTER 4 INITIAL START-UP EXHAUST MANIFOLD IGNITER-INJECTOR FLAME DETECTOR CLIP LEAD HARNESS WIRE LEAD #135 INTAKE MULTIMETER MANIFOLD CLIP LEAD Figure 4.2.4: Flame Strength Set-Up Using Multimeter – Rear View IMPORTANT! The unit is shipped from the factory set up for Natural Gas, as specified by the Style Number on the Sales Order.
  • Page 56 CHAPTER 4 INITIAL START-UP If you press the Back or Home buttons at any time before completion, the calibration operation is disabled and normal operation resumes. Complete the instructions below to perform combustion calibration. Combustion Calibration Instructions 1. Ensure that the Controller’s Enable/Disable switch is set to Disable. 2.
  • Page 57 CHAPTER 4 INITIAL START-UP 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: • Method 1: Toggle through the pre-set calibration points till you reach the desired valve position, then press Go to go to that point (left image below).
  • Page 58 CHAPTER 4 INITIAL START-UP Combustion Calibration Instructions TABLE 4.3-1: Gas Pressure Downstream of SSOV Models Natural Gas Propane Butane 1.9 ± 0.2” W.C.(473 ± 50 Pa) 1.8 ± 0.2” W.C. (448 ± 50 Pa) INN 600N 1.7 ± 0.2” W.C. (423 ± 50 Pa) 2.2 ±...
  • Page 59 CHAPTER 4 INITIAL START-UP NOTE: These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). Lower the Valve Position to the 80% calibration point using either the  (Left) arrow key or the Fine Valve Position – (Minus) key, then repeat step 13 and 17 at that valve position. The O , NOx and CO should stay within the ranges shown in these tables.
  • Page 60 CHAPTER 4 INITIAL START-UP Combustion Calibration Instructions TABLE 4.3-2c: Combustion Calibration Readings – Butane Valve Nitrogen Oxide Carbon Oxygen (O Flame µA Position (NOx) Monoxide (CO) 100% 5.0% ± 0.2% <60 ppm <100 ppm > 7 <60 ppm <100 ppm >...

  • Page 61: Reassembly

    CHAPTER 4 INITIAL START-UP Combustion Calibration Instructions 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. Reassembly Set the Controller’s Enable/Disable switch to the Disable position. Disconnect AC power from the unit.

  • Page 62: Setting The Outlet Water Temperature Setpoint

    CHAPTER 4 INITIAL START-UP • Main Menu → Advanced Setup → Performance → The Outlet Feedback option (in Temperature Control → FFWD Settings) is typically turned on in normal operation, but it must be disabled while performing Min Load Adj (Section 4.5.2). •...

  • Page 63: Minimum Load Adjustment

    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 Main Menu → Advanced Setup → Performance → Temperature Control → Go to: FFWD Settings.

  • Page 64: Maximum Load Adjustment

    CHAPTER 4 INITIAL START-UP 4.5.3 Maximum Load Adjustment Check the temperature control at maximum load as follows: Maximum Load Adjustment Main Menu → Advanced Setup → Performance → Temperature Control → Go to: FFWD Settings (see Figure 4.5.2, above). Set the Outlet Feedback parameter to Yes. While monitoring the Valve Position bar-graph, create a maximum load on the system that will yield a steady valve position between 80% and 90%.
  • Page 65 CHAPTER 4 INITIAL START-UP MANUAL RESET AUTOMATIC RESET OVER-TEMPERATURE OVER-TEMPERATURE LIMIT SWITCH LIMIT SWITCH (NON-ADJUSTABLE) (ADJUSTABLE) Figure 4.6: Over-Temperature Limit Switch Location • • •...

  • Page 66: Chapter 5. Safety Device Testing

    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. The following tests check to ensure that the system is operating as designed.

  • Page 67: High Gas Pressure Fault Test

    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) MANUAL SHUTOFF VALVE TO AIR/FUEL VALVE Figure 5.2: Low &...

  • Page 68: Low Water Level Fault Test

    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. Slowly open the drain valve on the rear of the unit.

  • Page 69: Interlock Tests

    CHAPTER 5 SAFETY DEVICE TESTING MANUAL RESET AUTOMATIC RESET OVER-TEMPERATURE OVER-TEMPERATURE LIMIT SWITCH LIMIT SWITCH (NON-ADJUSTABLE) (ADJUSTABLE) Figure 5.5: Over-Temperature Limit Switch Setting 5.6 Interlock Tests The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2.12-2) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.

  • Page 70: Flame Fault Tests

    CHAPTER 5 SAFETY DEVICE TESTING Delayed Interlock Instructions Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals (see Figure 2.12-2). Main Menu → Diagnostics → Manual Run Put the unit in Manual Mode by going to the and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.

  • Page 71: Air Flow Fault Tests

    CHAPTER 5 SAFETY DEVICE TESTING Flame Fault Tests Instructions GAS INLET LOW GAS PRESSURE SWITCH SSOV HIGH GAS PRESSURE SWITCH MANUAL SHUTOFF VALVE TO AIR/FUEL VALVE Figure 5.7: Manual Gas Shut-Off Valve Location (INN600N-800N Gas Train Shown) 5.8 Air Flow Fault Tests These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5.8-2.
  • Page 72 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 73: Ssov Proof Of Closure Switch

    CHAPTER 5 SAFETY DEVICE TESTING Air Flow Fault Tests Instructions PARTIAL FRONT VIEW Figure 5.8-2: Blower Proof & Blocked Inlet Switch Locations AIR INLET COLD WATER INLET DRAIN VALVE EXHAUST MANIFOLD PARTIAL REAR VIEW Figure 5.8-3: Water Heater Rear View Showing Air Inlet Location 5.9 Ssov Proof Of Closure Switch The SSOV shown in Figure 5.9 contains the Proof Of Closure switch.

  • Page 74: Purge Switch Open During Purge

    CHAPTER 5 SAFETY DEVICE TESTING SSOV Proof of Closure Switch Instructions SSOV ACTUATOR COVER ACTUATOR COVER SCREW Figure 5.9: SSOV Actuator Cover Location 5.10 Purge Switch Open During Purge The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Purge Switch Open During Purge Instructions Set the Controller’s Enable/Disable switch to the Disable position.

  • Page 75: Safety Pressure Relief Valve Test

    CHAPTER 5 SAFETY DEVICE TESTING Ignition Switch Open During Ignition Instructions The unit should begin its start sequence and then shut down and display Ign Switch Open During Ignition. Replace the wire on the Ignition switch and press the CLEAR button. The unit should restart.

  • Page 76: Chapter 6. Maintenance

    CHAPTER 6 MAINTENANCE CHAPTER 6. MAINTENANCE 6.1 Maintenance Schedule The Innovation Water Heater requires regular maintenance to ensure continued reliable operation throughout the service life of the unit. For optimum operation, AERCO requires the following routine maintenance procedures be performed in the time periods specified in Table 6-1. Appendix I contains a list of the recommended spare parts for maintenance.

  • Page 77: Igniter-Injector

    CHAPTER 6 MAINTENANCE TABLE 6-2: Water Quality Guideline Total Dissolved Solids: 500 ppm Hardness (CaCO See Table 6-8, Section 6.8.1 Chlorides: 250 ppm Free Chlorine 0.5 ppm Total dissolved solids are a measure of overall risk of water corrosivity/hardness/salinity/color. The EPA recommends keeping a level below 500 ppm. For calcium hardness limits, see Table 6-8 in Section 6.8.1, below.
  • Page 78 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 & Flame Detector Igniter-Injector Inspection/Replacement Instructions Set the Controller’s Enable/Disable switch to the Disable position, then disconnect AC power from the unit.
  • Page 79 CHAPTER 6 MAINTENANCE Igniter-Injector Inspection/Replacement Instructions FLAME DETECTOR FLAME OBSERVATION PORT GAS INJECTOR TUBE 60̊ POSITION THE GAS INJECTOR TUBE WITHIN THIS 60̊ ARC VIEWED FROM BELOW, LOOKING UP Figure 6.3-2: Igniter-Injector & Flame Detector Mounting Details Torque the ignitor-injector to 15 ft-lbs. Do Not Over Tighten Connect the ignition assembly to the gas injector tube of the igniter-injector by securing the compression nut to the elbow of the ignition assembly.

  • Page 80: Flame Detector

    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 81: Fireside Inspection

    CHAPTER 6 MAINTENANCE 6.7 Fireside Inspection NOTE: In addition to the inspection described below after the unit has shut down, the burned flame should be visually inspected periodically while the unit is in operation to ensure that it is operating normally and the there is no change to its appearance from pervious inspections. Fireside inspection of the Innovation Water Heater includes removing the exhaust manifold, intake manifold, and the burner assembly from the unit.
  • Page 82 CHAPTER 6 MAINTENANCE Fireside Inspection Instructions Loosen and remove the igniter-injector from the intake manifold flange. Retain the clocking washers (if present), for later reassembly. Refer to Figure 6.7-1. Loosen and remove the four (4) 1/4-20 cap screws securing the blower side of the intake manifold (P/N 44106).
  • Page 83 CHAPTER 6 MAINTENANCE Fireside Inspection Instructions Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as necessary. This completes the fireside inspection of the unit. Proceed to step 18 to reassemble the unit. EXHAUST MANIFOLD TO COMBUSTION CHAMBER GASKET (P/N 122537)
  • Page 84 CHAPTER 6 MAINTENANCE Fireside Inspection Instructions BURNER ASSEMBLY EXHAUST MANIFOLD BURNER MOUNTING PLATE 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 I M P O R T A N T ! During reassembly, apply high-temperature, anti-seize lubricant to the threads of the igniter- injector and grounding screw.

  • Page 85: 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 86: Waterside Port Inspection

    CHAPTER 6 MAINTENANCE 6.8.2 Waterside Port 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 Port Inspection Instructions Disconnect the electrical power to the unit.

  • Page 87: Waterside Heat Exchanger Cleaning

    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 88 CHAPTER 6 MAINTENANCE 6.8.3.2 Cleaning Procedure Cleaning Procedure Instructions Prepare a cleaning solution of Rydlyme Chemical Descaler and clean water according to manufacturer’s instructions. The amount of the solution should be approximately equal to the full volume of water that the heat exchanger holds. Slowly add the prescribe amount of the cleaning solution to the circulating bucket.

  • Page 89: Condensate Drain Trap

    CHAPTER 6 MAINTENANCE the solution has been expended, more cleaning solution will be required to complete the job. If the solution is still active at the end of the time, all the scale has been dissolved. pH Trend Charting The initial pH of the cleaning solution will measure between 1-3 (See pH sheet on Rydlyme Chemical Descaler packaging).

  • Page 90: Low Water Cutoff (Lwco) Capacitor Integrity Test

    CHAPTER 6 MAINTENANCE To inspect/replace the air filter, proceed as follows: Air Filter Replacement Instructions Set the Controller’s Enable/Disable switch to the Disable position. Disconnect AC power from the unit Remove the side panels from the unit. Refer to Figure 6.10 and locate the air filter attached to the air/fuel valve inlet. Using a flat-tip screwdriver or 5/16 nut driver, loosen the clamp securing the filter to the inlet flange of the air/fuel valve.

  • Page 91: Low Water Cutoff (Lwco) - Capacitor Electrical Short Test

    CHAPTER 6 MAINTENANCE LWCO Probe Plastic Acorn Nut Capacitor Assembly (Covered by Large Shrink Tubing) Connector (To Shell Harness) PARTIAL LEFT SIDE VIEW LWCO Probe Terminal Figure 6.11: LWCO Probe Location (INN 1350 Shown) 6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger.

  • Page 92: Low Water Cutoff (Lwco) - Standard Test

    CHAPTER 6 MAINTENANCE LWCO Capacitor Electrical Short Test Instructions 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. 4. Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed from the Edge Controller) as shown on right in Figure 6.11.1-2.

  • Page 93: Returning To Service After Prolonged Shutdown

    CHAPTER 6 MAINTENANCE Extended Period Shut-Down Instructions Set the Controller’s Enable/Disable switch to the Disable position to shut down the unit’s operating controls. Disconnect AC power from the unit. Close the water inlet and outlet valves to isolate unit. Close external gas supply valve. Open relief valve to vent water pressure.

  • Page 94: Chapter 7. Troubleshooting Guide

    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. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
  • Page 95 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blower stopped running due to Check combustion blower for signs of excessive heat or high current drain thermal or current overload. that may trip thermal or current overload devices. Blocked Blower Inlet or inlet Inspect the inlet to the combustion blower including any ductwork leading up ductwork.
  • Page 96 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Blocked Air Flow switch. Remove the air flow switch and inspect for signs of blockage, clean or replace as necessary. Blocked blower inlet or inlet Inspect the inlet to the combustion blower including any ductwork leading up ductwork.
  • Page 97 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION No spark from Spark Plug. Close the internal gas valve in the unit. Install and arc a spark igniter-injector outside the unit. Defective Ignition Transformer If there is no spark, check for 120 VAC at the primary side to the ignition transformer during the ignition cycle.
  • Page 98 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Defective SSOV Actuator. If gas supply pressure downstream of SSOV Actuator cannot be lowered to below 3.0” W.C. (747 Pa) using the gas pressure adjustment screw, see Section 4.3, Step 14, the SSOV Actuator may be defective.
  • Page 99 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 IGN SWITCH CLOSED switch.
  • Page 100 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Defective Low Gas Pressure Measure gas pressure at the Low Gas Pressure switch. If it is greater than 2.6” switch. W.C. (647 Pa), measure continuity across the switch and replace if necessary. Insufficient water level in system.
  • Page 101 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Defective IGST Board. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. Loose or broken wiring. Inspect Outdoor Temperature sensor for loose or broken wiring.
  • Page 102 CHAPTER 7 – TROUBLESHOOTING GUIDE TABLE 7-1. WATER HEATER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Floating Neutral. The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two. This measurement should be near zero or no more than a few millivolts.

  • Page 103: Additional Faults Without Specific Fault Messages

    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 Fluctuating Gas Pressure...
  • Page 104 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 FLAME DETECTOR OPEN/CLOSED (Kit P/N 24356-2) INDICATOR ACTUATOR...

  • Page 105: Chapter 8. Water Heater Management

    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 106: Whm Principles Of Operation

    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” / “Client” scenario where only one device, the Manager, can initiate a communication sequence.

  • Page 107: Temperature Sensor Calibration

    CHAPTER 8 – WATER HEATER MANAGEMENT 8.3.4 Temperature Sensor Calibration The Temperature Sensors screens allows you calibrate the unit’s temperature sensors to achieve optimal performance. Complete the following to calibrate the temperature sensors. Figure 8.3.4: Temperature Sensors Screen Temperature Sensor Calibration Instructions Main Menu →...

  • Page 108: High Temperature Governor

    CHAPTER 8 – WATER HEATER MANAGEMENT Only AERCO personnel are permitted to change this menu item. To increase the Run Hours or Main Menu → Advanced Setup → Unit → Unit Run Cycles, go to Settings. 8.3.8 High Temperature Governor The High Temperature Governor is a feature that aggressively prevents the outlet temperature from exceeding the “Temperature High Limit”.

  • Page 109: Whm Status Displays

    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 110: Whm Parameters

    CHAPTER 8 – WATER HEATER MANAGEMENT 8.6 WHM Parameters Main Menu → Advanced Setup → The WHM parameters are all in the various screens under Cascade. However, these parameters can only be viewed if the Unit Type option in the Main Menu →...
  • Page 111 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 – The minimum address in the WHM cascade Max Address WHM Manager only –...
  • Page 112 CHAPTER 8 – WATER HEATER MANAGEMENT TABLE 8-6b: WHM Cascade → Cascade Communication Parameters 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 113 CHAPTER 8 – WATER HEATER MANAGEMENT Figure 8.6-3: Application Configuration Screen Main Menu → Advanced Setup → WHM Cascade → The remaining WHM parameters are in Operating Controls. TABLE 8-6d: Operating Controls → Sequencing Control Parameters Available Choices or Limits Menu Item Display Default Minimum...
  • Page 114 CHAPTER 8 – WATER HEATER MANAGEMENT TABLE 8-6e: Operating Controls → Anti-Cycling Parameters Available Choices or Limits Menu Item Display Default Minimum Maximum On Delay The minimum length of time a unit must stay off after shutting down or going into standby. WHM Off Delay 30 sec.
  • Page 115 CHAPTER 8 – WATER HEATER MANAGEMENT Figure 8.6-6: Operating Controls: Valve Configuration Screen 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 Run Hours Select Lead/Lag Specify how the Lead and Lag units will be selected.

  • Page 116: Whm Hardware Installation & Set-Up Instructions

    CHAPTER 8 – WATER HEATER MANAGEMENT 8.7 WHM Hardware Installation & Set-Up Instructions The following sections provide the basic installation and set-up instructions for implementing a Water Heater Management System (WHM) to control up to 16 AERCO Innovation Water Heaters. Some of the descriptions and procedures included in Chapter 2 are repeated here to avoid unnecessary referencing.

  • Page 117: Whm Modbus Network Wiring

    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 8.7.2: 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 118: Control And Power Wiring

    CHAPTER 8 – WATER HEATER MANAGEMENT Modbus network wiring connections must be made using shielded twisted-pair wiring, (18 – 24 AWG) such as Belden #9841, #3105A, #8760, or equivalent. The Modbus wiring connections are made at the RS485 COMM terminals on the I/O board included with each Edge Controller.
  • Page 119 CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-878 rev F Figure 8.7.4-1: WHM Network Wiring Diagram • • •...
  • Page 120 CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-659 rev C Figure 8.7.4-2: WHM Network Wiring Diagram • • •...
  • Page 121 CHAPTER 8 – WATER HEATER MANAGEMENT Reference SD-A-927 rev C Figure 8.7.4-3: WHM Network Wiring Diagram • • •...

  • Page 122: Whm Programming & Start-Up

    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. AERCO recommends that the WHM Manager be set up first.
  • Page 123 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. Main Menu → Advanced Setup → WHM Cascade → Operating Controls → 5. Go to: Sequencing Control.

  • Page 124: Troubleshooting

    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 Manager LEDs are Two Edge Controllers Check the WHM Mode entries in flashing on 2 have their WHM Mode the units which have their displays...

  • Page 125: Sequencing Valve Description & Operation

    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. 8.10.1 Sequencing Valve Description The Actuator-Controlled Sequencing Valve shown in Figure 8.10.1-1 is comprised of the following main components:...

  • Page 126: Sequencing Valve Operating Characteristics

    CHAPTER 8 – WATER HEATER MANAGEMENT CLUTCH (See Note 2) AUTO-STROKE (RESET) BUTTON DIP SWITCHES (4) DO NOT PRESS 1–OFF (DOWN) (See Note 1) 2–OFF (DOWN) 3–OFF (DOWN) 4–ON (UP) NOTES: 1. DO NOT press Auto-Stroke (Reset) button. Doing so may alter actuator calibration. 2.
  • Page 127 CHAPTER 8 – WATER HEATER MANAGEMENT 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. During normal Water Heater Management (WHM), a control signal of less than (<) – 2 VDC will rotate the valve to the fully open (90°) position.

  • Page 129: Appendix A - Startup, Status And Fault Messages

    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 130: Appendix B - Temperature Sensor Resistance/Voltage Chart

    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 2.02 -17.2 854.8 2.05 -12.2 874.6 2.07 -6.7...

  • Page 131: Appendix D - Dimensional Drawings

    APPENDIX D – DIMENSIONAL DRAWINGS APPENDIX D – Dimensional Drawings Drawing Number: AP-A-1053 rev A • • •...
  • Page 132 APPENDIX D – DIMENSIONAL DRAWINGS Drawing Number: AP-A-1054 rev A • • •...

  • Page 133: Appendix E - Parts List Drawings

    APPENDIX E – PARTS LIST DRAWINGS APPENDIX E – Parts List Drawings * NOTE: The Temperature Sensors (Item 4, 123449) are direct immersion type sensors. Before removing, close water vales, relieve pressure and drain water below sensor level. Innovation Parts List – 28735-TAB rev D – Page 1 Item Qty.
  • Page 134 APPENDIX E – PARTS LIST DRAWINGS Innovation Parts List – 28735-TAB rev D – Page 2 Item Qty. Part # Description Item Qty. Part # Description 65175 THERMOSTAT, JUMO 22332 GAS TRAIN, 3/4” SSOV, INN 600N/800N FM 122843 LOW WATER, CUTOFF 22353 GAS TRAIN, 1”...
  • Page 135 APPENDIX E – PARTS LIST DRAWINGS INTAKE MANIFOLD – BURNER – EXHAUST MANIFOLD CROSS-SECTION VIEW Innovation Parts List – 28735-TAB rev D – Page 3 Item Qty. Part # Description Item Qty. Part # Description 44106 INTAKE MANIFOLD GP-18899 BURNER FLANGE GASKET 44085-3 EXHAUST MANIFOLD 122537...
  • Page 136 APPENDIX E – PARTS LIST DRAWINGS Innovation Parts List – 28735-TAB rev D – Page 4 Item Qty. Part # Description Item Qty. Part # Description 37185 FRONT DOOR ASSY. w/ LATCHES 37098 TOP PANEL 37094 FRONT PANEL ASSEMBLY 59133 LATCH, COMPRESSION •...
  • Page 137 APPENDIX E – PARTS LIST DRAWINGS Innovation Parts List – 28735-TAB rev D – Page 5 Item Qty. Part # Description Item Qty. Part # Description 37097 LEFT-REAR PANEL 37184 SIDE DOOR ASSY. 1a * 80111 LEFT-REAR PANEL, INSULATION 80115 SIDE DOOR ASSY., LOWER INSULATION 37102 ACCESS PANEL, RIGHT-REAR...
  • Page 138 APPENDIX E – PARTS LIST DRAWINGS * Older version I/O Boxes (P/N 69151) are compatible with Innovation units with Edge [i] Controller and the current I/O Box (P/N 69245). Innovation Parts List – 28735-TAB rev D – Page 6 Item Qty.
  • Page 139 APPENDIX E – PARTS LIST DRAWINGS Innovation 600N, 800N 3/4” NATURAL GAS Gas Train – P/N 22332 rev E, 3/20/2021 Item Qty Part # Description Item Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE (CLOSED) 92006-4 VALVE: FULL PORT BAL 3/4"...
  • Page 140 APPENDIX E – PARTS LIST DRAWINGS Innovation 1060N NATURAL GAS Gas Train – P/N 22353 rev E, 3/15/2021 Item Qty Part # Description Item Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE (CLOSED) 92006-5 VALVE: BALL 1"...
  • Page 141 APPENDIX E – PARTS LIST DRAWINGS Innovation 1350N NATURAL GAS Gas Train – P/N 22363 rev E, 3/15/2021 Item Qty Part # Description Item Qty Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE (CLOSED) 92006-6 VALVE: BALL BRASS 1-1/4"...
  • Page 142 APPENDIX E – PARTS LIST DRAWINGS Innovation 600N P, 800N P, PROPANE Gas Train – P/N 22387 rev B, 3/16/2021 Item Qty Part # Description Item Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE 92006-3 VALVE: BALL 1/2"...
  • Page 143 APPENDIX E – PARTS LIST DRAWINGS Innovation 1060N P, 1060N B BAH, 1350N P PROPANE Gas Train – P/N 22386 rev C, 3/16/2021 Item Qty Part # Description Item Part # Description 95026 1.25" NPT 125#: THREADED FLANGE 92077 1/4" NPT MXF BRASS BALL VALVE 92006-4 VALVE: BALL 3/4"...
  • Page 144 APPENDIX E – PARTS LIST DRAWINGS Innovation 600N, 800N, 1060N, 1060N B BAH, 1350N, 1400NK Air Fuel Delivery System – P/N 24648 rev D, 2/4/2020 Item Qty Part # Description Item Part # Description 43101 BLOWER INTAKE MANIFOLD 124149-1 WIRE ASSY, JUMPER O.T. SWITCHES FILTER, AIR 6”, INN 1060N, 1350N, 1400NK 81160 GASKET, 8.9”...
  • Page 145 APPENDIX E – PARTS LIST DRAWINGS Intake Manifold Assembly P/N 24234 rev E Innovation Burner Assembly P/N 24233-2 rev H Item Qty Part # Description Item Qty Part # Description 44106 INTAKE MANIFOLD 44179 BURNER PLATE 59104 OBSERVATION PORT 46062 BURNER ASSEMBLY 3 ...
  • Page 146 APPENDIX E – PARTS LIST DRAWINGS (This Page Is Intentionally Blank) • • •...

  • Page 147: Appendix F - Piping Drawings

    APPENDIX F – PIPING DRAWINGS APPENDIX F – Piping Drawings Drawing Number: SD-A-829 rev C • • •...
  • Page 148 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-830 rev C • • •...
  • Page 149 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-831 rev C • • •...
  • Page 150 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-845 rev C • • •...
  • Page 151 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-848 rev D • • •...
  • Page 152 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-851 rev D • • •...
  • Page 153 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-852 rev D • • •...
  • Page 154 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-854 rev G • • •...
  • Page 155 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-856 rev D • • •...
  • Page 156 APPENDIX F – PIPING DRAWINGS Drawing Number: SD-A-939 rev B • • •...

  • Page 157: Appendix G - Edge [I] Controller Views

    APPENDIX G – EDGE [i] CONTROLLER VIEWS APPENDIX G – Edge [i] Controller Views Figure G-1 – Edge Controller (P/N 64134) - Exploded View • • •...
  • Page 158 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. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) Figure G-2: Edge [i] Controller Rear View...

  • Page 159: Appendix H - Wiring Diagrams

    APPENDIX H – – Wiring Diagrams APPENDIX H – Wiring Diagrams Drawing Number: 68100 rev C Sheet 1 of 2 • • •...
  • Page 160 APPENDIX H – – Wiring Diagrams Drawing Number: 68100 rev C Sheet 2 of 2 • • •...

  • Page 161: Appendix I - Recommended Spares

    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. QUANTITY 120 VAC/Single-Phase Blower 58039...
  • Page 162 APPENDIX I – RECOMMENDED SPARES Edge [i] Controller 69344-5 TABLE I-4. Optional Spare Parts DESCRIPTION PART NO. QUANTITY Circulator Pump, for Dynamic Load Anticipator: 69197 One per site Stock one if site has Burner 24233-2 difficulty getting parts Air Inlet Temperature Sensor 61024 One per site Low Gas Pressure Switch, Natural Gas...
  • Page 163 © AERCO International, Inc., 2024 • • •...

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