Page 1
Innovation Water Heaters Installation, Operation & Maintenance Manual
Benchmark 3000
USER MANUAL
INNOVATION Series
Natural Gas or Propane
Modulating, Condensing
Water Heater Models
Applicable to Serial Numbers:
G-13-1854 and above
Other documents for this product
include:
• GF-5030 INN Gas Supply Guide
• GF-5050 INN Venting Guide
• GF-5060 INN El ect. Power Guide
• GF-5080 INN Sizing Guide
Latest Update: 11/22/2013
Installation, Opera ti on and Maintenance
Gas-Fired Water Heaters
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
Disclaimer
The information containe d in this manual is subject to c hange without notice from AERCO Inter national,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantabilit y and fitness for a par ticular application. AERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
FOREWORD ............................................................................................................................................. 7
CHAPTER 1. SAFETY PRECAUTIONS ......................................................................................... 13
1.1 WARNINGS & CAUTIONS ..................................................................................................13
1.2 EMERGENCY SHUTDOWN ...............................................................................................14
1.3 PROLONGED SHUTDOWN ...............................................................................................15
CHAPTER 2. INSTALLATION ........................................................................................................ 17
2.1 INTRODUCTION.................................................................................................................17
2.2 RECEIVING THE UNIT .......................................................................................................17
2.3 UNPACKING .......................................................................................................................17
2.4 SITE PREPARATION .........................................................................................................18
2.4.1 Installation Clearances ................................................................................................................... 18
2.4.2 Setting the Unit .............................................................................................................................. 19
2.5 WATER INLET AND OUTLET PIPING ................................................................................20
2.5.1 WHM Actuator-Controlled Ball Valve Installation.......................................................................... 20
2.6 TEST HOSE BIB CONNECTION ........................................................................................21
2.7 SYSTEM RECIRCULATION LOOP.....................................................................................22
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION .....................................24
2.9 CONDENSATE DRAIN & PIPING .......................................................................................24
2.10 GAS SUPPLY PIPING ......................................................................................................26
2.10.1 Gas Supply Specifications. ............................................................................................................ 26
2.10.2 Manual Gas Shutoff Valve ............................................................................................................ 26
2.10.3 External Gas Supply Regulator ..................................................................................................... 27
2.11 AC ELECTRICAL POWER WIRING ..................................................................................28
2.11.1 Electrical Power Requirements .................................................................................................... 28
2.12 FIELD CONTROL WIRING ...............................................................................................29
2.12.1 OUTDOOR AIR IN Terminal ........................................................................................................... 30
2.12.2 COMBUSTION AIR Terminals ........................................................................................................ 30
2.12.3 O2 SENSOR Terminals .................................................................................................................. 31
2.12.4 SPARK SIGNAL Terminals .............................................................................................................. 31
2.12.5 ANALOG IN Terminals................................................................................................................... 31
2.12.6 B.M.S. (PWM) IN Terminals .......................................................................................................... 31
2.12.7 SHIELD Terminals .......................................................................................................................... 31
2.12.8 ANALOG OUT Terminals ............................................................................................................... 31
2.12.9 RS485 Comm Terminals ............................................................................................................... 32
2.12.10 RS232 Comm Terminals ............................................................................................................. 32
2.12.11 VFD/BLOWER Terminals ............................................................................................................. 32
2.12.12 Interlock Terminals ..................................................................................................................... 32
2.12.13 FAULT RELAY Terminals .............................................................................................................. 33
2.12.14 AUX RELAY Terminals ................................................................................................................. 33
2.13 FLUE GAS VENT INSTALLATION ....................................................................................33
2.14 COMBUSTION AIR ...........................................................................................................34
2.14.1 Combustion From Outside the Building ....................................................................................... 34
2.14.2 Combustion Air from Inside the Building ..................................................................................... 34
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Innovation Water Heaters Installation, Operation & Maintenance Manual
2.15 DUCTED COMBUSTION ..................................................................................................34
CHAPTER 3. OPERATION .............................................................................................................. 35
3.1 INTRODUCTION.................................................................................................................35
3.2 CONTROL PANEL DESCRIPTION .....................................................................................35
3.3 CONTROL PANEL MENUS ................................................................................................39
3.3.1 Menu Processing Procedure .......................................................................................................... 39
3.4 OPERATING MENU ...........................................................................................................41
3.5 SETUP MENU ....................................................................................................................41
3.6 CONFIGU R ATION MENU ...................................................................................................42
3.7 WATER HEATER MANAGEMENT (WHM) MENU ..............................................................43
3.8 TUNING MENU ...................................................................................................................44
3.9 START SEQUENCE ...........................................................................................................45
3.10 START/STOP LEVELS .....................................................................................................48
CHAPTER 4. INITIAL START-UP .................................................................................................. 49
4.1 INITIAL START-UP REQUIREMENTS ................................................................................49
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION...........................49
4.2.1 Required Tools & Instrumentation ................................................................................................. 49
4.2.2 Installing Gas Supply Manometer .................................................................................................. 50
4.2.3 Accessing the Analyzer Probe Port ................................................................................................. 50
4.2.4 Connecting Multimeter to Flame Detector .................................................................................... 51
4.3 NATURAL GAS COMBUSTION CALI BRAT IO N .................................................................52
4.4 PROPANE COMBUSTION CALIBRATION .........................................................................55
4.5 REASSEMBLY ....................................................................................................................57
4.6 TEMPERATURE CONTROL CALI BRAT ION ......................................................................57
4.6.1 Setting the Outlet Water Temperature Setpoint ........................................................................... 58
4.6.2 Minimum Load Adjustment ............................................................................................................ 58
4.6.3 Maximum Load Adjustment ........................................................................................................... 59
4.7 OVER-TEMPERATURE LIMIT SWITCHes .........................................................................60
CHAPTER 5. MODE OF OPERATION ........................................................................................... 61
5.1 INTRODUCTION.................................................................................................................61
5.2 LOW GAS PRESSURE FAULT TEST .................................................................................61
5.3 HIGH GAS PRESSURE FAULT TEST ................................................................................62
5.4 LOW WATER LEVEL FAULT TEST ....................................................................................63
5.5 WATER TEMPERATURE FAULT TEST .............................................................................63
5.6 INTERLOCK TESTS ...........................................................................................................64
5.6.1 Remote Interlock ............................................................................................................................ 64
5.6.2 Delayed Interlock ........................................................................................................................... 65
5.7 FLAME FAULT TESTs ........................................................................................................65
5.8 AIR FLOW FAULT TESTS ..................................................................................................66
5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................68
5.10 PURGE SWITCH OPEN DURING PURG E .......................................................................69
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................69
5.12 SAFETY PRESSURE RELIEF VALVE TEST ....................................................................70
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 6. MAINTENANCE ......................................................................................................... 71
6.1 MAINTENANCE SCHEDULE ..............................................................................................71
6.2 IGNITER 72
6.3 FLAME DETECTOR ...........................................................................................................74
6.4 COMBUSTION CALIBRATION ...........................................................................................74
6.5 SAFETY DEVICE TESTING ...............................................................................................74
6.6 FIRESIDE INSPECTION .....................................................................................................74
6.7 WATERSIDE INSPECTION ................................................................................................79
6.8 HEAT EXCHANGER CLEANING ........................................................................................80
6.8.1 Pumping System Set-Up Instructions ............................................................................................. 80
6.8.2 Cleaning Procedure ........................................................................................................................ 82
6.8.3 Testing HydroSkrub Effectiveness .................................................................................................. 82
6.9 CONDENSATE DRAIN TRAP .............................................................................................83
6.10 AIR FILTER REPLACEMENT ...........................................................................................84
6.11 SHUTTING THE WATER HEATER DOW N FOR AN EXTENDED PERIOD OF TIME ......85
6.12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ......86
CHAPTER 7. TROUBLESHOOTING GUIDE ................................................................................ 87
7.1 INTRODUCTION.................................................................................................................87
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ....................................99
CHAPTER 8. RS232 COMMUNICATION .................................................................................. 103
8.1 INTRODUCTION............................................................................................................... 103
8.1.1 Acquiring the PuTTY Application .................................................................................................. 103
8.1.2 Logging on to a Remote Machine Using PuTTY ............................................................................ 103
8.1.3 Running a Command on a Remote Machine Using PuTTY ........................................................... 104
8.2 RS232 COMMUNICATION SETUP................................................................................... 105
8.3 MENU PROCESSING UTILIZING RS23 2 COMMUNI CATION ......................................... 105
8.4 DATA LOGGING ............................................................................................................... 106
8.4.1 Fault Log ....................................................................................................................................... 106
8.4.2 Operation Time Log ...................................................................................................................... 107
8.4.3 Sensor Log .................................................................................................................................... 107
CHAPTER 9. WATER HEATER MANAGEMENT .................................................................... 109
9.1 INTRODUCTION............................................................................................................... 109
9.2 GENERAL DESCRIPTION ................................................................................................ 109
9.3 WHM Principles of Operation ............................................................................................ 110
9.4 WHM MENU ..................................................................................................................... 110
9.5 WHM hardware INSTALLATION & SET-UP INSTRUCTIONS .......................................... 111
9.5.1 Hardware Installation ................................................................................................................... 111
9.5.2 WHM Modbus Network Wiring .................................................................................................... 112
9.5.3 Control and Power Wiring ............................................................................................................ 113
9.6 WHM MENU SETTINGS ................................................................................................... 114
9.6.1 WHM Mode .................................................................................................................................. 114
9.6.2 Comm Address (Located in Setup Menu) ..................................................................................... 114
9.6.3 WHM Setpoint .............................................................................................................................. 114
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Innovation Water Heaters Installation, Operation & Maintenance Manual
9.6.4 WHM Nxt On VP ........................................................................................................................... 114
9.6.5 WHM Nxt Off VP ........................................................................................................................... 114
9.6.6 Lead/Lag Hours ............................................................................................................................. 114
9.6.7 Setback Setpoint ........................................................................................................................... 114
9.6.8 Setback Start & Setback End ........................................................................................................ 115
9.6.9 WHM Auto Mstr ........................................................................................................................... 115
9.6.10 WHM Auto Timer ....................................................................................................................... 115
9.7 WHM PROGRAMMING & START-UP .............................................................................. 115
9.8 TROUBLESHOOTING ...................................................................................................... 117
9.9 SEQUENCING VALVE DESCRIPTION & OPERATION ................................................... 118
9.9.1 Sequencing Valve Description ...................................................................................................... 118
9.9.2 Sequencing Valve Operating Characteristics ................................................................................ 120
APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS .................................................. 121
APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES ................................................. 127
APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART ...................... 131
APPENDIX D – INNOVATION DEFAULT SETTINGS ................................................................ 133
APPENDIX E – DIMENSIONAL DRAWINGS ................................................................................ 135
APPENDIX F – PARTS LIST DRAWINGS ..................................................................................... 137
APPENDIX G – PIPING DRAWINGS .............................................................................................. 153
APPENDIX H – C-MORE CONTROL PANEL VIEWS .................................................................. 177
APPENDIX I – C-MORE WIRING DIAGRAMS ............................................................................ 179
APPENDIX J – RECOMMENDED SPARES .................................................................................... 187
APPENDIX K – COMBUSTION CALIBRATION (KOREA ONLY) ............................................ 189
APPENDIX L – WARRANTY ........................................................................................................... 193
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Innovation Water Heaters Installation, Operation & Maintenance Manual
FORWARD
FOREWORD
The AERCO Innovation Series Potable Water Heaters are modulating units which represent a
true industry advance that meets the needs of today's energy efficiency and environmental
concerns. Designed for use in any domestic water heating system, each Innovation model
provides precisely-controlled potable water within ±2°F of setpoint, regardless of flow rate.
Innovation’s compact size and varied venting capabilities allow maximum installation flexibility.
The Innovation Series Heaters, with their load tracking controls modulate over a 20:1 turn down
ratio to match the system demand and yield high thermal efficiencies.
Innovation Water Heaters are available in four (4) different sizes ranging from 600,000 BTU/Hr.
Input to 1,350,000 BTU/Hr. Input. In addition, all Innovation Heater sizes now include Water
Heater Management (WHM) software which is built in to the C-More Controllers furnished with
each unit. When the heater is ordered with a Sequencing Valve (SV), up t o eight (8) Innovation
Water Heaters can be controlled by the WHM system utilizing RS485 Modbus protocol. All
available Innovation Water Heater models are listed in the table on the following page. As this
table shows, units can be ordered with Factory Mutual (FM) or Double Block and Bleed
(formerly IRI) Gas Trains with or without Sequencing Valves.
When installed and operated on natural gas in accordance with this Instruction Manual, the
Innovation Series Models covered herein comply with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
• Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117,
Rule 117.465
Whether used in singular or modular arrangements, the Innovation Heaters offer the maximum
flexibility in venting with minimum installation space requirements. Innovation’s advanced
electronic controls offer simplified integration with today’s Energy Management Systems.
For service or parts, contact your local sales representative or AERCO International, Inc.
IMPORTANT
Unless otherwise specified, the descriptions and procedures provided in
this Installation, Operation & Maintenance Manual apply to all Innovation
Series Water Heaters.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Shipping
Weight
INN600
INN600P
Innovation Potable Water Heater, 600,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train
1,060 lbs.
INN600SVP
Innovation Potable Water Heater, 600,000 BTU/HR
Sequencing Valve
1,080 lbs.
INN600PDBB
Innovation Potable Water Heater, 600,000 BTU/HR
(Formerly IRI) Gas Train
1,085 lbs.
INN600SVPDBB
Innovation Potable Water Heater, 600,000 BTU/HR
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,105 lbs.
INN800
INN800P
Innovation Potable Water Heater, 800,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train
1,080 lbs.
INN800SVP
Innovation Potable Water Heater, 800,000 BTU/HR
Sequencing Valve
1,100 lbs.
INN800PDBB
Innovation Potable Water Heater, 800,000 BTU/HR
(Formerly IRI) Gas Train
1,095 lbs.
INN800SVPDBB
Innovation Potable Water Heater, 800,000 BTU/HR
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,115 lbs.
INN1060
INN1060P
Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train
1,100 lbs.
INN1060SVP
Innovation Potable Water Heater, 1,060,000 BTU/HR
Sequencing Valve
1,120 lbs.
INN1060PDBB
Innovation Potable Water Heater, 1,060,000 BTU/HR
(Formerly IRI) Gas Train
1,115 lbs.
INN1060SVPDBB
Innovation Potable Water Heater, 1,060,000 BTU/HR
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,135 lbs.
INN1350
INN1350P
Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas or Propane, FM Gas Train
1,150 lbs.
INN1350SVP
Innovation Potable Water Heater, 1,350,000 BTU/HR
Sequencing Valve
1,170 lbs.
INN1350PDBB
Innovation Potable Water Heater, 1,350,000 BTU/HR
(Formerly IRI) Gas Train
1,165 lbs.
INN1350SVPDBB
Innovation Potable Water Heater, 1,350,000 BTU/HR
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,205 lbs.
FORWARD
INNOVATION POTABLE W ATER HEATER MODELS
Part Number Description
INN600SV
INN600DBB
INN600SVDBB
INN800SV
INN800DBB
INN800SVDBB
INN1060SV
Input, Natural Gas or Propane, FM Gas Train with WHM
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas, or Propane FM Gas Train with WHM
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas or Propane, FM Gas Train with WHM
INN1060DBB
INN1060SVDBB
INN1350SV
INN1350DBB
INN1350SVDBB
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Input, Natural Gas, or Propane Double Block & Bleed
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas or Propane, FM Gas Train with WHM
Input, Natural Gas or Propane, Double Block & Bleed
Input, Natural Gas or Propane, Double Block & Bleed
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
A (Amp)
Ampere
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes
second, unless each symbol is 1 bit long.
BLDG (Bldg)
Building
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound of water 1°F.
CCP
Combustion Control Panel
C-More Controller
(or Control Box)
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
DBB
Double Block & Bleed. Used to define gas trains containing two
SSOVs and a solenoid operated vent valve. Used interchangeably
with IRI.
DIP
Dual In-Line Package
EMS
Energy Management System; often used interchangeably with BAS
FM
Factory Mutual. Used to define boiler gas trains.
GND
Ground
HDR
Header
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN
Ignition
IGST Board
Ignition/Stepper Board contained in C-More
Box
INN
Innovation Water Heater
INTLK (INTL’K)
Interlock
I/O
Input/Output
FORWARD
Phrases, abbreviations and acronyms used in this manual are listed in the following Table:
PHRASES, ABBREVIATIO NS AND ACRONYMS
Meaning
BAS
(signaling events) transmitted per second. It is not equal to bits per
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Control
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP
Internet Protocol
IRI
Industrial Risk Insurers. Used to define gas trains containing two
SSOVs and a solenoid operated vent valve.
ISO
Isolated
LED
Light Emitting Diode
LN
Low NOx
MA (mA)
Milliampere (1 thousandth of an ampere)
MAX (Max)
Maximum
MIN (Min)
Minimum
A serial, half-duplex data transmission protocol developed by AEG
Modicon
NC (N.C.)
Normally Closed
NO (N.O.)
Normally Open
NOx
Nitrogen Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
PMC Board
A Primary Micro-Controller (PMC) board is contained in the C-More
Control Box used on all Benchmark units.
PPM
Parts Per Million
PTP
Point-to-Point (usually over RS232 networks)
REF (Ref)
Reference
RES.
Resistive
(or EIA-232)
the RS232 Standard
RS422
(or EIA-422)
A standard for serial, full-duplex (FDX) transmission of data based on
the RS422 Standard
RS485
(or EIA-485)
A standard for serial, half-duplex (HDX) transmission of data based on
the RS485 Standard
RTN (Rtn)
Return
SETPT (Setpt)
Setpoint Temperature
SHLD (Shld)
Shield
SSD
Slave to Slave programming
SSOV
Safety Shut Off Valve
SV
Sequencing Valve (Used with Water Heater Management (WHM)
system)
TEMP (Temp)
Temperature
FORWARD
PHRASES, ABBREVIATIO NS AND ACRONYMS - Continued
Meaning
Modbus®
RS232
A standard for serial, full-duplex (FDX) transmission of data based on
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network in
that may cause invalid data in the
communication
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, or Variable Frequency Drive
W
Watt
W.C.
Water Column
WHM
Water Heater Management
FORWARD
PHRASES, ABBREVIATIONS AND ACRON YMS - Continued
order to prevent reflections
µA Micro amp (1 millionth of an ampere)
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FORWARD
(This Page Is Intentionally Blank)
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Innovation Water Heaters Installation, Operation & Maintenance Manual
WARNING
WARNING
WARNING
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. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired heaters and ANSI/NFPASB for LP gas-fired heaters. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See pages 15 and 16 for information on installations within the Commonwealth of
Massachusetts.
IMPORTANT
This Instruction Manual is an integral part of the product and must be
maintained in legible condition. It must be given to the user by the installer
and kept in a safe place for future reference.
Read the following restrictions prior to installing the water heater:
1. The water heater can only be used for applications where the chlorine
concentrations Do Not Exceed 4 mg/L which is the Environmental
Protection Agency limit for chlorine concentrations in drinking water.
2. Do Not use this heater for a pool heating application.
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFO RE THE COVER ON THE UNIT ’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
IMPORTANT
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Innovation Water Heaters Installation, Operation & Maintenance Manual
WARNING
CHAPTER 1 – SAFETY PR EC AU TIONS
A DOUBLE-POLE SWITCH MUST BE INST ALLED O N T HE ELECTRICAL
SUPPLY LINE OF THE UNIT. T HE SWIT CH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO
UNIT SHEET METAL ENCLOSURES.
CAUTION
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
CAUTION
DO NOT use this heater if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
IMPORTANT
The Installer must identify and indicate the location of the emergency
shutdown manual gas valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
VALVE OPEN
VALVE CLOSED
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Figure 1-1. Manual Gas Shutoff Valve
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed to verify all systemoperating parameters. If there is an emergency, turn off the electrical power supply to the
AERCO heater and close the manual gas valve located upstream of the unit. The installer must
identify the emergency shut-off device.
IMPORTANT – 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.
• Prior to unit operation, the complete gas train and all connections must be
leak tested using a non-corrosive soap.
• The vent termination must be located a minimum of 4 feet above grade
level. If side-wall venting is used, the installation must conform to the
following requirem ent s extract ed from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
building or structure used in whole or in part for residential purposes, including those owned or
operated by the Commonwealth and where the side wall exhaust vent termination is less than
seven (7) feet above finished grade in the area of the venting, including but not limited to decks
and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DET ECTORS. At the time of installation of
the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building
or structure served by the side wall horizontal vented gas fueled equipment. It shall be the
responsibility of the property owner to secure the services of qualified licensed professionals
for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in
a crawl space or an attic, the hard wired carbon monoxide detector with alarm and
battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the
exterior of the building at a minimum height of eight ( 8) feet above grade directly in line with
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CHAPTER 1 – SAFETY PR EC AU TIONS
the exhaust vent terminal for the horizontally vented gas fueled heating appliance or
equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUC TIONS".
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas
fueled equipment shall not approve the installation unless, upon inspection, the inspector
observes carbon monoxide detectors and signage installed in accordance with the
provisions of 248 CMR 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
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.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM
PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas
equipment provides a venting system design or venting system components with the equipment,
the instructions provided by the manufacturer for installation of the equipment and the venting
system shall include:
1. Detailed instructions for the installation of the venting system design or the venting
system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT
PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas
fueled equipment does not provide the parts for venting the flue gases, but identifies "special
venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the
instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
______________________________________
[End of Extracted Information From 248 CMR 5.08 (2)]
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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 Heater Models INN600, INN800, INN1060 and INN1350.
2.2 RECEIVING THE UNIT
Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight
is approximately 1200 pounds. The unit must be moved with the proper rigging equipment for
safety and to avoid equipment damage. The unit should be completely inspected for evidence of
shipping damage and shipment completeness at the time of receipt fr om the carrier and before
the bill of lading is signed.
NOTE
AERCO is not responsible for lost or damaged freight. Each unit has a TipN-Tell indicator on the outside of the crate. This indicates if the unit has
been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap
• 1” Gas Supply Shutoff Valve
If the Innovation Water Heater is equipped for use with the AERCO Water Heater Management
(WHM) system, an actuator-controlled ball valve will also be included with the unit.
When optional accessories are ordered, they may be packed within the unit’s shipping
container, factory installed on the unit, or packed and shipped in a separate container. Any
standard or optional accessories shipped loose should be identified and stored in a safe place
until ready for installation or use.
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50.9"
18"
97.25"
75.25"
18.6"
SEQUENCING
VALVE
30"
24"
24"
24"
4" HIGH PAD
WARNING
CAUTION
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 120 VAC, Single-Phase, 60 Hz @ 20 Amps.
• Access to Natural Gas line at a minimum pressure of 4 inches W.C. or to Propane at a
minimum pressure of 7 inches W.C. with the unit operating at maximum capacity.
2.4.1 Installation Clearances
All Innovation Models are packaged in enclosures having identical exterior dimensions. The unit
must be installed with the prescribed clearances for service as shown in Figure 2-1 (shown with
optional Sequencing Valve). The minimum clearance dimensions, required by AERCO, are
listed below. However, if Local Building Codes require additional clearances, these codes shall
supersede AERCO’s requirements. Minimum acceptable clearances required are as follows:
Sides: 24 inches
Front : 24 inches
Rear: 30 inches
Top: 18 inches
All gas piping, water piping and electrical conduit or cable must be arranged so that t hey do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
Ensure that
condensate
assembly is
not located
housekeeping
NOTE
over the
pad.
Figure 2-1. Innovation Water Heater Clearances
KEEP THE UNIT AREA CLEAR AND FREE FR OM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
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LIFTING LUGS
CHAPTER 2 – INSTALLATION
FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 (Safety Precautions), pages 13 and 14.
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate
drainage. Two lifting lugs are provided with the unit and are wire-tied to the top of the heat
exchanger. The top sheet metal cover of the unit must first be removed and the lifting lugs must
be installed as shown in Figure 2-2. USE THESE TW O LUGS TO LIFT AND MOVE THE UNI T.
Remove the top panel from the unit to provide access to the lifting lugs. Remove the four (4) lag
screws securing the unit to the shipping skid. Lift the unit of f the shipping skid and position it on
the 4 inch to 6 inch housekeeping concrete pad (required) in the desired location.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
Figure 2-2. Partial Top View Showing Installed Lifting Lugs
IMPORTANT
If the Innovation Water Heater is equipped for use with the C-More W ater
Heater Management (WHM) system, then an actuator-controlled ball valve
will be included with the shipment. If the valve is not already installed on
the water inlet of the unit, refer to section 2.5.1 for installation instructions
prior to connecting inlet piping.
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P&T RELIEF
COLD WATER INLET
DRAIN VALVE
EXHAUST MANIFOLD
AIR INLET
NATURAL GAS INLET
HOT WATER OUTL E T
CHAPTER 2 – INSTALLATION
2.5 WATER INLET AND OUTLET PIPING
The locations of the 2" NPT cold water inlet and hot water outlet piping connections are shown
in Figure 2-3a. Flow rates through the unit are limited to 50 gpm continuous and 75 gpm
intermittent.
Shut-off valves and union connections must be installed in the inlet and outlet lines for
maintenance. The use of dielectric unions is recommended.
NOTE
All piping must be arranged so that it does not interfere with
removal of any covers, inhibit service or maintenance, or prevent
access between the unit and walls, or another unit
.
2” NPT
1” NPT
VALVE
2” NPT
Figure 2-3a. Water Inlet & Outlet Locations
2.5.1 WHM Actuator-Controlled Ball Valve Installation
If the Innovation Water Heater was ordered for use with the C-More Water Heater Management
(WHM) system and the actuator-controlled ball valve is not already installed on t he unit (Figure
2-3b), it will be packed separately within the shipping container. If installation is required,
proceed as follows:
1. Remove the ball valve from its stowed location within the shipping container.
2. Attached the valve to the cold water inlet of the unit using the pipe union and nipple
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WHM Ball Valve Installation
provided.
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HEATER DRAIN VALVE
2” NPT UNION
BALL VALVE
2” NPT NIPPLE
CHAPTER 2 – INSTALLATION
WHM Ball Valve Installation – Continued
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure
2-3A.
4. AERCO recommends that another pipe nipple and union be attached to the valve inlet
prior to connecting the cold water supply piping.
5. Tighten all pipe connections after the valve is properly positioned.
6. Connect the 3-pin Molex connector on the valve to the mating connector on the Innovation
harness at the rear of the unit.
7. This completes the actuator-controlled ball valve installation.
WITH ACTUATOR
Figure 2-3b. Innovation Water Heater Equipped With Sequencing Valve
2.6 TEST HOSE BIB CONNECTION
A Test Hose Bib connection, upstream of the shut off valve on the hot water outlet, is required
for startup and testing (Figure 2-4). The pipe diameter should be a minimum of 3/4". The Test
Hose Bib cannot be omitted.
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TO DRAIN
TEST
HOT
HOSE
CHAPTER 2 – INSTALLATION
CONNECTION
HOSE BIB
WATER
OUT
Figure 2-4. Test Hose Bib Location
2.7 SYSTEM RECIRCULATION LOOP
The System Recirculation Loop Assembly is located inside the unit enclosure at the rear of the
unit. In order to access this assembly, the right rear middle panel must be removed. Refer to
Figure 2-5. This assembly contains a recirculator pump which connects between the upper hot
water outlet and lower cold water inlet of the unit’s heat exchanger. The purpose of this loop is
to provide feed-forward (FFWD) temperature control by mixing a portion of the hot water outlet
with the cold water inlet of the unit. Temperature sensors located in the hot water outlet and cold
water inlet provide temperature data to the C-More Control System. The Control System utilizes
this data to modulate the fire rate (Air/Fuel Valve position) to precisely maintain the hot water
outlet temperature at the selected setpoint temperature.
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RECIRCULATION
HOT WATER OUTL E T
P&T VALVE
RECIRCULATION
COLD WATER INLET
DRAIN VALVE
CHAPTER 2 – INSTALLATION
LOOP PIPING
PUMP
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REAR VIEW WITH CENTER PANEL; REMOVED
Figure 2-5. Recirculation Loop
NOTE
The maximum working pressure for installations within the Province of
Alberta is 87 psig. Therefore, a pressure & temperat ure relief valve with a
setting of 75 psig/210°F is supplied with Alberta shipments.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
COLD WATER
DRAIN VALVE
AIR INLET
EXHAUST MANIFOLD
CONDENSATE DRAIN
CHAPTER 2 – INSTALLATION
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALL ATION
An ASME rated Pressure & Temperature (P&T) Relief Valve is supplied with each Innovation
Water Heater. With the exception of Alberta installations (see above Note), the valve setpoint is
150 psig/210°F. The P&T Relief Valve is installed on the hot water outlet at the top of the
Recirculation Loop Assembly as shown in Figure 2-5. A suitable pipe joint compound should be
used on the threaded connections. Any excess should be wiped off to avoid getting any into the
valve body. The relief valve should be piped to within 12 inches of the floor to pr event injury in
the event of a discharge. The relief outlet piping must be equal to the outlet size of the relief
valve without reduction. No valves, restrictions, or other blockages are allowed in the discharge
line. In multiple unit installations the discharge lines must not be manifolded together. Each
must be individually run to a suitable discharge location.
2.9 CONDENSATE DRAIN & PIPING
The Innovation Water Heater is designed to condense water vapor from the flue products.
Therefore, the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port is located on the exhaust m anif old at t he r ear of the unit (Figure 2-6).
This drain port must be connected to the Condensate Trap (part no. 24060) which is packed
separately within the unit’s shipping container. The Condensate Trap inlet and outlet
connections contain tapped 3/4” NPT ports.
INLET 2” NPT
CONNECTION (3/4” NPT)
PARTIAL REAR VIEW
Figure 2-6. Condensate Drain Connection Location
A sample Condensate Trap installation is shown in Figure 2-7. However, the actual installation
details for the trap will vary depending on the available clearances, housekeeping pad height/
dimensions and other prevailing conditions at the site. The following g eneral guidelines must be
observed to ensure proper condensate drainage:
• The condensate trap inlet (Figure 2-7) must be level with, or lower than the exhaust
• The base of the condensate trap must be supported to ensure that it is level (horizontal).
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manifold drain port.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Housekeeping pad should not extend
CHAPTER 2 – INSTALLATION
• The trap must be removable f or routine maintenance. AERCO recommends t hat a union
be utilized between the exhaust manifold condensate drain port and the trap inlet port.
While observing the above guidelines, install the condensate trap as follows:
Condensate Trap Installation
1. Connect the condensate trap inlet to the exhaust manifold drain connection using the
appropriate piping components (nipples, reducers, elbows, etc.) for the heater installation
site
2. At the condensate trap outlet, install a 3/4” NPT nipple.
3. Connect a length of 1” I.D. polypropylene hose to the trap outlet and secure with a hose
clamp.
4. Route the hose on the trap outlet to a nearby floor drain.
If a floor drain is not available, a condensate pump can be used to remove the condensate to
drain. The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated
fittings and drain line must be removable for routine maintenance.
NOTE
Two different styles of condensate traps are currently in use. The functions
and connections provided by each style are identical however the two
styles look slightly different. Figure 2-7 shows the two styles that are
currently in use.
under the condensate assembly
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Figure 2-7. Sample Condensate Trap Installation
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WARNING
CAUTION
CHAPTER 2 – INSTALLATION
2.10 GAS SUPPLY PIPING
The AERCO Innovation Gas Components and Supply Design Guide, GF-5030 must be
consulted prior to designing or installing any gas supply piping.
NEVER USE MATCHES, CANDLES, FLAMES O R OT HER SO URCES OF
IGNITION TO CHECK FOR GAS LEAKS
Many soaps used for gas pipe leak testing are corrosive to metals.
Therefore, piping must be rinsed thoroughly with clean water after leak
checks have been completed.
NOTE
All gas piping must be arranged so that it does not interfere with removal of any
covers, inhibit service/maintenance, or restrict access between the unit and
walls, or another unit.
.
Innovation units contain a 1 inch NPT gas inlet connection on t he rear of the unit as shown in
Figure 2-3.
Prior to installation, all pipes should be de-burred and internally cleared of any scale, metal
chips or other foreign particles. Do Not install any flexible connectors or unapproved gas
fittings. Piping must be supported from the floor, ceiling or walls only and must not be supported
by the unit.
A suitable piping compound, approved for use with natural gas, should be used. Any excess
must be wiped off to prevent clogging of components.
To avoid unit damage when pressure testing gas piping, isolate the unit from the gas supply
piping. At no time should the gas pressure applied to the unit exceed 14” W.C.. Leak test all
external piping thoroughly using a soap and water solution or suitable equivalent. The gas
piping used must meet all applicable codes.
2.10.1 Gas Supply Specifications.
The gas supply input specifications to the unit for Natural Gas are as follows:
• The maximum static pressure to the unit must not exceed 14” W.C.
• The gas supply pressure to the unit must be of sufficient capacity to provide 1060 cfh
while maintaining the gas pressure of 7“ W .C. for FM gas trains operating at ma xi mum
capacity.
2.10.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line upstream of the Heater as
shown in Figure 2-8. The maximum allowable gas pressure to the Heater is 14” W.C.
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CHAPTER 2 – INSTALLATION
2.10.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions
(see sections 2.10.3.1 and 2.10.3.2, below). Regulators must conform to the following
specifications:
• The external nat ural gas regulator must be capable of regulating 200,000 – 3,180,000
BTU/HR of natural g as while maintaining a gas pressure of 8.0” W .C. minimum to the
unit.
• A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C.
2.10.3.1
Massachusetts Installations Only
For Massachusetts installations, a mandatory external gas supply regulator must be
positioned as shown in Figure 2-8. The gas supply regulator must be properly vented to
outdoors. Consult the local gas utility for detailed requirements concerning venting of the
supply gas regulator.
2.10.3.2
All Installations (Except Massachusetts)
For all installations (other than Massachusetts) that EXCEED 7” W.C. gas pressure, a
mandatory external gas supply regulator must be positioned as shown in Figure 2-8. No
regulator is required for gas pressures below 7” W.C. of pressure. Consult the local gas utility
for detailed requirements concerning venting of the supply gas regulator.
Figure 2-8. Manual Gas Shut-Off Valve Location
NOTE
It is the responsibility of the customer to source and purchase the
appropriate gas regulator as described above. However, AERCO
offers for sale an appropriate regulator, which may be ordered at
the time of unit purchase or separately. Contact AERCO for more
information.
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CHAPTER 2 – INSTALLATION
2.11 AC ELECTRICAL POWER WIRING
The AERCO Innovation Electrical Power Wiring Guide, GF-5060, must be consulted prior to
connecting any AC power wiring to the unit. External AC power connections are made to the
unit inside the Power Box on the front of the unit. Remove the front door of the unit to access
the Power Box mounted directly above the Control Box. Loosen the four Power Box cover
screws and remove the cover to access the AC terminal connections inside the Power Box
(Figure 2-9).
NOTE
All electrical conduit and hardware must be installed so that it does not
interfere with the removal of any unit covers, inhibit service/maintenance,
or prevent access between the unit and walls or another unit.
POWER BOX WITH COVER POWER BOX WITH COVER REMOVED
Figure 2-9. Power Box Location – Partial Front View, Front Panel Removed
2.11.1 Electrical Power Requirements
The AERCO Innovation Heater accepts 120 VAC, single-phase, 60 Hz @ 20A. The Power Box
contains a terminal block as shown in Figure 2-10. In addition, a wiring diagram showing the
required AC power connections is provided on the front cover of the Power Box.
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE HEATER.
A double-pole switch must be installed on the electrical supply line in an easily accessible
location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet
metal enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external
electrical power source is used, the installed boiler must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction. In the absence of such
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CHAPTER 2 – INSTALLATION
requirements, the installation shall conform to National Electrical Code (NEC), ANSI/ NFPA 70
and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.
For electrical power wiring diagrams, see the AERCO Innovation Electrical Power Wiring Guide,
(GF-5060).
Figure 2-10. AC Terminal Block Configurations
2.12 FIELD CONTROL WIRING
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 C-More control system used with all
Innovation Heaters does allow for some control and monitoring features. W iring connections for
these features are made in the Input/Output (I/O) Box. The I/O Box is located on the upper-left
portion of the unit front panel (Figure 2-11) behind the removable front panel door. To access
the I/O Box terminal strips shown in Figure 2-11, loosen the four cover screws and remove the
cover. All field wiring is installed from the rear of the panel by routing t he wires through one of
the four bushings provided.
Refer to the wiring diagram provided on the cover of t he I/O Box (Figure 2-12) when making all
wiring connections.
Figure 2-11. Input/Output (I/O) Box Location – Partial Front View
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CAUTION
CHAPTER 2 – INSTALLATION
Since identical I/O Boxes are used with both AERCO gas-fired boilers and water heaters, some
of the input and output connections apply only to boilers while others are common to both
boilers and heaters. These I/O Box connections are noted in the sections below.
NOTE
Use Figure 2-12 to determine the functions of the I/O PCB connections. Do
not use the silkscreened labels on the PCB itself, as these may not match.
DO NOT make any connections to the I/O Box terminals labeled “NOT
USED”. Attempting to do so may cause equipment damage.
2.12.1 OUTDOOR AIR IN Terminal
The OUTDOOR AIR IN and AIR SENSOR COMMON terminals are not applicable to this unit.
2.12.2 COMBUSTION AIR Terminals
The COMBUSTION AIR and AIR SENSOR COMMON terminals are not applicable to this unit.
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Figure 2-12. I/O Box Terminal Strips
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CHAPTER 2 – INSTALLATION
2.12.3 O2 SENSOR Terminals
The O2 SENSOR (–) and O2 SENSOR (+) terminals are not currently used in this unit.
2.12.4 SPAR K SIGNAL Terminals
The SPARK SIGNAL terminals (+ & -) permit an external current sensor to be connected for
ignition spark monitoring purposes. If no spark is present during the ignition sequence, the
controller will shut down and display a fault message.
2.12.5 ANALOG IN Terminals
The ANALOG IN terminals (+ & -) are used when an external signal is used to change the
setpoint (Remote Setpoint Mode) of the heater.
Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the setpoint or air/fuel valve position. The factory default setting is for 4 to 20 mA / 1 to 5 VDC,
however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu
described in Chapter 3.
If volt age rather than current is selected as the drive signal, a DIP switch must be set on the
PMC Board located inside the C-More Control Box. Refer to Appendix D in C-More Manual GF112 for information on set ting DIP switche s.
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 Heater’s I/O Box.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to
240°F setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.12.6 B.M.S. (PWM) IN Terminals
The B.M.S. (PWM) IN Terminals are not applicable to Water Heaters.
2.12.7 SHIELD Terminals
The two SHIELD terminals are used to terminate any shields used on sensor wires connected to
the unit. Only shields must be connected to these terminals.
2.12.8 ANALOG OUT Terminals
The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor
Setpoint, Outlet Temperature, Valve Pos ition 4-20 mA, Valve Position 0-10v or be set to OFF.
Default sett ing in the C -More controller is Valve Position 0-10v and settings behave as follows:
1) When 0-10VDC is selected, the voltage output is used by the controller to modulat e the
combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.12.11).
2) If “On Board” boiler or Water Heater Management is enabled, the Analog Output
terminals are used to drive the isolation valve, open and closed.
3) When the 4-20mA is selected for the Analog Output, the 0-10VDC is disabled at the
VFD/Blower terminals, and the selected output is available at the terminals labeled
Analog Output +/-.
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CHAPTER 2 – INSTALLATION
2.12.9 RS485 Comm Terminals
The RS485 communication terminals (+, GND, & -) are used when the Innovation Water
Heaters are being controlled by an Energy Management System (EMS) or the C-Mo re Water
Heater Management (WHM) system using Modbus (RS485) communication. The WHM
software required to control up to 8 AERCO Innovation Water Heaters is included in the C -More
Control System used with each Innovation unit.
2.12.10 RS232 Comm Terminals
The RS232 communication terminals (TxD, RxD) are enabled by setting DIP switch 2 (DIP2) on
the I/O Board to RS232 ENABLE position. When enabled these RS232 terminals permit a
laptop computer or other suitable terminal to be connected to the unit. This RS232
communication feature permits viewing or changing of control panel menu opt ions. In addition, it
provides access to data logs showing: Event Time Line, Fault Log and Sensor Log displays.
2.12.11 VFD/BLOWER Terminals
These terminals (0-10 & AGND) send an analog signal to control the blower speed. When any
of the 4-20mA options is selected for the Analog Outputs (Section 2.12.8), the output from the
VFD/Blower terminals is disabled.
2.12.12 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. These interlocks are called
the Remote Interlock and Delayed Interlock (REMOTE INTL’K IN an d DELAYED INTL’K IN in
Figure 2-12). Both interlocks, described below, are factory wired in the closed position.
NOTE
Both the Remote Interlock and Delayed Interlock must be in the closed
position for the unit to fire.
2.12.12.1
The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if
desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped).
2.12.12.2
The delayed interlock is typically used in conjunction with the Auxiliary Relay Contacts
described in section 2.12.14. This interlock circuit is located in the purge section of the start
string. It can be connected to the proving device (end switch, flow switch etc. ) of an auxiliary
piece of equipment started by the unit’s auxiliary relay. The delayed interlock must be closed for
the heater to fire. If the delayed interlock is connected to a proving device that requires time to
close (make), a time delay (Aux Start On Dly) that holds the start sequence of the unit long
enough for a proving switch to make (close) can be programmed.
REMOTE INTL’K Terminals
DELAYED INTL’K Terminals
Should the proving switch not prove within the programmed t ime frame, the unit will shut down.
The Aux Start On Dly can be programmed from 0 to 120 seconds. This option is located in the
Configuration Menu (Chapter 3).
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Selkirk Corporation - Heatfab Division
Watertown Supply
M. A. Peacard
www.mapeacard.com
Glover Sheet Meatal, Inc.
www.gloversheetmetal.com
CHAPTER 2 – INSTALLATION
2.12.13 FAULT RELAY Terminals
The fault relay is a single pole double throw (SPDT) relay having a normally open and normally
closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC. The
relay energizes when any fault condition occurs and remains energized until the fault is cleared
and the CLEAR button is depressed. The Fault Relay connections are shown in Figure 2-12.
2.12.14 AUX RELAY Terminals
Each unit is equipped with a single pole double throw (SPDT) auxiliary relay that is energized
when there is a demand for heat and de-energized after the demand for heat is satisfied. The
relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be
used as a unit status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 amps.
Refer to Figure 2-12 to locate the AUX RELAY terminals (N.C., COM, & N.O.) for wiring
connections.
2.13 FLUE GAS VENT INSTALLATION
AERCO Gas Fired Venting and Combustion Air Guide, GF-5050 mu st be consulted before any
flue or combustion air venting is designed or installed. Suitable, U/L approved, positive
pressure, watertight vent materials MUST be used for safety and UL certification. Because the
unit is capable of discharging low temperature exhaust gases, the flue must be pitched back
towards the unit a minim um of 1/4" per foot to avoid any condensate pooling and to allow for
proper drainage.
While there is a positive flue pressure during operation, the combined pressure drop of vent and
combustion air systems must not exceed 140 equivalent feet of 1.9” W.C. Fittings as well as
pipe lengths must be calculated as part of the equivalent length. For a natural draft installation
the draft must not exceed - 0.10” W.C. These factors must be planned into the vent installation.
If the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate
properly or reliably.
For Massachusetts installations, the following companies provide vent systems which conform
to all applicable requirements for installations within the Commonwealth of Massachusetts.
Contact information is as follows:
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
1250 Massachusetts Ave.
Boston MA 02125-1689
Phone: (617) 288-0629
33Grove St.
Watertown, MA 02472
Phone: (617) 924-2840
http://www.watertownsupply.com/
44 Riverdale Ave.
Newton, MA 02485
Phone: (617) 527-8178
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CHAPTER 2 – INSTALLATION
2.14 COMBUSTION AIR
The AERCO Gas-Fired Heater Venting and Combustion Air Guide, GF-5050 MUST be
consulted before any flue or inlet air venting is designed or installed. Air supply is a direct
requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be
consulted before a permanent design is determined.
The combustion air must be fr ee of chlorine, halogenated hydrocarbons or other chemicals that
can become hazardous when used in gas-fired equipment. Common sources of these
compounds are swimming pools, degreasing compounds, plastic processing, and refriger ants.
Whenever the environment contains these types of chemicals, combustion air MUST be
supplied from a clean area outdoors for the protection and longevity of the equipment and
warranty validation.
The more common methods of combustion air supply are outlined in the following sections. For
combustion air supply from ducting, consult the AERCO GF-5050, Gas Fired Venting and
Combustion Air Guide.
2.14.1 Combustion From Outside the Building
Air supplied from outside the building must be provided through two permanent openings. For
each unit these two openings must have a free area of not less than one square inch for each
4000 BTUs input of the equipment or 250 square inches of free area. The free area must take
into account restrictions such as louvers and bird screens. For Canada installations, refer to the
requirements specified in CSA B149.1-10, 8.4.1 and 8.4.3.
2.14.2 Combustion Air from Inside the Building
When combustion air is provided from within the building, it must be supplied through two
permanent openings in an interior wall. Each opening must have a free area of not less than
one square inch per 1000 BTUH of total input or 1000 square inches of free area. The fr ee area
must take into account any restrictions, such as louvers.
2.15 DUCTED COMBUSTION
The AERCO Innovation Water Heater is UL listed for 100%-ducted combustion. For ducted
combustion installations, the screen inlet air ductwork must then be attached directly to the
unit’s air inlet.
In a ducted combustion air application, the combustion air ducting pressure losses must be
taken into account when calculating the total maximum allowable venting run. See the AERCO
Innovation Venting and Combustion Air Guide, GF-5050. When using the heater in a ducted
combustion air configuration, each unit must have a minimum 6 inch diameter connection at the
unit.
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CAUTION
WARNING
WARNING
CHAPTER 3 – OPERATION
CHAPTER 3. OPERATION
3.1 INTRODUCTION
The information in this Chapter provides a guide to the operation of t he Innovation Water Heater
using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of
this unit be performed by factory trained personnel. Oper ation prior to initial startup by factory
trained personnel will void the equipment warranty. In addition, the following WARNINGS and
CAUTIONS must be observed at all times.
All of the installation procedures in Chapter 2 must be completed before
attempting to start the unit.
ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24
VOLTS AC. IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED
SERVICE TECHNICIANS
DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTING THE UNIT
WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE
UNIT AND MAY RESULT I N INJURY TO PERSONNEL OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID ANY WARRANTY.
3.2 CONTROL PANEL DESCRIPTION
The Innovation Control Panel shown in Figure 3-1 contains all of the controls, indicators and
displays necessary to operate, adjust and troubleshoot the Innovation Water Heater. These
operating controls, indicators and displays are listed and described in Table 3-1. Additional
information on these items is provided in the individual operating procedures provided in this
Chapter.
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3
2
1
*4
5 7 8
9
10
11
12
6
CHAPTER 3 – OPERATION
Figure 3-1. Control Panel Front View
*NOTE
If there is a requirement to use the RS232 port (Item 4) on the CMore controller front panel, contact AERCO to purchase the
RS232 Adaptor Cable (P/N 124675), which is designed for this
purpose. This cable features a DB9 connector for connection to
older computers with serial ports or can be used with a Serial-toUSB adaptor for use in modern computer USB ports.
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CONTROL,
DISPLAY
Vacuum Fluorescent Display (VFD) consists of 2 lines each
Port permits a Laptop Computer or External Modem to be
which is designed to
8
CHAPTER 3 – OPERATION
Table 3-1 Operating Controls, Indicators and Displays
ITEM
NO.
1
2
3
INDICATOR OR
Four Status LEDs indicate the current operating status as follows:
COMM
MANUAL
REMOTE
DEMAND
OUTLET
TEMPERATURE
Display
VFD Display
FUNCTION
LED Status Indicators
Lights when RS-232 communication is occurring
Lights when the val ve position (fire rate) is bei ng controlled using
the front panel keypad. This mode of operation is for service
technician use only.
Lights when the un it is being con trolled b y an external sig nal from
an Energy Management System
Lights when there is a demand for heat.
3–Digit, 7–Segm ent LED display continuously displays the outlet
water temperature. The °F or °C LED next to the dis play lights to
indicate whether the displayed temperature is in degrees
Fahrenheit or degrees Celsius. The °F or °C blinks when operating
in the Deadband Mode.
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
• Startup Messages
• Fault Messages
• Operating Status Messages
• Menu Selection
connected to the unit’s Con trol Pane l. AERCO of fer s for purchas e
RS-232 Port
4
FAULT Indicator
5
CLEAR Key
6
READY Indicator
7
ON/OFF Switch
LOW WATER LEVEL
9
TEST/RESET Switches
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the RS232 Adaptor Cable (P/N 124675),
work with this port. This cable features a DB9 connector for
connection to older computers with serial ports or can be used
with a Serial-to-USB adaptor for use in computer USB ports.
Red FAULT LED indicator lights when a boiler alarm condition
occurs. An alarm message will appear in the VFD.
Turns off the FAULT indica tor an d cl ear s the alarm mess age if t he
alarm is no longer valid. Lock out type alarms will be latched and
cannot be cleared by simply pressing this key. Troubleshooting
may be required to clear these types of alarms.
Lights when ON/OFF switch is set to ON and all Pre-Purge
conditions have been satisfied.
Enables and disables boiler operation.
Allows operator to test operation of the water level monitor.
Pressing TEST opens the water level prob e c irc uit an d s imulates a
Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Six (6) keys which provide the following functions for the Control Panel Menus:
shown.
main menu category.
the selected setting.
selected setting.
setting.
display will stop flashing.
disabled.
Bargraph
Air/Fuel Valve position in 5% increments from 0 to 100%
CHAPTER 3 – OPERATION
Table 3-1 Operating Controls, Indicators and Displays – Continued
ITEM
NO.
10
CONTROL,
INDICATOR OR
DISPLAY
FUNCTION
MENU Keypad
MENU Steps through the main menu categories shown in Figure
3-2. The Menu categories wrap around in the order
BACK Allows you to go back to the previous menu level without
changing any information. Continuously pressing this key
will bring you back to the default status display in the
VFD. Also, this key allows you to go back to the top of a
▲ (UP) Arrow When in one of the main menu categories (Figure 3-2),
pressing the ▲ arrow key will select the displayed menu
category. I f the CHANGE key was pressed and the menu
item is flashing, pressing the ▲ arrow key will increment
▼ (DOWN) Arrow When in one of the main menu categories (Figure 3-2),
pressing this key will select the displayed menu category.
If the CHANGE key was pressed and the menu item is
flashing, pressing the ▼ arrow key will decrement the
CHANGE Permits a setting to be changed (edited). When the
ENTER Saves the modified menu settings in memory. The
AUTO/MAN Switch
11
12
VALVE POSITION
CHANGE key is pressed, the displayed menu item will
begin to flash. Pressing the ▲ or ▼ arrow key when the
item is flashing will increment or decrement the displayed
This switch toggles the heater between the Automatic
and Manual modes of operation. When in the Manual
(MAN) mode, the front panel controls are enabled and
the MANUAL status LED lights. Manual operation is for
service technicians only.
When in the Automatic (AUTO) mode, the MANUAL
status LED will be off and the front panel controls
20 segment red LED bargraph continuously shows the
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CHAPTER 3 – OPERATION
3.3 CONTROL PANEL MENUS
The Control Panel incorporates an extensive menu structure which permits the operator to set
up, and configure the unit. The menu structure consists of five major menu categories which are
applicable to this manual. These categories are shown in Figure 3-2. Each of the menus
shown, contain options which permit operating parameters to be viewed or changed. The
menus are protected by password levels to prevent unauthorized use.
Prior to entering the correct password, the options contained in the Operation, Setup,
Configuration and Tuning Menu categories can be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration Menu), none of the viewable menu options can be
changed.
Once the valid level 1 password (159) is entered, the options listed in the Setup. Configuration,
Water Heater Management (WHM) and Tuning Menus can be viewed and changed, if desired.
3.3.1 Menu Processing Procedure
Accessing and initiating each menu and option is accomplished using the Menu Keys shown in
Figure 3-1. Therefore, it is imperative that you be thoroughly familiar with the following basic
steps before attempting to perform specific menu procedures.
Menu Processing Procedure
1. The Control Panel will normally be in the Operating Menu and the VFD will display the
current unit status. Pressing the ▲ or ▼ arrow key will display the other available data
items in the Operating Menu.
2. Press the MENU k ey. The display will show the Setup Menu, which is the next menu
category shown in Figure 3-2. This menu contains the Password option which must be
entered if other menu options will be changed.
3. Continue pressing the MENU key until the desired menu is displayed.
4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.
Pressing the ▲ arrow key will display the available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.
The menu options will wrap-around after the first or last available option is reached.
6. To change the value or setting of a displayed menu option, press the CHANGE key. The
displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the
available menu option choices for the option to be changed. The menu option choices do
not wrap around.
7. To select and store a changed menu item, press the ENTER key.
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NOTE
THE WHM MENU IS ONLY
DISPLAYED WHEN THE UNIT
TYPE IN THE CONFIGURATION
CHAPTER 3 – OPERATION
MENU IS SET TO INNOVATION
WH.
The following sections provide brief descriptions of the options contained in
each menu. Refer to Appendix A for detailed descriptions of each menu
option. Refer to Appendix B for listings and descriptions of displayed
startup, status and error messages.
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Figure 3-2. Menu Structure
NOTE
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
CHAPTER 3 – OPERATION
3.4 OPERATING MENU
The Operating Menu displays a number of key operating parameters for the unit as listed in
Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any
displayed items. Since this menu is “Read-Only”, it can be viewed at any time without entering a
password. Pressing the ▲ arrow key to display the menu items in the order listed (Top-Down).
Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up).
Table 3-2. Operating Menu
Active Setpoint 40°F 240°F
Inlet Temp 40°F 140°F
Air Temp -70°F 245°F
Outdoor Temp* -70°F 130°F
Valve Position In 0% 100%
Valve Position Out 0% 100%
FFWD Temp 80°F 160°F
Flame Strength 0% 100%
Run Cycles 0 999,999,999
Run Hours 0 999,999,999
Fault Log 0 19 0
NOTE
The Outdoor Temp display item shown with an asterisk in T able 3-2 will not
be displayed unless the Outdoor Sensor function has been enabled in the
Configuration Menu (Table 3-4).
3.5 SETUP MENU
The Setup Menu (Table 3-3) permits the operator to enter the unit password (159) which is
required to change the menu options. To prevent unauthorized use, the password will time-out
after 1 hour. Therefore, the correct password must be reenter ed when required. In addition to
permitting password entries, the Setup Menu is also used to enter date and time, units of
temperature measurements and entries required for external communication and control of the
unit via the RS-232 port. A view-only software version display is also provided to indicate the
current Control Box software version.
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Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Password
0
9999
0
Language
English
English
Time
12:00 am
11:59 pm
Date
01/01/00
12/31/99
Unit of Temp
Fahrenheit or Celsius
Fahrenheit
Comm Address
0
127
0
Baud Rate
2400, 4800, 9600, 19.2K
9600
Software
Ver 0.00
Ver 9.99
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Internal Setpt
Lo Temp
Limit
Hi Temp Limit
130°F
Unit Type
KC Boiler, KC Boiler LN,
Innovation WH
Innovation
Unit Size
600 MBH, 800 MBH, 1060
600, 800,
Fuel Type
Natural Gas, Propane
Natural Gas
Water Heater Mode
Constant Setpoint,
Remote Setpoint,
Constant
Setpoint
CHAPTER 3 – OPERATION
Table 3-3. Setup Menu
3.6 CONFIGURATION MENU
The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Setpt)
temperature regardless of whether the valid password has been entered. Setpt is required for
operation in the Constant Setpoint mode. The remaining options in this menu require the valid
password to be entered, prior to changing existing entries. This menu contains a number of
other configuration settings which may or may not be displayed, depending on the current
operating mode setting.
NOTE
The Configuration Menu settings shown in Table 3-4 are FactorySet in accordance with the requirements specified for each
individual order. Therefore, under normal operating conditions, no
changes will be required.
Table 3-4. Configuration Menu
(Only if Unit Type is
Innovation WH)
BMK Boiler, BMK Boiler LN,
BMK Boiler Dual, KC Water
Heater, KC Water Heater LN,
MBH, 1350 MBH
WH
1060 or
1350 MBH
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Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Remote Signal
or Combination)
4 – 20 mA/1 – 5V
Network
4 – 20 mA,
Bldg Ref Temp
Reset)
40°F
230°F
70°F
Reset)
Outdoor Sensor
Enabled or Disabled
Disabled
System Start Tmp
Enabled)
30°F
100°F
60°F
Setpt Lo Limit
40°F
Setpt Hi Limit
60°F
Setpt Hi Limit
Setpt Lo Limit
220°F
140°F
Temp Hi Limit
40°F
240°F
160°F
Max Valve Position
40%
100%
100%
Pump Delay Timer
0 min.
30 min.
0 min.
Aux Start On Dly
0 sec.
120 sec.
0 sec.
Failsafe Mode
Shutdown or Constant Setpt
Shutdown
Low Fire Timer
2 sec.
600 sec.
2 sec.
Setpt Limiting
Enabled or Disabled
Disabled
Setpt Limit Band
0°F
10°F
0
Network Timeout
5 Sec
999 Sec
30 Sec
HI DB Setpt EN
0%
100%
30%
Demand Offsert
0
25
0
Deadband High
0
25
0
Deadband Low
0
25
0
* CAUTION
CHAPTER 3 – OPERATION
Table 3-4. Configuration Menu - Continued
(If Mode = Remote
Setpoint, Direct Drive
(If Mode = Outdoor
Reset Ratio
(If Mode = Outdoor
(If Outdoor Sensor =
0 -20 mA/0 – 5V
PWM Input (Legacy BMS),
0.1 9.9 1.2
1-5V
3.7 WATER HEATER MANAGEMENT (WHM) MENU
The WHM Menu in each C-More can only be viewed when the Unit Type option in the
Configuration Menu is set to Innovation WH. Most of the options in this menu are preset at the
factory and cannot be altered by the user. Therefore, t he WHM Menu contains only eight (8)
user-selectable menu options. These menu options are listed in Table 3-5. Descriptions for each
of these menu items are included in Appendix A.
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DO NOT CHANGE the Analog Output Menu Item from its Default
setting (Valve Position 0-10V).
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Available Choices or Limits
Display
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
CHAPTER 3 – OPERATION
Table 3-5. WHM Menu
Menu Item
WHM Mode
Minimum Maximum Default
Off, WHM Slave,
Off
WHM Master
WHM Setpoint
WHM Nxt On FR
WHM Nxt Off FR
Lead/Lag Hours
Setback Setpoint
Setback Start
Setback End
*WH M Auto Mstr
*WHM Auto Timer
40°F 200°F 130°F
16% 100% 75%
16% 100% 35%
25 225 72
40°F 220°F 130°F
12:00am 11:59pm 12:00am
12:00am 11:59pm 12:00am
Yes or No No
10 sec. 120 sec. 30 sec.
*NOTE
The Level 2 Password (6817) in the Setup Menu must be entered to view
or change the WHM Auto Mstr and WHM Auto Timer options.
3.8 TUNING MENU
The Tuning Menu items in Table 3-6 ar e Factory set for each individual unit. Do not change
these menu entries unless specifically requested to do so by Factory-Trained personnel.
Table 3-6. Tuning Menu
Prop Band
Integral Gain 0.00 2.00 1.6
Derivative Time 0.0 min 2.00 min 0.10 min
Reset Defaults? Yes, No, Are You Sure? No
1°F 120°F 8°F
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GAS INLET
MANUAL
SSOV
CHAPTER 3 – OPERATION
3.9 START SEQUENCE
When the Control Box ON/OFF switch is set to the ON 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
• Low Water Level switch
• High Water Temperature switch
• High Gas Pressure switch
• Low Gas Pressure switch
• Blowe r Proof switch
NOTE
The downstream Low Gas Pressure switch is not checked prior to starting
the pre-purge.
If all of the above switches are closed, the READY light above the ON/OFF switch will lig ht and
the unit will be in the Standby mode.
When there is a demand for hot water, the following events will occur:
NOTE
If any of the Pre-Purge safety device switches are open, the appropriate
fault message will be displayed. Also, if the required conditions are not
observed at any point during the start sequence, appropriate messages will
be displayed and the unit will go into fault mode.
1. The DEMAND LED status indicato r will light.
2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream
Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location.
SHUTOFF
VALVE
Figure 3-3. SSOV Location (INN1060 Gas Train)
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TO BLOWER
AIR IN
OUTLET TO BLOWER
CHAPTER 3 – OPERATION
3. With all required safety device switches closed, a purge cycle will be initiated and the
following events will occur:
(a) The Blower relay energizes and turns on blower.
(b) The Air/Fuel Valve rotates to the full-open purge position and closes purge
position switch. The dial on the Air/Fuel Valve (Figure 3-4) will read 100 to
indicate that it is full-open (100%).
(c) The VALVE POSITION bargraph will show 100%.
STEPPER
PURGE
VALVE POSITIO N
DIAL AT 100%
MOTOR
Figure 3-4. Air/Fuel Valve In Purge Position
4. Next, the blower proof switch on the Air/Fuel Valve (Figure 3-5) closes. The display will
show Purging and indicate the elapsed time of the purge cycle in seconds.
AIR/FUEL
BLOWER PROOF
SWITCH
VALVE
Figure 3-5. Blower Proof Switch
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TO BLOWER
AIR IN
CHAPTER 3 – OPERATION
5. Upon completion of the purge cycle, the Control Box initiates an ignition cycle and the
following events occur:
(a) The Air/Fuel Valve rotates to the low-fire ignition position and closes the ignition
switch. The dial on the Air/Fuel Valve (Figure 3-6) will read between 25 and 35
to indicate that the valve is in the low-fire position.
(b) The igniter relay is activated and provides ignition spark.
(c) The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to
flow into the Air/Fuel Valve.
IGNITION
VALVE POSITIO N
DIAL AT
25% to 35%
STEPPER
MOTOR
Figure 3-6. Air/Fuel Valve In Ignition Position
6. Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned
off one second after flame is detected.
7. After 2 seconds of continuous flame, Flame Proven will be displayed and the flame
strength will be indicated. After 5 seconds, the current date and time will be displayed in
place of the flame strength.
8. With the unit firing properly, it will be controlled by the temperature controller circuitry. The
heater’s VALVE POSITION will be continuously displayed on the front panel bar-graph.
Once the demand for hot water has been satisfied, the Control Box will turn off the SSOV gas
valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will
be displayed.
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CHAPTER 3 – OPERATION
3.10 START/STOP LEVELS
The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit,
based on load. These levels are Factory preset as follows:
Start Level: 25%
Stop Level: 16%
Normally, these settings should not require adjustment.
Note that the energy input is not linearly related to the Air/Fuel Valve posit ion. Refer to Table 3-
7 for the relationship between the energy input and Air/Fuel Valve position for a unit running on
natural gas.
Table 3-7. Relationship Between Air/Fuel Valve Position and Energy Input
For Units Running Natural Gas
Air/Fuel Valve
Position (%
Open)
16% 45,000 45,000 45,000 45,000
20% 87,000 97,000 97,000 181,000
30% 174,000 192,000 222,000 370,000
40% 243,000 330,000 416,000 665,000
50% 306,000 424,000 520,000 870,000
60% 370,000 486,000 715,000 1,001,000
80% 483,000 615,000 845,000 1,203,000
100% 600,000 800,000 1,060,000 1,350,000
Innovation Water Heater Model: Energy Input (BTU/Hr.)
INN600 INN800 INN1060 INN1350
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WARNING
CHAPTER 4 – INITIAL ST ART-UP
CHAPTER 4. INITIAL START-UP
4.1 INI TIAL 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)
• Perform combustion calibration (Chapter 4)
• Test safety devices (Chapter 5)
All applicable installation procedures in Chapter 2 must be fully completed prior to performing the
initial start-up of the unit. The initial start-up must be successfully completed prior to putting the
unit into service. Starting a unit without the proper piping, venting, or electrical systems can be
dangerous and may void the product warranty. The following start-up instructions should be
followed precisely in order to operate the unit safely and at a high thermal efficiency, with low flue
gas emissions.
Initial unit start-up must be performed ONLY by AERCO factory trained start-up and service
personnel. After performing the start-up procedures in this Chapter, it will be necessary to
perform the Safety Device Testing procedures specified in Chapter 5 to complet e all initial unit
start-up requirements.
An AERCO Gas Fired Startup Sheet, included with each I nnovation Heater, must be completed
for each unit for warranty validation and a copy must be returned promptly to AERCO at:
AERCO International, Inc.
100 Oritani Drive
Blauvelt, New York 10913
(FAX: 845-580-8090)
DO NOT ATTEMPT TO DRY FIRE THE HEATER. ST ARTING THE UNIT
WITHOUT A FULL WATER LEVEL CAN SERIOUSL Y DAMAGE THE UNIT
AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID ANY WARRANTY.
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
To properly perform combustion calibration, the proper instruments and tools must be used and
correctly attached to the unit. The following sections outline the necessary tools and
instrumentation as well as their installation.
4.2.1 Required Tools & Instrumentation
The following tools and instrumentation are necessary to perform combustion calibration of the
unit:
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MANUAL
SSOV
TO AIR/FUEL
VALVE
CHAPTER 4 – INITIAL ST ART-UP
• Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and
Nitrogen Oxide (NOx) resolution to 1PPM.
• 16 inch W.C. manometer or equivalent gauge and plastic tubing.
• Multimeter (Capable of measuring 0 – 10 µA)
• 1/8 inch NPT-to-barbed fittings for use with gas supply manometer or gauge.
• Small and large flat blade screwdrivers.
• Tube of silicone adhesive
4.2.2 Installing Gas Supply Manometer
The gas supply manometer is installed in the gas train as follows:
Installing Gas Supply Manometer
1. Close the main manual gas supply shut-off valve upstream of the unit.
2. Remove the front door and left side panels from the heater to access the gas train
components.
3. Remove the 1/4 inch NPT pipe plug from the leak detection ball valve on the downstream
side of the Safety Shut Off Valve (SSOV) as shown in Figure 4-1.
4. Insta ll a NPT-to-barbed fitting into the tapped plug port.
5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch
W.C. manometer.
LOW GAS
PRESSURE SWITCH
LEAK
DETECTION
BALL VALVE
1/4" NPT PLUG
(Install manometer here)
SHUTOFF
VALVE
HIGH GAS
PRESSURE
SWITCH
Figure 4-1. 1/4 Inch Gas Plug Location (INN1060 Gas Train Shown)
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. Prepare the port for the combustion
analyzer probe as follows:
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CHAPTER 4 – INITIAL ST ART-UP
Accessing Analyzer Probe Port
1. Refer to Figure 4-2 and remove the 1/8” NPT plug from the rear of the exhaust manifold.
2. If necessary, adjust the stop on the combustion analyzer probe so it will extend mid-way
into the flue gas flow. DO NOT install the probe at this time
VENT PROBE
EXHAUST
MANIFOLD
PORT WITH 1/8”
NPT PLUG
CONDENSATE
DRAIN
Figure 4-2. Analyzer Probe Hole Location
IMPORTANT
For Innovation Water Heater installations in Korea, refer to the Natural Gas
Combustion Calibration procedures in Appendix K.
4.2.4 Connecting Multimeter to Flame Detector
During Combustion Calibration, the flame strength generated by the flame detector is measured
using a multimeter set to the µA scale. The flame detector is mounted on the f lange of the blower
side intake manifold as shown in Figure 4-3.
Proceed as follows to set up the multimeter to measure the flame strength current:
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CLIP
LEAD
MULTIMETER
CHAPTER 4 – INITIAL ST ART-UP
Connecting Multimeter to Measure Flame Strength
1. Refer to Figure 4-3 and remove the right side panel from the unit to access the flame
detector.
2. Disconnect the flame detector wire lead 135 from the detector and connect the multimeter
in series with the wire lead using alligator clips as shown in Figure 4-3.
3. Ensure that the multimeter is set to the µA scale.
FLAME
DETECTOR
CLIP
LEAD
BLOWER-SIDE
INTAKE
MANIFOLD
IGNITOR
HARNESS
WIRE LEAD
135
Figure 4-3. Flame Strength Set-Up Using Multimeter
IMPORTANT
The unit is shipped from the factory set up for either Natural Gas or Propane, as
specified by the Style Number on the Sales Order. Perform the appropriate
Combustion Calibration procedures in section 4.3 for Natural Gas, or section 4.4
for Propane.
4.3 NATURAL GAS COMBUSTION CALIBRATION
The Innovation Heater is combustion calibrated at the factory prior to shipping. However,
recalibration is necessary as part of initial start-up due to changes in the local altitude, gas BTU
content, gas supply piping and supply regulators. Start-Up & Registration Test Data sheets are
shipped with each unit. These sheets must be filled out and returned to AERCO for proper
Warranty Validation.
It is important to perform the calibration procedure as outlined below. This will keep
readjustments to a minimum and provide optimum performance.
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INNOVATION MODEL
GAS PRESSURE RANGE
DOWNSTREAM OF SSOV
INN 1350
3.0” – 3.2” W.C.
INN1060
2.6” – 2.8” W.C.
INN800
1.5” – 1.7” W.C.
INN600
0.9” – 1.1” W.C.
BRASS HEX
CHAPTER 4 – INITIAL ST ART-UP
Natural Gas Combustion Calibration
1. Open the water supply and return valves to the unit and ensure that the system pumps are
running.
2. Open the natural gas supply valve(s) to the unit.
3. Set the control panel ON/OFF switch to the OFF position.
4. Turn on external AC power to the unit. The display will show LOSS OF POWER and the
time and date.
5. Set the unit to the Manual Mode by pressing the AUTO/MAN key. A flashing Manual Valve
Position message will be displayed with the present position in %. Also, the MANUAL LED
will light.
6. Adjust the air/fuel valve position to 0% by pressing the ▼ arrow key.
7. Ensure that the leak detection ball valve downstream of the SSOV is open.
8. Set the ON/OFF switch to the ON position.
9. Change the valve position to 29% using the ▲ arrow key. The unit should begin its start
sequence and fire.
10. Next, verify that the gas pressure downstream of the SSOV is within the appropriate range
shown below for the Innovation Model being tested. If gas pressure adjustment is required,
remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment
screw (Figure 4-4). Make gas pressure adjustments using a flat-tip screwdriver to obtain a
gas pressure reading within the required range for the INN model being tested.
HEAD CAP
(Remove to
access gas
pressure
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Figure 4-4. Gas Pressure Adjustment Screw Location
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Oxygen %
± 0.5
Carbon
Monoxide
NOx
Flame
Strength
6.5 %
<50 ppm
<15 ppm
>2.0 µA
INNOVATION MODEL
GAS PRESSURE RANGE
DOWNSTREAM OF SSOV
INN 1350
3.0” – 3.2” W.C.
INN1060
2.6” – 2.8” W.C.
INN800
1.5” – 1.7” W.C.
INN600
0.9” – 1.1” W.C.
CHAPTER 4 – INITIAL ST ART-UP
Natural Gas Combustion Calibration - Continued
11. Next, decrease the valve open position to 16% using the ▼ arrow key. Verify that the gas
pressure at the inlet of the SSOV is 8.0” to 11.0” W.C. Readj ust the inlet gas pressure if
necessary.
12. Insert the combustion analyzer probe into the 1/8” port at the rear of the exhaust manifold.
Allow enough time for the combustion analyzer to settle.
13. Verify that the oxygen (O2) level is within the range shown below. Also, ensure that the
carbon monoxide (CO), nitrogen oxide (NOx) and flame strength readings are within the
values shown.
14. If the oxygen level is not within the required tolerance, the gas pressure on the downstream
side of the SSOV must be adjusted using the adjustment screw on the SSOV regulator
(Figure 4-4). Slowly rotate the gas pressure adjustment (approximately 1/4-turn
increments). Allow the combustion analyzer to stabilize following each adjustment.
Clockwise rotation reduces the oxygen level, while counterclockwise rotation increases the
oxygen level.
Combustion Oxygen Level at 16% Valve Position
15. Once the oxygen level is within the required range listed in step 13, the gas pressure on the
downstream side of the SSOV should be within the appropriate range shown below for the
Innovation Model being tested.
16. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed.
17. Following combustion calibration at the 16% valve position, check the combustion readings
at each of the valve positions listed below and record the readings on the Start-Up &
Registration data sheets provided with the unit. During these checks, DO NOT attempt to
adjust the downstream gas pressure using the SSOV gas pressure adjustment screw.
NOTE
Based on the water heater load, it may not be possible to obtain data at all of
the points listed without encountering an Over-Temp condition.
18. Valve Positions to be checked:
• 20%,
• 30%,
• 40%,
•
50%,
This completes the Natural Gas combustion calibration procedure.
• 60%,
• 80%,
• 100%
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CHAPTER 4 – INITIAL ST ART-UP
4.4 PROPANE COMBUSTION CALIBRATION
IMPORTANT
The unit is shipped from the factory set up for either Nat ural Gas or Propane as
specified by the Style Number on the Sales Order. Complete the instructions
below only if your unit has been set up for Propane.
The Innovation Heater is combustion calibrated at the factory prior to shipping. However,
recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU
content, gas supply piping and supply regulators. Start-Up & Registration Test Data sheets are
shipped with each unit. These sheets must be filled out and returned to AERCO for proper
Warranty Validation.
It is important to perform the calibration procedure as outlined in the following steps. This will
keep readjustments to a minimum and provide optimum performance.
Propane Combustion Calibration
1. Open the water supply and return valves to the unit and ensure that the system pumps are
running.
2. Open the propane gas supply valve(s) to the unit.
3. Set the control panel ON/OFF switch to the OFF position.
4. Turn on external AC power to the unit. The display will show LOSS OF POWER and the
time and date.
5. Set the unit to the Manual Mode by pressing the AUTO/MAN key. A flashing Manual Valve
Position message will be displayed with the present position in %. Also, the MANUAL LED
will light.
6. Adjust the air/fuel valve position to 0% by pressing the ▼ arrow key.
7. Ensure that the leak detection ball valve downstream of the SSOV is open.
8. Set the ON/OFF switch to the ON position.
9. Change the valve position to 29% using the ▲ arrow key. The unit should begin its start
sequence and fire.
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INNOVATION MODEL
GAS PRESSURE RANGE
DOWNSTREAM OF SSOV
INN 1350
2.0” – 2.2” W.C.
INN1060
1.8” – 2.0” W.C.
INN800
2.8” – 3.0” W.C.
INN600
1.6” – 1.8” W.C.
Oxygen %
± 0.5
Carbon
Monoxide
NOx
Flame
Strength
6.0 %
<50 ppm
<15 ppm
>2.0 µA
INNOVATION MODEL
GAS PRESSURE RANGE
DOWNSTREAM OF SSOV
INN 1350
2.0” – 2.2” W.C.
INN1060
1.8” – 2.0” W.C.
INN800
2.8” – 3.0” W.C.
INN600
1.6” – 1.8” W.C.
CHAPTER 4 – INITIAL ST ART-UP
Propane Combustion Calibration - Continued
10. Next, verify that the gas pressure downstream of the SSOV is within the appropriate range
shown below for the Innovation Model being tested. If gas pressure adjustment is required,
remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment
screw (Figure 4-4). Make gas pressure adjustments using a flat-tip screwdriver to obtain a
gas pressure reading within the required range for the INN model being tested.
11. Next, decrease the valve open position to 16% using the ▼ arrow key. Verify that the gas
pressure at the inlet of the SSOV is 11.0” W.C. Readjust the inlet gas pressure if
necessary.
12. Insert the combustion analyzer probe into the 1/8” port at the rear of the exhaust manifold.
Allow enough time for the combustion analyzer to settle.
13. Verify that the oxygen (O2) level is within the range shown below. Also, ensure that the
carbon monoxide (CO), nitrogen oxide (NOx) and flame strength readings are within the
values shown.
Combustion Oxygen Level at 16% Valve Position
14. If the oxygen level is not within the required tolerance, the gas pressure on the downstream
side of the SSOV must be adjusted using the adjustment screw on the SSOV regulator
(Figure 4-4). Slowly rotate the gas pressure adjustment (approximately 1/4-turn
increments). Allow the combustion analyzer to stabilize following each adjustment.
Clockwise rotation reduces the oxygen level, while counterclockwise rotation increases the
oxygen level.
15. Once the oxygen level is within the required range listed in step 13, the gas pressure on the
downstream side of the SSOV should be within the appropriate range shown below for the
Innovation Model being tested.
16. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed.
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• 20%,
50%,
• 60%,
CHAPTER 4 – INITIAL ST ART-UP
Propane Combustion Calibration - Continued
17. Following combustion calibration at the 16% valve position, check the combustion readings
at each of the valve positions listed below and record the readings on the Start-Up &
Registration data sheets provided with the unit. During these checks, DO NOT attempt to
adjust the downstream gas pressure using the SSOV gas pressure adjustment screw.
NOTE
Based on the water heater load, it may not be possible to obtain data at all of
the points listed without encountering an Over-Temp condition.
18. Valve Positions to be checked:
• 30%,
• 40%,
• 80%,
• 100%
•
This completes the Propane combustion calibration procedure.
4.5 REASSEMBLY
Once the combustion calibration adjustments are properly set, the unit can be reassembled for
service operation.
Reassembly
1. Set the ON/OFF switch in the OFF position.
2. Disconnect AC power from the unit.
3. Shut off the gas supply to the unit.
4. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe
thread compound.
5. Remove the combustion analyzer probe from the 1/8” vent hole in the exhaust manifold.
Replace the 1/8” NPT plug in the manifold.
6. Replace the unit’s side panels and front door.
4.6 TEMPERATURE CONTROL CALIBRATION
The unit normally comes factory set and calibrated for a 130°F setpoint (default value). Ho wever,
if a different setpoint temperature is desired, it can be changed using the procedure in section
4.6.1. If the setpoint is changed, it must be done prior to temperature control calibration.
There are two primary adjustments for performing temperature calibration. These are Min Load
Adj and Max Load Adj (minimum and maximum load adjustment).
Adjustments to these settings are made at minimum and maximum load conditions and should be
made in small increments from 1 to 3 degrees. After making an adjustment, the outlet water
temperature must be allowed to settle for several minutes prior to making any further
adjustments.
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CHAPTER 4 – INITIAL ST ART-UP
When calibrating temperature control, observe the following:
Temperature Control Calibration
1. The unit must be in the Auto mode of operation.
2. The Outlet Feedback option in the Tuning Menu must be set to DISABLED while
performing calibration.
3. Monitor the OUTLET TEMPERATURE display and VALVE POSITION bar-graph to set load
conditions and observe the effect of adjustments.
4. Perform the calibration using the Tuning Menu of the C-More Control Box.
5. Make small adjustments and allow time between adjustments for the outlet water
temperature to stabilize.
6. Maintain water flow as constant as possible during these adjustments.
7. Ensure that recirculation loops are operational while the calibration is being performed.
8. Upon completion of calibration, set the Outlet Feedback back to ENABLE.
Temperature control calibration is accomplished by performing the Minimum and Maximum Load
Adjustment procedures in sections 4.6.2 and 4.6.3, respectively.
4.6.1 Setting the Outlet Water Temperature Setpoint
The setpoint temperature of the unit may be changed using the following steps. However, once a
setpoint has been changed, recalibration may be necessary. The temperature calibration
procedures are provided in sections 4.6.2 and 4.6.3.
To adjust the unit’s setpoint, proceed as follows:
Setting Outlet Water Temperature Setpoint
1. Press the MENU k ey until Configuration Menu is displayed.
2. Press the ▲ or ▼ arrow key until Internal Setpt is displayed along with the present setpoint
temperature.
3. To change the setpoint, press the CHANGE key. The display will begin to flash.
4. Press the ▲ or ▼ arrow key until the desired setpoint is displayed.
5. Press the ENTER key to save the change.
4.6.2 Minimum Load Adjustment
With the unit in operation, check the temperature control at minimum load as follows:
Minimum Load Adjustment
1. While monitoring the VALVE POSITION bar-graph, create a minimum load on the system
that will yield a steady valve position between 25% and 35%.
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CHAPTER 4 – INITIAL ST ART-UP
Minimum Load Adjustment – Continued
NOTE
It may be desirable to shut off the outlet valve and use the hose bib (see
Figure 2-4) to simulate a minimum flow load condition
2. Wait several minutes to allow the outlet temperature to stabilize under load conditions.
3. Once stabilized, the OUTLET TEMPERATURE display should read no more than 2 to 3
degrees above the unit’s setpoint.
4. If the outlet temperature is stabilized, proceed to the Maximum Load Adjustment procedure
in section 4.6.3. If the temperature is not stabilized, proceed to step 5.
5. Press the MENU k ey and select the Tuning Menu.
6. Press the ▲ or ▼ arrow key until Min Load Adj is displayed.
7. Press the CHANGE key. The display will begin to flash.
8. Raise or lower the minimum load adjustment in increments of one or two using the ▲ or ▼
arrow key. Increasing this value will increase outlet water temperature, while decreasing it
will decrease outlet water temperature.
.
9. Press ENTER to save the change. Allow time for the system to stabilize between
adjustments
10. Repeat steps 5 through 9 as needed until the temperature is stabilized at no more than 2 to
3 degrees above the unit’s setpoint.
4.6.3 Maximum Load Adjustment
Check the temperature control at maximum load as follows:
1. 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%.
It may be necessary to open the outlet valve if it was closed during minimum
load adjustment to obtain a sufficient flow rate for maximum adjustment.
2. Wait several minutes to allow the outlet water temperature to stabilize under load
conditions.
3. Once stabilized, the OUTLET TEMPERATURE display should read no more than 2 to 3
degrees below the unit’s setpoint.
Maximum Load Adjustment
NOTE
4. If the outlet temperature is stabilized, no adjustment is necessary. If the temperature is not
stabilized, proceed to step 5.
5. Press the MENU k ey and select the Tuning Menu.
6. Press the ▲ or ▼ arrow key until Max Load Adj is displayed.
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ADJUSTABLE
SWITCH
CHAPTER 4 – INITIAL ST ART-UP
Maximum Load Adjustment – Continued
7. Press the CHANGE key. The display will begin to flash.
8. Raise or lower the maximum load adjustment using the ▲ or ▼ arrow key. Increasing this
value will increase outlet water temperature, while decreasing it will decrease water
temperature.
9. Press ENTER to save the change. Allow time for the system to stabilize between
adjustments.
10. Repeat steps 5 through 9 as needed until the temperature is stabilized 2 to 3 degrees
below the unit’s setpoint.
If the outlet temperature does not maintain setpoint after a reasonable amount of time and
adjustment, contact your local AERCO representative.
NOTE
After performing Temperature Calibration and prior to placing the water
heater into service, be sure to set the Outlet Feedback option in the Tuning
Menu back to ON.
4.7 OVER-TEMPERATURE LIMIT SWITCHES
The unit contains both automatic and manual reset over-temperature limit switches. These
switches are mounted on a plate as shown in Figure 4-5. The switches can be accessed by
opening the front panel door of the unit. The manual reset switch is not adjustable and is
permanently fixed at 210°F. This switch will shut down and lock out the heater if the water
temperature exceeds 210°F. Following an over-temperature condition, it must be manually reset
by pressing the RESET button before the heater can be restarted. The automatic reset overtemperature switch is adjustable and allows the unit to restart, once the temperature drops below
its temperature setting. Set the automatic over-temperature switch to the desired setting.
RESET
BUTTON
TEMERATURE LIMIT
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Figure 4-5. Over Temperature Limit Switch Location
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Innovation Water Heaters Installation, Operation & Maintenance Manual
WARNING
CHAPTER 5 – MODE OF OPERATION
CHAPTER 5. MODE OF OPERATION
5.1 INTRODUCTION
Periodic safety device testing is required to ensure that the control system and safety devices
are operating properly. The heater control system comprehensively monitors all combustionrelated safety devices before, during and after the start sequence. The following tests check to
ensure that the system is operating as designed.
Operating controls and safety devices should be tested on a regular basis or following service or
replacement. All testing must conform to local codes such as ASME CSD-1.
NOTE
MANUAL and AUTO modes of operation are required to perform the
following tests. For a complete explanation of these modes, see Chapter 3.
NOTE
It will be necessary to remove the front door and side panels from the unit
to perform the following tests.
ELECTRICAL VOLTAGES IN THI S SYSTEM MAY INCLUDE 12 0 AND 24
VOLTS AC. POWER MUST BE REMOVED PRIOR TO PERFORMING
WIRE REMOVAL OR OTHER TEST PROCEDURES T HAT CAN RESULT
IN ELECTRICAL SHOCK.
5.2 LOW GAS PRESSURE FAULT TEST
Refer to Figure 5-1 and ensure that the leak detection ball valve located at the high gas
pressure switch is closed.
Low Gas Pressure Fault Test
1. Remove the 1/8“ plug from the ball valve at the low gas pressure switch shown in the
lower portion of Figure 5-1.
2. Install a 0 – 16“ W.C. manometer or a W.C. gauge where the 1/8" plug was removed.
3. Slowly open the ball valve near the low gas pressure switch.
4. Place the unit in Manual Mode and adjust the air/fuel valve position (% open) between 25
and 30%.
5. While the unit is firing, slowly close the external manual gas shut-off valve.
6. The unit should shut down and display a LOW GAS PRESSURE fault message at
approximately 2.6” W.C. The FAULT indicator should also start flashing.
7. Fully open the external manual gas shut-off valve and press the CLEAR button on the
Control Box.
8. The fault message should clear and the FAULT indicator should go off. The unit should
restart.
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MANUAL
SSOV
TO AIR/FUEL
VALVE
CHAPTER 5 – MODE OF OPERATION
Low Gas Pressure Fault Test – Continued
9. Upon test completion, close the ball valve and remove the manometer. Replace the 1/8“
plug removed in step 1.
DETECTION
BALL VALVE
1/4" NPT PLUG
(Install manometer here for
HIGH gas pressure test)
SHUTOFF
LEAK
VALVE
HIGH GAS
PRESSURE
SWITCH
LOW GAS
PRESSURE
SWITCH
1/4" NPT PLUG
(Install manometer here for
LOW gas pressure test)
Figure 5-1. Low & High Gas Pressure Testing (INN1060 Gas Train)
5.3 HIGH GAS PRESSURE FAULT TEST
To simulate a high gas pressure fault, refer to Figure 5-1 and proceed as follows:
High Gas Pressure Fault
1. Remove the 1/8“ plug from the leak detection ball valve shown in Figure 5-1.
2. Install a 0 – 16” W.C. manometer (or W.C. gauge) where the 1/8” plug was removed.
3. Slowly open the leak detection ball valve
4. Start the unit in Manual mode at a valve position (firing rate) of 25%.
5. Slowly increase the gas pressure using the adjustment screw on the SSOV.
6. The unit should shut down and display a HIGH GAS PRESSURE fault message when the
gas pressure exceeds 4.0” W.C. The FAULT indicator should also start flashing.
7. Reduce the gas pressure back to 2.8” W.C.
8. Press the CLEAR button on the Control Box to clear the fault.
9. The fault message should clear and the FAULT indicator should go off. The unit should
restart.
10. Upon test completion, close the ball valve and remove the manometer. Replace the 1/8“
plug removed in step 1.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 5 – MODE OF OPERATION
5.4 LOW WATER LEVEL FAULT TEST
To simulate a low water level fault:
Low Water Level Fault Test
1. Set the ON/OFF switch to the OFF position
2. Close the water shut-off valves in the supply and return piping to the unit.
3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may
be opened to aid in draining.
4. Continue draining the unit until a LOW WATER LEVEL fault message is displayed and
the FAULT indicator flashes.
5. Place the unit in the Manual Mode and raise the valve position above 30%.
6. Set the ON/OFF switch to the ON position. The READY light should remain off and the
unit should not start. If the unit does start, shut the unit off immediately and refer fault to
qualified service personnel.
7. Close the drain and pressure relief valve used in draining the unit.
8. Open the water shut-off valve in the return piping to the unit.
9. Open the water supply shut-off valve to the unit to refill.
10. After the shell is full, press the LOW WATER LEVEL RESET button to reset the low water
cutoff.
11. Press the CLEAR butt on to reset the FAULT LED and clear the displayed error message.
12. Set the ON/OFF switch to the ON position. The unit is now ready for operation.
5.5 WATER TEMPERATURE FAULT TEST
A high water temperature fault is simulated by adjusting the automatic over -temperature switch.
This switch is accessible from the front of the unit as shown in Figure 5-2.
Water Temperature Fault Test
1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint.
2. Lower the adjustable over-temperature switch setting to match the displayed OUTLET
TEMPERATURE.
3. Once the adjustable over-temperature switch setting is approximately at, or just below, the
actual outlet water temperature, the unit should shut down. The FAULT indicator should
start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be
displayed. It should not be possible to restart the unit.
4. Reset the adjustable over-temperature switch to its original setting.
5. The unit should start once the adjustable temperature limit switch setting is above the
actual outlet water temperature.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
ADJUSTABLE
SWITCH
CHAPTER 5 – MODE OF OPERATION
Water Temperature Fault Test – Continued
6. Once the adjustable over-temperature switch setting is approximately at, or just below, the
actual outlet water temperature, the unit should shut down. The FAULT indicator should
start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be
displayed. It should not be possible to restart the unit.
7. Reset the adjustable over-temperature switch to its original setting. The unit should start
once the adjustable temperature limit switch setting is above the actual outlet water
temperature.
RESET
BUTTON
TEMERATURE LIMIT
Figure 5-2. 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) and
are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the
unit in the event that an interlock is opened. These interlocks are shipped from the factory
jumpered (closed). However, each of these interlocks may be utilized in the f ield as a remote
stop and start, an emergency cut-off, or to prove that a device such as a pump, gas booster, or
louver is operational.
5.6.1 Remote Interlock
1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals (see
2. Start the unit in the Manual Mode and set the valve position between 25% and 30%.
3. If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the
4. The unit should shut down and display INTERLOCK OPEN.
5. Once the interlock connection is reconnected, the INTERLO CK OPEN message should
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Remote Interlock
Figure 2-12).
jumper. If the interlock is being controlled by an external device, either open the interlock
via the external device or disconnect one of the wires leading to the external device.
automatically clear and the unit should restart.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 5 – MODE OF OPERATION
5.6.2 Delayed Interlock
Delayed Interlock
1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals (see
Figure 2-12).
2. Start the unit in the Manual Mode at a valve position between 25% and 30%.
3. If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the
jumper. If the interlock is connected to a proving switch of an external device, disconnect
one of the wires leading to the proving switch.
4. The unit should shut down and display a DELAYED INTERLOCK OPEN fault message.
The FAULT LED should be flashing.
5. Reconnect the wire or jumper removed in step 3 to restore the interlock.
6. Press the CLEAR button to reset the fault.
7. The unit should start.
5.7 FLAME FAULT TESTS
Flame faults can occur during ignition or while the unit is already running. To simulate each of
these fault conditions, proceed as follows:
Flame Fault Tests
1. Set the ON/OFF switch to the OFF position.
2. Place the unit in the Manual Mode and set the valve position between 25% and 30%.
3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV)
and the Air/Fuel Valve (see Figure 5-3).
4. Set the ON/OFF switch to the ON position to start the unit.
5. The unit should shut down after reaching the Ignition cycle and display FLAME LOSS
DURING IGN.
6. Open the valve previously closed in step 3 and press the CLEAR button.
7. Restart the unit and allow it to prove flame.
8. Once flame is proven, close the 1” manual gas shut-off valve located between the SSOV
(Figure 5-3) and the Air/Fuel Valve.
9. The unit should shut down and execute an IGNITION RETRY cycle by performing the
following:
a) The unit will execute a shutdown purge cycle for a period of 15 seconds and display
WAIT F AULT PURGE.
b) The unit will execute a 30 second re-ignition delay and display WAIT RETRY
PAUSE.
c) The unit will then execute a standard ignition sequence and display WAIT IGNITION
RETRY
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.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
MANUAL
SSOV
TO AIR/FUEL
VALVE
CHAPTER 5 – MODE OF OPERATION
Flame Fault Tests – Continued
10. Since the manual gas shutoff valve is still closed, the unit will shut down and display
FLAME LOSS DURING IGNITION following the IGNITION RETRY cycle.
11. Open the valve previously closed in step 8.
12. Press the CLEAR button. The unit should restart and fire.
HIGH GAS
PRESSURE
SWITCH
LOW GAS
PRESSURE
SWITCH
SHUTOFF
VALVE
Figure 5-3. Manual Gas Shut-Off Valve Location (INN1060 Gas Train)
5.8 AIR FLOW FAULT TESTS
These tests check the operation of the Blower Proof Switch and Block ed Inlet Switch shown in
Figure 5-4.
Air Flow Fault Tests
1. Disable the blower output drive voltage as follows:
(a) Press the MENU key until CONFIGURATION MENU is displayed.
(b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, then
press the CHANGE key.
(c) Press the ▼ arrow key until OFF is displayed, then press the ENTER key.
2. Start the unit in the Manual Mode at a valve position of 25%.
3. The unit should shut down and execute an IGNITION RETRY cycle by performing the
following steps:
(a) The unit will execute a 30 second re-ignition delay and display WAIT RETRY
PAUSE.
(b) The unit will then execute a standard ignition sequence and display WAIT
IGNITION RETRY.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
AIR/FUEL
VALVE
CHAPTER 5 – MODE OF OPERATION
Air Flow Fault Tests – Continued
4. The unit should perform two IGNITION RETRY cycles and then shut down on the third
successive ignition attempt. The unit will display AIRFLOW FAULT DURING PURGE.
5. Re-enable the blower output drive voltage by performing the following steps:
(a) Press the MENU key until CONFIGURATION MENU is displayed.
(b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, then
press the CHANGE key.
(c) Press the ▲ arrow key until VALVE POSITION 0-10V is displayed, then press the
ENTER key.
6. Once the unit has proved flame, turn off the blower by going to the Configuration Menu,
Analog Output menu item and select OFF.
7. The Blower Proof Switch will open and the blower should stop. The unit should shut down
and display AIRFLOW FAULT DURING RUN.
8. Go to the Configuration Menu, Analog Output item and select VALVE POSITION 0-10v.
9. Press the CLEAR button. The unit should restart.
10. Next, check the operation of the Blocked Inlet Switch located on the inlet side of the
Air/Fuel Valve (Figure 5-4).
11. Ensure that the sheet metal panels are securely installed on the water heater and the unit
is running.
12. At the rear of the unit, partially block the air inlet (Figure 5-5) with a plywood sheet or
metal plate.
13. The unit should shut down and again display AIRFLOW FAULT DURING RUN.
14. Unblock the air inlet and press the CLEAR button. The unit should restart.
BLOCKED INLET
SWITCH
BLOWER PROOF
SWITCH
BLOWER
PARTIAL FRONT VIEW
Figure 5-4. Blower Proof & Blocked Inlet Switch Locations
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Innovation Water Heaters Installation, Operation & Maintenance Manual
EXHAUST
MANIFOLD
COLD WATER
INLET
CHAPTER 5 – MODE OF OPERATION
AIR INLET
DRAIN VALVE
PARTIAL REAR VIEW
Figure 5-5. Water Heater Rear View Showing Air Inlet Location
5.9 SSOV PROOF OF CLOSURE SWITCH
The SSOV shown in Figure 5-1 contains the proof of closure switch. The proof of closure switch
circuit is checked as follows:
SSOV Proof of Closure Switch
1. Set the unit’s ON/OFF switch to the OFF position.
2. Place the unit in Manual Mode and set the valve position between 25% and 30%
3. Refer to Figure 5-1 and locate the SSOV.
4. Remove the cover from the SSOV by loosening the screw shown in Figure 5-6. Lift off the
cover to access the terminal wiring connections.
5. Disconnect wire #148 from the SSOV to “open” the proof of closure switch circuit.
6. The unit should fault and display SSOV SWITCH OPEN.
7. Replace wire #148 and press the CLEAR button.
8. Set the ON/OFF switch to ON to start the unit.
9. Remove the wire again when the unit reaches the purge cycle and PURGING is
displayed.
10. The unit should shut down and display SSOV FAULT DURING PURGE.
11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 5 – MODE OF OPERATION
SSOV ACTUATOR
COVER
ACTUATOR
COVER SCREW
Figure 5-6. SSOV Actuator Cover Location
5.10 PURGE SWITCH OPEN DURING PURGE
The Purge Switch (and Ignition Switch) is located on the Air/Fuel Va lve. To check the switch,
proceed as follows:
Purge Switch Open During Purge
1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set
the valve position between 25% and 30%.
2. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it (see
Figure 5-7).
3. Remove one of the two wires (#171 or #172) from the Purge Switch (Figure 5-8).
4. Initiate a unit start sequence.
5. The unit should begin its start sequence, then shut down and display PRG SWITCH
OPEN DURING PURGE.
6. Replace the wire on the Purge Switch and depress the CLEAR button. The unit should
restart.
5.11 IGNITION SWITCH OPEN DURING IGNITION
The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the
switch, proceed as follows:
Ignition Switch Open During Ignition
1. Set the unit’s ON/OFF switch to the OFF position.
2. Place the unit in Manual Mode and set the valve position between 25% and 30%.
3. Remove the Air/Fuel Valve cover (see Figure 5-7) by rotating the cover counterclockwise
to unlock and lift up to remove.
4. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 5-8).
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Ignition Position
Purge Position
TO BLOWER
VALVE POSITION
170
169
172
AIR/FUEL VALVE
AIR IN
CHAPTER 5 – MODE OF OPERATION
Ignition Switch Open During Ignition – Continued
5. Initiate a unit start sequence.
6. The unit should begin its start sequence and then shut down and display IGN SWITCH
OPEN DURING IGNITION.
7. Replace the wire on the Ignition Switch and press the CLEAR button. The unit should
restart.
AIR/FUEL VALVE
COVER
(Rotate CCW to remove)
Figure 5-7. Typical Air/Fuel Valve Cover Location
DIAL
Switch
SWITCH WIRING
BREAKOUT
Switch
Figure 5-8. Air/Fuel Valve Purge and Ignition Switch Locations
5.12 SAFETY PRESSURE REL IEF VALVE TEST
Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code, Section
VI.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Labor
Time
Igniter
Flame Detector
Combustion
Testing of
Safety Devices
Fireside
Inspection
Inspect &
Clean
Waterside
Inspect &
Condensate
Drain Trap
Inspect &
Clean
Air Filter
(59138)
Clean or
Replace
WARNING
CHAPTER 6 – MAINTENANCE
CHAPTER 6. MAINTENANCE
6.1 MAINTENANCE SCHEDULE
The Innovation Water Heater requires regular routine maintenance to ensure cont inued reliable
operation throughout the service life of the unit. For optimum operation, AERCO recommends
that the following routine maintenance procedures be performed in the time periods specified in
Table 6-1.
Appendix I contains a list of the recommended spare parts for maintenance of the Innovation
Heater.
TO AVOID PERSONAL INJURY, PRIOR TO SERVICING ENSURE THAT
THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED:
• DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE
SWITCH AND AC SUPPLY CIRCUIT BRE AKER.
• SHUT OFF THE GAS SUPPLY AT T HE MANUAL SHUT-OFF VALVE
PROVIDED WITH THE UNIT
• ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO
PREVENT BURNING OR SCALDING
Table 6-1 - Maintenance Schedule
Section Item 6 Mos. 12 Mos. 24 Mos.
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
(66023)
(66018)
Calibration
Inspection
Heat Exchanger
Cleaning
*Inspect Inspect Replace 15 mins.
*Inspect Inspect Replace 15 mins.
*Check Check 1 hr.
Test 20 mins.
*Inspect Inspect 1 hr.
*Inspect
Clean (as
required)
30 mins.
5 mins.
2 hrs.
2 hrs.
* Only performed after initial 6 month period after initial startup.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
FLAME
BLOWER SIDE
MANIFOLD
IGNITOR
FLAME
DETECTOR
FLAME DETECTOR
BURNER FLANGE
GASKET
OBSERVATION
IGNITOR
CHAPTER 6 – MAINTENANCE
6.2 IGNITER
The igniter is located on the flange of the blower-side intake m anifold located at the bottom of the
unit’s heat exchanger. The igniter part number (66023) is the same for Natural Gas and Propane
units. Figure 6-1 shows the blower-side intake manifold removed from the heater and indicates
the locations of the igniter, flame detector and other related components.
The igniter may be hot, therefore, care should be exercised to avoid burns. It is easier to remove
the igniter from the unit after the unit has cooled to room temperature.
DETECTOR
INTAKE
GASKET
PORT
Figure 6-1. Blower-Side intake Manifold With Igniter & Flame De tector
To inspect/replace the Igniter:
Igniter Inspection/Replacement
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit.
2. Remove the side and rear panels from the unit.
3. Disconnect the ignition cable and ground wire from the Igniter.
4. Next, loosen and remove the igniter from the intake manifold flange using a 1" open-end
wrench.
5. Check the igniter for evidence of erosion or carbon build-up. If there is evidence of
substantial erosion or carbon build-up, the igniter should be replaced. If carbon build-up is
present, clean the component using fine emery cloth. Repeated carbon build-up is an
indication that the combustion settings of the unit should be checked. Refer to Chapter 4 for
combustion calibration procedures.
6. Prior to reinstalling the igniter, a high temperature, conductive, anti-seize compound must
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be applied to the threads.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
BLOWER SIDE
IGNITOR
FLAME
DETECTOR
OBSERVATION
PORT
MOUNTING
SCREWS
FLAME
IGNITOR
CHAPTER 6 – MAINTENANCE
Igniter Inspection/Replacement – Continued
NOTE
If a replacement igniter is being installed, clocking (indexing) washers will be
included with the replacement part. These washers may be needed to
properly position the ground tab of the igniter to ensure that it is pointing
outward toward the perimeter of the intake manifold flange.
7. Refer to Figure 6-2 and reinstall the igniter on the intake manifold flange. Install clocking
washers as needed, to ensure that the igniter ground tab is pointing outward toward the
perimeter of the intake manifold flange. Torque to 15 ft-lbs. Do not over tighten.
DETECTOR
GASKET
8.
Figure 6-2. Igniter & Flame Detector Mounting Details
9. Reconnect the igniter cable and ground wire.
10. Reinstall the side and rear panels on the unit.
INTAKE
MANIFOLD
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CHAPTER 6 – MAINTENANCE
6.3 FLAME DETECTOR
Flame detector (part no. 66018) is used on ALL Innovation Water Heater Models. The flame
detector is also locat ed on the flange of the blower-side intake m anifold as shown in Figures 6-1
and 6-2. The flame detector may be hot. Allow the unit to cool sufficiently before removing the
flame detector.
To inspect or replace the flame detector:
66018 Flame Detector Inspection/Replacement
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit.
2. Remove the side and rear panels from the unit.
3. Disconnect the flame detector lead wire.
4. Remove the two (2) hex standoffs securing the flame detector to the intake manifold
(Figures 6-1 and 6-2). The flame detector is secured to the burner intake manifold with one
(1) #10-32 and one (1) #8-32 hex standoff.
5. Remove the flame detector and gasket from the manifold flange.
6. Thoroughly inspect the flame detector. If eroded, the detector should be replaced.
Otherwise, clean the detector with a fine emery cloth.
7. Reinstall the flame detector and flame detector gasket.
8. Reconnect the flame detector lead wire.
9. Reinstall the side and rear panels on the unit.
6.4 COMBUSTION CALIBRATION
Combustion settings must be checked at the intervals shown in Table 6-1 as part of the
maintenance requirements. Refer to Chapter 4 for combustion calibration instructions.
6.5 SAFETY DEVICE TESTING
Systematic and thorough tests of the operating and safety devices should be performed to ensure
that they are operating as designed. Also, certain code req uirements specify that these tests be
performed on a scheduled basis. Test schedules must conform to local jurisdictions. The results
of the tests should be recorded in a log book. See Chapter 5 for Safety Device Test Procedures.
6.6 FIRESIDE INSPECTION
Fireside inspection of the Innovation Water Heater will include removal of the exhaust manifold,
Blower-side intake manifold, and the burner assembly from the Innovation Water Heater.
The purpose of this inspection is to check for the formation of deposits on the inside of the heat
exchanger tubes, exhaust manifold, and/or the burner assembly. These deposits can be caused
by the presence of even trace amounts of chlorides and/or sulfur, in the combustion air and fuel
sources. Such deposits can be influenced by the extent of the condensing operation and the
chloride and sulfur levels that can vary significantly from application to application.
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CHAPTER 6 – MAINTENANCE
Since the fireside inspection will include removal of the exhaust manifold, burner assembly and
blower-side intake manifold from the Innovation W ater Heater, the following replacement gaskets
will be necessary for reassembly upon completion of the inspection:
Part No. Description
18899 Burner Flange Gasket
81150 Flame Detector Gasket
124749 Fiber Frax Gasket
161151 Combustion Chamber Liner (If damaged)
The blower-side intake manifold may be hot. Therefore, allow the unit to cool sufficiently before
starting the removal process described in the following steps.
Fireside Inspection
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit and turn off the gas supply.
2. Remove the side and rear panels from the unit. Also remove the bottom panel of the
cabinet to expose the mechanical room floor beneath the burner. This is need to provide
clearance for pulling the burner.
3. Refer to Figures 6-3 and 6-4 to locate the blower-side intake manifold (part no. 44106) at
the bottom of the unit's heat exchanger.
4. Disconnect the lead wire from the flame detector installed on the intake manifold flange
(Figure 6-2).
5. Remove the two (2) hex standoffs securing the flame detector to the intake manifold
(Figures 6-1 and 6-2). The flame detector is secured to the burner intake manifold with one
(1) #10-32 and one (1) #8-32 hex standoff.
6. Remove the flame detector and gasket from the blower side intake manifold flange.
7. Disconnect the cable from the igniter (66023), which is also installed on the blower-side
intake manifold flange.
8. Next, loosen and remove the igniter from the intake manifold flange using a 1" open-end
wrench.
9. Refer to Figure 6-3. Loosen and remove the four (4) 1/ 4-20 cap screws securing the blower
side of the intake manifold (44106). DO NOT REMOVE the two 1/4-20 screws and nuts
securing the manifold support bracket.
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CAUTION
EXHAUST
HEAT
BLOWER
5/16-18 HEX
CAP SCREWS
EXHAUST
CHAPTER 6 – MAINTENANCE
Fireside Inspection - Continued
EXCHANGER
MANIFOLD
SENSOR
SIDE
INTAKE
NUTS (6)
1/4-20 X 7/8” LG. (4)
PARTIAL RIGHT-SIDE VIEW (SUPPORT BRACKET REMOVED)
MANIFOLD
Figure 6-3. Blower-Side Intake Manifold & Exhaust Manifold Locations
The intake manifold, burner and exhaust manifold assemblies weigh
approximately 25 pounds. Use care when removing these assemblies in the
following steps.
10. While supporting the blower-side intake manifold, loosen and remove the six (6) 5/16-18
hex nuts securing it to the studs protruding from the exhaust manifold.
11. Carefully lower and remove the blower side intake manifold (44106), burner assembly
(46023), burner gasket (18899) and fiber frax gasket (124749) from the unit. See Figures 63 and 6-4.
12. Disconnect the exhaust temperature sensor (Figure 6-3) by unscrewing it from the exhaust
manifold.
13. While supporting the exhaust manifold, remove the two (2) side nuts (Figure 6-5) s ecuring
the manifold to the heat exchanger. Loosen, but do not remove the third nut nearest to the
front of the unit.
14. Remove the exhaust manifold (44085) from the unit.
15. Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as
necessary.
16. Using a flashlight, inspect the combustion chamber liner (161151) shown in Figure 6-6.
Replace the liner if there is evidence of cracking or warping.
17. This completes the fireside inspection of the unit. Proceed to step 18 and reas semble the
unit as indicated.
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BURNER
INTAKE
CONDENSATE
BURNER GASKET
FIBER FRAX GASKET
EXHAUST
5/16-18 STUDS
SIDE NUTS (2)
FRONT NUT
EXHAUST SENSOR
CHAPTER 6 – MAINTENANCE
Fireside Inspection - Continued
ASSEMBLY
46023
18899
SHIELD
49209
MANIFOLD
44106
124749
Figure 6-4. Innovation Heater – Partial Left-Side View
(1)
MANIFOLD
(6)
PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED
Figure 6-5. Innovation Heater – Partial Cut-Away View
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FIBER FRAX
BURNER
18899
BURNER
BURNER
ASSEMBLY
BURNER
ASSEMBLY
INTAKE
MANIFOLD
INTAKE
EXHAUST
MANIFOLD
CHAPTER 6 – MAINTENANCE
Fireside Inspection – Continued
FLANGE
GASKET
CONDENSATE
SHIELD 49209
GASKET
124749
MANIFOLD
BURNER, BLOWER AND EXHAUST MANIFOLD
Figure 6-6. Combustion Chamber Liner & Gasket Locations
IMPORTANT
Prior to reassembly, ensure that the combustion chamber liner is installed
before reinstalling the exhaust manifold.
During reassembly, apply high-temperature, anti-seize lubricant to the
threads of the igniter and grounding screw. Also, ensure that the igniter are
properly positioned and are not contacting other components. Torque the
igniter to 15 ft-lbs.
18. Beginning with the exhaust manifold assembly removed in step 14, reinstall all the
components in the reverse order that they were removed.
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CHAPTER 6 – MAINTENANCE
6.7 WATERSIDE INSPECTION
The waterside of the heating surfaces may be inspected by removal of the top heater head (see
Figure 6-7). Prior to performing the inspection, ensure that the following replacement gaskets are
available:
• GP-18556 Release Gasket
• GP-18532 Shell Gasket
To inspect the waterside of the heat exchanger, proceed as follows:
Waterside Inspection
1. Disconnect the electrical power to the unit.
2. Close the water inlet, outlet, and recirculation shut-off valves to the unit.
3. Carefully open the drain valve while opening the relief valve on the rear of the unit t o relieve
pressure and allow air into the shell.
4. Remove the wing nut from the top center of the shell cap and remove the cap.
5. Remove the nuts and cap screws from the upper head. Remove the upper head and upper
head-liner, (See Figure 6-7).
6. Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly
before reassembling the upper head. AERCO recommends that NEW gaskets be used
when reassembling.
7. Place a shell head gasket on top of the shell ring first, then place the release gasket on top
of the shell head gasket. Align the gasket holes with those in the shell ring.
8. Place the upper head liner on top of the gaskets.
9. Place the upper head on next aligning the holes.
10. Reassemble the cap screws and nuts through the upper head and shell ring. C ros s tig hte n
the nuts to approximately 75 ft.-lb. torque to obtain a uniform seating, then progressively
tighten the nuts to 150 ft.-lb.
11. Replace the unit Cap. Close the drain valve and reopen the inlet, outlet, and recirculation
valve.
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CAUTION
CAUTION
5/8-11 X 3-3/4” STUD
5/8-11 HEX NUT
UPPER HEAD
SHELL RING
HEAT EXCHANGER
UPPER HEAD LINER
HEAD RELEASE
HEAD GASKET
CHAPTER 6 – MAINTENANCE
(p/n 123077)
GASKET (p/n 18556)
(p/n 18532)
Figure 6-7. Flat Style Head Configuration
6.8 HEAT EXCHANGER CLEANING
AERCO recommends that the heat exchanger of the unit be cleaned annually to maintain
maximum heat transfer efficiencies using a solution of HydroSkrub and water. HydroSkrub is
distributed by AERCO International, Inc. and is designed to dissolve the toughest water scale,
lime, mud and rust deposits from virtually any type of water-based equipment.
Please review MSDS, specifications, and our website (www.aerco.com) for
additional information, or call technical service at (800) 526-0288.
Do not drain the unit without venting the shell! A vacuum in the unit may displace
the head liner causing serious damage not covered by warranty.
6.8.1 Pumping System Set-Up Instructions
A sample pumping set-up diagram is shown in Figur e 6-8 for an Innovation Water Heater. As this
diagram shows, heat exchanger cleaning is accomplished by pumping the HydroSkrub solution
from a large circulating bucket to the heat exchanger drain valve, through the heat exchanger and
then out through the output connection of the heater. Set up the pumping system as follows:
1. Turn off the water heater and close the inlet and outlet isolation valves.
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CHAPTER 6 – MAINTENANCE
Set-Up Instructions – Continued
2. Open the drain valve at the rear of the heater and drain at least half of the heat exchanger
water-side volume. When full Innovation models hold approximately the gallons of water
listed below:
• INN600: 24.5 gallons (drain at least 12.25 gallons)
• INN800 24.5 gallons (drain at least 12,25 gallons)
• INN1060: 23 gallons (drain at least 11.5 gallons)
• INN1350 20.6 gallons (drain at least 10.3 gallons)
For the Innovation model being cleaned, drain at least the amount of eater shown in
parentheses.
3. Prepare a 50% solution of HydroSkrub and clean water. The amount of the solution should
be approximately equal to the full volume of water that the heat exchanger holds.
4. Mix 11 gallons of HydroSkrub with 11 gallons of water to provide a 50% solution.
5. Close the unit drain valve and connect a suitable size bucket and pump to the unit drain as
shown in Figure 6-8.
6. Install a “T”, ball valve and hose connection in the outlet piping of the heater (Figure 6-8).
Route the hose back to the top of the circulation bucket.
Figure 6-8. Sample Heat Exchanger Cleaning Set-Up
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CHAPTER 6 – MAINTENANCE
6.8.2 Cleaning Procedure
Cleaning Procedure
1. Slowly add the prescribe amount of the HydroSkrub solution to the circulating bucket.
2. Open the drain valve, outlet hose connection valve and turn on the pump. Periodically
check for leaks and maintain the liquid level in the bucket. A lowering volume level is an
indication that there is an open drain in the system.
3. Check the cleaning circuit to ensure that the HydroSkrub solution is flowing from the
circulation bucket, through the pump and the heater and back to the top of the top of the
bucket.
4. Return discharge foaming indicates an active HydroSkrub solution and the presence of
mineral deposits in the equipment.
5. Additional HydroSkrub and/or water may be required to maintain circulation and to prevent
the pump from cavitating.
6. Circulate the cleaning solution through the heat exchanger and piping for 1 to 3 hours.
Estimate the circulation period based on the time in service and water hardness. When the
foaming action stops, HydroSkrub strength is depleted (two pounds of deposits removed
per gallon used) or the equipment is free from calcium and other water-formed mineral
deposits.
7. Periodically test the solution for effectiveness to determine if more HydroSkrub is needed.
Refer to “Testing HydroSkrub Effectiveness” in the next section for details. If the cleaning
solution is expended before circulation time is up, additional HydroSkrub will be needed and
circulation time may be extended to complete the cleaning.
8. Upon completion of the cleaning process, begin flushing the solution by adding clean water
to the circulation bucket, then disconnect the return valve and hose connection from the top
of the circulating bucket and thoroughly flush. Continue water flushing the equipment for a
minimum of 10 minutes or until discharge runs clear.
9. HydroSkrub is biodegradable, and in most instances may be purged down sewers. Check
with local authorities before disposing of any complex compositions
10. Turn off water, shut off the pump and immediately close discharge valves to prevent
backflow.
11. Completely drain pump bucket. Disconnect the hoses from equipment and thoroughly rinse
the bucket, pump, and associated hoses used.
6.8.3 Testing HydroSkrub Effectiveness
There are two methods of testing the effectiveness of HydroSkrub during cleaning: the calcium
carbonate spot test of the circulating solution and the chart ing of a trend in the pH of the cleaning
solution.
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CHAPTER 6 – MAINTENANCE
Calcium Carbonate Spot Test
A calcium carbonate spot test is performed by exposing a form of calcium carbonate t o the
HydroSkrub solution. Samples of the deposit, a Tums or Rolaids tablet, or bare concrete
can be used. Observe the reaction of the HydroSkrub solution on the calcium carbonate.
Foaming and bubbling indicates the solution is still active. Little or no reaction indicates that
the solution is expended. This test should be performed near the end of the circulating time.
If the solution has been expended, more HydroSkrub 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
HydroSkrub packaging). To test the effectiveness of the circulating solution as a function of
pH, take readings at regular intervals and chart as a trend. Note that the deposits can
cause a premature jump in the pH. After circulating for approximately 75% of the cycle time,
begin testing the pH at 10-15 minute intervals. Once the solution’s pH reads 6.0-7.0 on
three or more consecutive readings, the solution is expended. If the pH reads below 6.0
after the circulating time, the application is clean.
6.9 CONDENSATE DRAIN TRAP
The Innovation Water Heater contains a condensate trap as shown in Chapter 2, Figure 2-7. The
trap is located external to the unit and attached to the drain connection from the exhaust
manifold. This trap should be inspected and, if necessary, cleaned to ensure proper operation.
.
Currently, two styles of the condensate traps are in use. Both styles perf orm the same functions
and contain identical internal floats. However, the older style has a separate inlet adapter and the
newer style contains a built-in adapter. Refer to Figure 6-9. Maintenance tasks for both styles are
basically identical, however the newer style does not require an orifice gasket.
To inspect and clean the trap, proceed as follows:
Condensate Trap Inspection and Cleaning
1. Disconnect the external condensate trap by loosening the union pipe connection between
the trap and the exhaust manifold drain.
2. Remove the connections on the inlet and outlet sides of the condensate trap shown in
Figure 6-9.
3. Loosen the four (4) thumbscrews securing the cover on the condensate trap. Remove the
cover.
4. Remove the float from the condensate trap.
5. For older style condensate traps, remove the orifice gasket shown in Figure 6-9.
6. Thoroughly clean the trap, float and orifice gasket (if so equipped). Also inspect the drain
piping for blockage. If the trap cannot be thoroughly cleaned, replace the trap.
7. After the above items have been thoroughly cleaned and inspected, replace the orifice
gasket (older style only) and the float in the condensate trap and replace the trap cover.
8. Reassemble all piping and hose connections to the condensate trap inlet and outlet.
Reconnect the trap to exhaust manifold drain.
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Orifice
Thumb Screws
(4)
Thumb Screws
(4)
Condensate
Float
Float Guide
Thumb
Screw
O-Rings
NEWER STYLE TRAP
OLDER STYLE TRAP
Adapter
Opening
3/4" NPT Port
3/4" NPT Port
INLET
OUTLET
INLET
OUTLET
CHAPTER 6 – MAINTENANCE
Trap O-Ring
(2)
Figure 6-9. External Condensate Trap– Cross-Sections
Gasket
6.10 AIR FILTER REPLACEMENT
The Innovation heater is equipped with an air filter (part no. 59138) which should be cleaned or
replaced every 12 months. The air filter is located at the inlet of the air fuel valve as shown in
Figure 6-10.
To inspect/replace the air filter, proceed as follows:
Air Filter Replacement
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit
2. Remove the side panels from the unit.
3. Refer to Figure 6-10 and locate the air filter attached to the air/fuel valve inlet.
4. 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. Remove the filter and clamp.
5. Each replacement air filter is equipped with its own clamp. Therefore, simply install the
replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat-tip
screwdriver or 5/16” nut driver.
6. Replace the side panels on the unit and return heater to service use.
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BARE HEATER – PARTIAL FRONT VIEW
AIR FILTER
FILTER CLAMP
AIR/FUEL
VALVE
CHAPTER 6 – MAINTENANCE
BLOWER
MOTOR
Figure 6-10. Air Filter Mounting Location
6.11 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME
If the heater is to be taken out of service for an extended period of time (one year or more),
complete the following instructions.
Extended Period Shut-Down
1. Set ON/OFF switch on the front panel to the OFF position to shut down the heater’s
operating controls.
2. Disconnect AC power from the unit.
3. Close the water inlet and outlet valves to isolate unit.
4. Close external gas supply valve.
5. Open relief valve to vent water pressure.
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CHAPTER 6 – MAINTENANCE
6.12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGE D SHUTDOWN
After a prolonged shutdown (one year or more), the following procedures must be followed:
Placing Heater Back In Service After Prolonged Shutdown
1. Review installation requirements included in Chapter 2.
2. Inspect all piping and connections to the unit.
3. Inspect exhaust vent, air duct (if applicable).
4. Perform initial startup per Chapter 4.
5. Perf o rm s af ety device testing and scheduled maintenance procedures per Chapters 5 and
6 of this manual.
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CHAPTER 7 – TROUBLESHOOTING GUIDE
CHAPTER 7. TROUB LE S H O OTI NG GU I D E
7.1 INTRODUCTION
This troubleshooting guide is intended to aid service/maintenance personnel in isolating the
cause of a fault in a Innovation Water Heater. The troubleshoot ing proc edures cont ained 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. The numbered items
in the Probable Cause and Corrective Action columns correspond to each other. For example,
Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.
NOTE
The front panel of the C-More Control Box contains an RS232 port which
can be interfaced to a laptop computer or other suitable device. This
RS232 communication feature permits service personnel to view menu
items and data logs which can be useful in isolating faults. Refer to Chapter
7 of this manual for detailed RS232 communication set-up and procedures.
When a fault occurs in the unit, proceed as follows to isolate and correct the fault:
General Troubleshooting Instructions
1. Observe the fault messages displayed in the Control Box display.
2. Refer to the Fault Indication column in Troubleshooting Table 7-1 which follows and locate
the Fault that best describes the existing conditions.
3. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault
Indication.
4. Perform the checks and procedures listed in the Corrective Action column for the first
Probable Cause candidate.
5. Continue checking each additional Probable Cause for the existing fault until the fault is
corrected.
6. Section 7.2 and Table 7-2 contain additional troubleshooting information which may apply
when no fault message is displayed.
If the fault cannot be corrected using the information provided in the Troubleshooting Tables,
contact your local AERCO Representative.
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CHAPTER 7 – TROUBLESHOOTING GUIDE
(This Page Is Intentionally Blank)
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
Blower stopped running due to thermal
Check combustion blower for signs of excessive heat or high
should match the dial readings on the Air/Fuel Valve dial.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG
AIRFLOW FAULT
DURING IGNITION
1.
or current overload
2. Blocked Blower inlet or inlet ductwork
3. Blocked Blower proof switch
4. Blocked blocked-air inlet switch
5. Defective Blower proof switch
6. Defective blocked-air inlet switch
7. Loose temperature to AUX connection in
I/O Box
8. Defective temperature sensor
9. Loose wire connection between the 0-
10V signal from I/O box to the Blower
Motor input
10. Defective I/O box
11. Wrong 0-10V output selection on the
control box
12. Defective Air-Fuel Valve potentiometer
1.
current drain that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower including any
ductwork leading up to the combustion blower for signs of
blockage.
3. Remove the Blower proof switch and inspect for signs of
blockage, clean or replace as necessary.
4. Remove the blocked-air inlet switch and inspect for signs of
blockage, clean or replace as necessary.
5. Measure the Blower proof switch for continuity with the
combustion blower running. If there is an erratic resistance
reading or the resistance reading is greater than zero ohms,
replace the switch.
6. Measure the blocked-air inlet switch for continuity with the
combustion blower running. If there is an erratic resistance
reading or the resistance reading is greater than zero ohms,
replace the switch.
7. Check the actual inlet air temperature and measure voltage at
AUX input in the I/O Box. Verify that the voltage conforms to the
values shown in the tabular listing provided in Appendix C.
8. Refer to CORRECTIVE ACTION 7 and verify that the voltage
conforms to the values shown in Appendix C.
9. Check wire connection from I/O Box 0-10V signal to the Blower
Motor.
10. Measure voltage at the I/O box 0-10V output. A voltage of 8.2V
equates to a 100% open valve position.
11. Check the Analog Out option on the C-More Configuration
Menu. Valve Position 0-10V should be selected.
12. Check Air/Fuel Valve position at 0%, 50% and 100% open
positions. The positions on the VALVE POSITION bargraph
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
applies for this fault
applies for this fault
FAULT DURING IGNITION.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
AIRFLOW FAULT
DURING PURGE
AIRFLOW FAULT
DURING RUN
1. Blower not running or running too slow
2. Defective Air Flow Switch
3. Blocked Air flow Switch
4. Blocked Blower inlet or inlet ductwork.
5. No voltage to switch from control box.
6. PROBABLE CAUSES from 3 to 12 for
AIRFLOW FAULT DURING IGNITION
1. Blower stopped running due to thermal
or current overload
2. Blocked Blower inlet or inlet ductwork
3. Blocked airflow switch
4. Defective airflow switch
5. Combustion oscillations
6. PROBABLE CAUSES from 3 to 16 for
AIRFLOW FAULT DURING IGNITION
1. Start the unit. If the blower does not run check the blower
solid state relay for input and output voltage. If the relay is
okay, check the blower.
2. Start the unit. If the blower runs, check the airflow switch for
continuity. Replace the switch if there is no continuity.
3. Remove the air flow switch and inspect for signs of blockage,
clean or replace as necessary.
4. Inspect the inlet to the combustion blower including any
ductwork leading up to the combustion blower for signs of
blockage.
5. Measure for 24 VAC during start sequence from each side of
the switch to ground. If 24VAC is not present refer to qualified
service personnel.
6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW
FAULT DURING IGNITION.
1. Check combustion blower for signs of excessive heat or high
current draw that may trip thermal or current overload
devices.
2. Inspect the inlet to the combustion blower including any
ductwork leading up to the combustion blower for signs of
blockage.
3. Remove the airflow switch and inspect for signs of blockage,
clean or replace as necessary.
4. Measure the airflow switch for continuity with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the
switch.
5. Run unit to full fire. If the unit rumbles or runs rough, perform
combustion calibration.
6. See CORRECTIVE ACTIONS from 3 to 16 for AIRFLOW
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
interlock)
and reinstall.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
DELAYED
INTERLOCK OPEN
FLAME LOSS
DURING IGN
1. Delayed Interlock Jumper not
installed or removed.
2. Device proving switch hooked to
interlocks is not closed
1. Burner Ground Screw not installed
or loose.
2. Worn flame detector
3. No spark from Spark Plug
4. Defective Ignition Transformer
5. Defective Ignition/Stepper (IGST)
Board
6. Defective SSOV
7. Carbon or other debris on Burner.
1. Check for a jumper properly installed across the delayed
interlock terminals in the I/O box.
2. If there are 2 external wires on these terminals, check to see if
an end switch for a device such as a pump, louver, etc. is tied
these interlocks. Ensure that the device and or its end switch
are functional. (jumper may be temporarily installed to test
1. Inspect and install/retighten Burner Ground Screw.
2. Remove and inspect the flame detector for signs of wear.
Replace if necessary.
3. Close the internal gas valve in the unit. Install and arc a spark
ignitor outside the unit.
4. If there is no spark, check for 120VAC at the primary side to the
ignition transformer during the ignition cycle.
5. If 120VAC is not present, the IGST Board in the Control Box
may be defective. Refer fault to qualified service personnel.
6. While externally arcing the spark ignitor, observe the
open/close indicator in the Safety Shut-Off Valve to ensure it is
opening. If the valve does not open, check for 120VAC at the
valves input terminals. If 120VAC is not present, the IGST
board in the Control Box may be defective. R efer faul t to
qualified service personnel.
7. Remove the burner and inspect for any carbon or debris. Clean
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
5. Remove blockage in condensate drain.
Demand
2. Heat exchanger has scale.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
FLAME LOSS
DURING RUN
HEAT DEMAND
FAILURE
HIGH EXHAUST
TEMPERATURE
HIGH GAS
PRESSURE
1. Worn Flame Detector or cr acked
ceramic.
2. Defective Regulator.
3. Poor combustion calibration.
4. Debris on burner.
5. Blocked condensate drain.
1. The Heat Demand Relays on the
Ignition/Stepper board failed to
activate when commanded.
2. Relay is activated when not in
1. Poor combustion calibration
1. Incorrect supply gas pressure.
2. Defective SSOV Actuator.
3. Defective High Gas Pressure
Switch
1. Remove and inspect the Flame Detector for signs of wear
or cracked ceramic. Replace if necessary.
2. Check gas pressure readings using a gauge or
manometer into and out of the Air/Fuel Valve to ensure
that the gas pressure into and out of the valve is correct.
3. Check combustion calibration. Adjust as necessary.
4. Remove the burner and inspect for any carbon or debris.
Clean and reinstall.
1. Press CLEAR button and restart the unit. If the fault
persists, replace Ignition/Stepper (IGST) Board.
2. Defective relay. Replace IGST Board.
1. Check combustion calibration using procedures in
Chapter 4.
2. Clean heat exchanger using procedures in Chapter 6.
1. Check to ensure gas pressure at inlet of SSOV is 2 psig
maximum.
2. If gas supply pressure downstream of SSOV Actuator
cannot be lowered to below 3.0” W.C. using the gas
pressure adjustment screw (see
section 4.3, step 10), the
SSOV Actuator may be defective.
3. Remove the leads from the high gas pressure switch and
measure continuity across the common and normally
closed terminals with the unit not firing. Replace the
switch if it does not show continuity.
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
respond.
than what the units can respond to.
2. Temp HI Limit setting is too low.
2. Check Temp HI Limit setting.
Ignition/Stepper (IGST) board
replace the switch.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
HIGH WATER TEMP
SWITCH OPEN
HIGH WATER
TEMPERATURE
IGN BOARD
COMM FAULT
1. Faulty Water temperature switch.
2. Incorrect PID settings.
3. Faulty shell temperature sensor.
4. Unit in Manual mode
5. Unit setpoint is greater than Over
Temperature Switch setpoint.
6. System flow rate changes are
occurring faster than units can
1. See HIGH WATER TEMPERATURE
SWITCH OPEN.
1. Communication fault has occurred
between the PMC board and
1. Test the temperature switch to insure it trips at its actual
water temperature setting.
2. Check PID settings against Menu Default settings in the
Appendix. If the settings have been changed, record the
current readings then reset them to the default values.
3. Using the resistance charts in the Appendix C, Measure the
resistance of Shell sensor and BTU sensor at a known water
temperature.
4. If unit is in Manual Mode switch to Auto Mode.
5. Check setpoint of unit and setpoint of Temperature Switch;
Ensure that the temperature switch is set higher than the
unit’s setpoint.
6. If the system is a variable flow system, monitor system flow
changes to ensure that the rate of flow change is not faster
1. See HIGH WATER TEMPERATURE SWITCH OPEN.
1. Press CLEAR button and restart unit. If fault persists,
contact qualified Service Personnel.
IGN SWTCH CLOSED
DURING PURGE
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1. Air/Fuel Valve not rotating
2. Defective or shorted switch
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position. If the valve does not rotate at all or does not
rotate fully open, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air-Fuel Valve
or the Control Box. Refer to qualified service personnel
2. If the Air/Fuel Valve does rotate to purge, check the ignition
switch for continuity between the N.O. and COM terminals. If
the switch shows continuity when not in contact with the cam
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
OFF every second. If not, replace IGST Board
interlock circuit is closing and that the device is operational.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
(continued) 3. Switch wired incorrectly
4. Defective Power Supply Board or
fuse
5. Defective IGST Board
IGN SWTCH OPEN
DURING IGNITION
1. Air/Fuel Valve not rotating to
ignition position.
2. Defective ignition switch
3. Defective Power Supply Board or
fuse
4. Defective IGST Board
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals). If the switch is
wired correctly, replace the switch
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are
not steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON &
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to
the ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve
or the Control Box. Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check
the ignition position switch for continuity between the N.O.
and COM terminals when in contact with the cam.
3. Check DS1 & DS2 LEDs on Power Supply Board. If they are
not steady ON, replace Power Supply Board.
4. Check “Heartbeat” LED DS1 and verify it is blinking ON &
OFF every second. If not, replace IGST Board.
INTERLOCK
OPEN
1. Interlock jumper not installed or
removed
2. Energy Management System
does not have unit enabled.
1. Check for a jumper properly installed across the interlock
terminals in the I/O box.
2. If there are two external wires on these terminals check any
Energy Management system to see if they have the units
disabled (a jumper may be temporarily installed to see if the
interlock circuit is functioning).
3. Device proving switch hooked to
3. Check that proving switch for any device hooked to the
interlocks is not closed.
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
transformer wiring.
box transformer wiring diagram to ensure it is wired correctly.
and replace if necessary.
is no continuity.
Unit not seeing information from
(correct wire numbers on the normally open terminals).
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHO OTING – Continued
LINE VOLTAGE
OUT OF PHASE
LOW GAS
PRESSURE
LOW WATER
LEVEL
MODBUS COMM
FAULT
PRG SWTCH CLOSED
DURING IGNITION
1. Line and Neutral switched in AC
Power Box.
2. Incorrect power supply
1. Incorrect supply gas pressure.
2. Defective Low Pressure Gas
Switch.
1. Insufficient water level in system.
2. Defective water level circuitry.
3. Defective water level probe.
Modbus network
1. A/F Valve rotated open to purge
and did not rotate to ignition
position.
2. Defective or shorted switch.
1. Check hot and neutral in AC Power Box to ensure they are not
reversed.
2. Check transformer wiring, in AC Power Box, against the power
1. Measure gas pressure upstream of the SSOV Actuator(s) with
the unit firing. For both FM and DBB gas trains, ensure it is
between 4.0” W.C. and 14” W.C. (see section 2.10.1).
2. Measure gas pressure at the low gas pressure switch. If it is
greater than 2.6” W.C., measure continuity across the switch
1. Check system for sufficient water level.
2. Test water level circuitry using the Control Box front panel LOW
WATER TEST and RESET buttons. Replace water level
circuitry if it does not respond.
3. Check continuity of probe end to the shell, change probe if there
Check network connections. If fault persists, contact qualified
Service Personnel.
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to the
ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve or
the Control Box. Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check
the purge switch for continuity between the N.O. and COM
terminals. If the switch shows continuity when not in contact
with the cam, check to ensure that the switch is wired correctly
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
every second. If not, replace IGST Board.
every second. If not, replace IGST Board.
3. Incorrect Sensor.
3. Ensure that the correct sensor is installed.
7. Replace recirculation pump.
type (voltage or current).
Configuration Menu.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
(continued) 3. Switch wired incorrectly.
4. Defective Power Supply Board or
fuse
5. Defective IGST Board
PRG SWTCH OPEN
DURING PURGE
OUTDOOR TEMP
SENSOR FAULT
RECIRC PUMP FAILURE 1. Internal recirculation pump failed.
REMOTE SETPT
SIGNAL FAULT
1. Defective purge switch.
2. No voltage present at switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or
fuse
5. Defective IGST Board
1. Loose or broken wiring.
2. Defective Sensor.
1. Remote setpoint signal not present:
Not yet installed.
Wrong polarity.
Signal defective at source.
Broken or loose wiring.
2. Signal is not isolated (floating) if 4 to
20 mA.
3. Control Box signal type selection
switches not set for correct signal
3. If the switch is wired correctly, replace the switch.
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
1. If the air-fuel valve does rotate, check purge switch for continuity
when closing. Replace switch if continuity does not exist.
2. Measure for 24 VAC from each side of the switch to ground. If
24VAC is not present, refer fault to qualified service personnel.
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
1. Inspect Outdoor Temperature sensor for loose or broken wiring.
2. Check resistance of sensor to ensure it is within specification.
1. Check I/O Box to ensure signal is hooked up.
Hook up if not installed.
If installed, check polarity.
Measure signal level.
Check continuity of wiring between source and unit.
2. Check signal at source to ensure it is isolated.
3. Check DIP switch on PMC board to ensure it is set correctly for
the type of signal being sent. Check control signal type set in
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FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
2. Replace Flame Detector.
PURGE
15 seconds
3. Hot and Neutral reversed at SSOV.
3. Check SSOV power wiring.
4. Incorrectly wired switch.
4. Ensure that the SSOV Proof of Closure switch is correctly wired.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTI NG – Continued
RESIDUAL
FLAME
SSOV FAULT DURING
SSOV FAULT
DURING RUN
SSOV RELAY
FAILURE
SSOV
SWITCH OPEN
1. SSOV not fully closed.
2. Defective Flame Detector
See SSOV SWITCH OPEN
SSOV switch closed for
during run.
1. SSOV relay failed on IGST board.
2. Floating Neutral.
1. Actuator not allowing for full
closure of gas valve
2. SSOV powered when it should not
be
3. Defective Switch or Actuator
1. Check open/close indicator window of Safety Shut-Off Valve
(SSOV) and ensure that the SSOV is fully closed. If not fully
closed, replace the valve and or actuator.
Close the 1” Gas Shut-Off Valve downstream of SSOV (Figure 7-
1). Install a manometer or gauge at the leak detection port
between the SSOV and Gas Shut Off Valve. If a gas pressure
reading is observed replace the SSOV Valve and/or Actuator.
Replace or adjust microswitch in SSOV actuator. If fault persists,
replace actuator.
1. Press CLEAR button and restart unit. If fault persists, replace
Ignition/Stepper (IGST) Board.
2. 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.
1. Observe operation of the Safety Shut-Off Valve (SSOV) through
indicator on the Valve actuator and ensure that the valve is fully
and not partially closing.
2. If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
qualified service personnel.
3. Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas
valve closed, either adjust or replace the switch or actuator.
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OFF every second. If not, replace IGST Board.
2. Clean heat exchanger using procedures in Chapter 6.
CHAPTER 7 – TROUBLESHOOTING GUIDE
TABLE 7-1. WATER HEATER TROUBLESHOOTING – Continued
STEPPER MOTOR
FAILURE
1. Air/Fuel Valve out of calibration.
Air/Fuel Valve unplugged.
2.
3.
Loose wiring connection to the
stepper motor.
4. Defective Air/Fuel Valve stepper
motor.
5. Defective Power Supply Board or
fuse
6. Defective IGST Board
1. Perform Stepper Test per GF-112 (para. 6.3.5) to ensure
stepper motor rotates properly from 0% (fully closed) to
100% (fully open) positions. Verify VALVE POSITION
bargraph and dial on the Air/Fuel Valve track each other to
indicate proper operation. If operation is not correct,
perform the Stepper Feedback Calibration (GF-112,
section 6.2.1).
2. Check that the Air/Fuel Valve is connected to the Control
Box.
3. .Inspect for loose connections between the Air/Fuel Valve
motor and the wiring harness.
4. Replace stepper motor.
5. Check DS1 & DS2 LEDs on Power Supply Board. If they
are not steady ON, replace Power Supply Board.
6. Check “Heartbeat” LED DS1 and verify it is blinking ON &
WARNING EXHAUST
1. Poor combustion calibration
TEMP HIGH
Heat exchanger has scale.
(Flashing WARNING)
2.
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1.
Check combustion calibration using procedures in Chapter
4.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
OBSERVED INCIDENT
PROBABLE CAUSES
CORRECTIVE ACTION
Actuator).
the 80% Valve Position
in Control Box are outdated.
are Rev. E or higher.
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 TROUBLESHOOTI NG WI TH NO FAULT MESSAGE DISPLAYED
Fluctuating Gas Pressure 1. Gas pressure going into unit is
fluctuating.
2. Damping Orifice not installed.
Air/Fuel Valve “hunting” at
1. IGST and Power Supply Boards
1. Stabilize gas pressure going into unit. If necessary,
troubleshoot Building Supply Regulator.
2. Check to ensure that the Damping Orifice is installed in the
SSOV Actuator shown in Figure 7-3. (For DBB Gas Trains,
the Damping Orifice is installed in the downstream SSOV
1. Check to ensure that the IGST and Power Supply Boards
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MANUAL
SSOV
TO AIR/FUEL
VALVE
GAS INLET
FLAME
BLOWER SIDE
MANIFOLD
IGNITOR
FLAME
DETECTOR
FLAME DETECTOR
BURNER FLANGE
GASKET
OBSERVATION
IGNITOR
CHAPTER 7 – TROUBLESHOOTING GUIDE
HIGH GAS PRESSURE
SWITCH
LEAK
DETECTION
BALL VALVE
SHUTOFF
VALVE
DETECTOR
LOW GAS
PRESSURE SWITCH
Figure 7-1. Gas Train Component Locations
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INTAKE
GASKET
PORT
Figure 7-2. Blower-Side Intake Manifold (Shown removed from Heater)
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