Innovation Water Heaters Installation, Operation & Maintenance Manual
INNOVATION Series
Natural Gas or Propane
Modulating, Condensing
Water Heater Models
Applicable to Serial Number
G-14-2265 and above
This guide applies to the
following Innovation models
• Innovation 600
• Innovation 800
• Innovation 1060
• Innovation 1350
USER MANUAL
Installation, Opera ti on and Maintenance
Gas-Fired Water Heaters
Other documents for this
product include:
• GF-5030 INN-Recon Gas Supply Guide
• GF-5050 INN-Recon Venting Guide
• GF-5060 INN-Recon Elect. Power Guide
• GF-5080 INN Sizing Guide
Latest Update: 11/25/2014
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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 contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to t his mater ial, including
but not limited to implied warranties of merchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual. Nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of t his
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 .....................................23
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 .................................................................................................................. 30
2.12.4 SPARK SIGNAL Terminals .............................................................................................................. 30
2.12.5 ANALOG IN Terminals .................................................................................................................. 31
2.12.6 VALVE FEEDBACK 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
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2.14.2 Combustion Air from Inside the Building ..................................................................................... 34
2.15 DUCTED COMBUSTION ..................................................................................................35
CHAPTER 3. OPERATION .............................................................................................................. 37
3.1 INTRODUCTION.................................................................................................................37
3.2 CONTROL PANEL DESCRIPTION .....................................................................................37
3.3 CONTROL PANEL MENUS ................................................................................................41
3.3.1 Menu Processing Procedure .......................................................................................................... 41
3.4 OPERATING MENU ...........................................................................................................43
3.5 SETUP MENU ....................................................................................................................44
3.6 CONFIGU R ATION MENU ...................................................................................................44
3.7 TUNING MENU ...................................................................................................................46
3.8 CALIBRATION MENU .........................................................................................................47
3.9 START SEQUENCE ...........................................................................................................49
3.10 START/STOP LEVELS .....................................................................................................52
CHAPTER 4. INITIAL START-UP .................................................................................................. 53
4.1 INITIAL START-UP REQUIREMENTS ................................................................................53
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION...........................53
4.2.1 Required Tools & Instrumentation ................................................................................................. 53
4.2.2 Installing Gas Supply Manometer .................................................................................................. 54
4.2.3 Accessing the Analyzer Probe Port ................................................................................................. 55
4.2.4 Connecting Multimeter to Flame Detector .................................................................................... 55
4.2.5 Recommendations for Temperature Calibration ........................................................................... 56
4.2.6 Recommendations for WHM (Water Heater Management) Operation ........................................ 56
4.3 NATURAL GAS COMBUSTION CALI BRAT IO N .................................................................57
4.4 PROPANE COMBUSTION CALIBRATION .........................................................................59
4.5 REASSEMBLY ....................................................................................................................61
4.6 TEMPERATURE CONTROL CALI BRAT ION ......................................................................62
4.6.1 Setting the Outlet Water Temperature Setpoint ........................................................................... 63
4.6.2 Minimum Load Adjustment............................................................................................................ 63
4.6.3 Maximum Load Adjustment ........................................................................................................... 64
4.7 OVER-TEMPERATURE LIMIT SWITCHes .........................................................................65
CHAPTER 5. SAFETY DEVICE TESTING ..................................................................................... 67
5.1 INTRODUCTION.................................................................................................................67
5.2 LOW GAS PRESSURE FAULT TEST .................................................................................67
5.3 HIGH GAS PRESSURE FAULT TEST ................................................................................68
5.4 LOW WATER LEVEL FAULT TEST ....................................................................................69
5.5 WATER TEMPERATURE FAULT TEST .............................................................................69
5.6 INTERLOCK TESTS ...........................................................................................................70
5.6.1 Remote Interlock ............................................................................................................................ 70
5.6.2 Delayed Interlock ........................................................................................................................... 71
5.7 FLAME FAULT TESTs ........................................................................................................71
5.8 AIR FLOW FAULT TESTS ..................................................................................................72
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5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................74
5.10 PURGE SWITCH OPEN DURING PURGE .......................................................................75
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................75
5.12 SAFETY PRESSURE RELIEF VALVE TEST ....................................................................76
CHAPTER 6. MAINTENANCE ......................................................................................................... 77
6.1 MAINTENANCE SCHEDULE ..............................................................................................77
6.2 IGNITER -INJECTOR ..........................................................................................................78
6.3 FLAME DETECTOR ...........................................................................................................80
6.4 COMBUSTION CALIBRATION ...........................................................................................80
6.5 SAFETY DEVICE TESTING ...............................................................................................80
6.6 FIRESIDE INSPECTION .....................................................................................................80
6.7 WATERSIDE INSPECTION ................................................................................................85
6.7.1 Anode Replacement ....................................................................................................................... 86
6.8 HEAT EXCHANGER CLEANING ........................................................................................87
6.8.1 Pumping System Set-Up Instructions ............................................................................................. 88
6.8.2 Cleaning Procedure ........................................................................................................................ 89
6.8.3 Testing HydroSkrub Effectiveness .................................................................................................. 89
6.9 CONDENSATE DRAIN TRAP .............................................................................................90
6.10 AIR FILTER REPLACEMENT ...........................................................................................91
6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ...................................92
6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................ 93
6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test ..................................................................... 95
6.12 SHUTTING THE WATER HEATER DOW N FOR AN EXTENDED PERIOD OF TIME ......95
6.13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ......96
CHAPTER 7. TROUBLESHOOTING GUIDE ................................................................................ 97
7.1 INTRODUCTION.................................................................................................................97
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................. 109
CHAPTER 8. WATER HEATER MANAGEMENT .................................................................... 113
8.1 GENERAL DESCRIPTION ................................................................................................ 113
8.2 WHM PRINCIPLES OF OPERATION ............................................................................... 114
8.3 NEW AERCO WHM FEATURES ...................................................................................... 114
8.3.1 Valve Feedback ............................................................................................................................. 114
8.3.2 Valve Supervisor ........................................................................................................................... 114
8.3.3 Valve Control ................................................................................................................................ 114
8.3.4 Modbus Header Sensor ................................................................................................................ 115
8.3.5 Automatic Temperature Sensor Calibration ................................................................................ 115
8.3.6 Manual Mode Password Required ............................................................................................... 115
8.3.7 Quick Re-Flash Feature ................................................................................................................. 115
8.3.8 WHM Auto Mstr ........................................................................................................................... 116
8.3.9 Run Hours and Run Cycles ............................................................................................................ 116
8.3.10 High Temperature Governor ...................................................................................................... 116
8.4 WHM STATUS DISPLAYS ................................................................................................ 116
8.5 BST ALTERNATING STATUS DISPLAYS ........................................................................ 117
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8.6 WHM MENU ..................................................................................................................... 117
8.7 WHM MENU ITEM DESCRIPTIONS ................................................................................. 119
8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIO NS .................................... 123
8.8.1 Hardware Installation ................................................................................................................... 123
8.8.2 WHM Modbus Network Wiring .................................................................................................... 124
8.8.3 Control and Power Wiring ............................................................................................................ 125
8.9 WHM PROGRAMMING & START-UP .............................................................................. 127
8.10 TROUBLESHOOTING .................................................................................................... 129
8.11 SEQUENCING VALVE DESCRIPTION & OPERATI ON ................................................. 129
8.11.1 Sequencing Valve Description .................................................................................................... 129
8.11.2 Sequencing Valve Operating Characteristics.............................................................................. 132
APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS ................................................ 133
Table A-1: Operating Menu Item Descriptions ......................................................................... 133
Table A-2: Setup Menu Item Descriptions ............................................................................... 134
Table A-3: Configuration Menu Item Descriptions ................................................................... 135
Table A-4: Tuning Menu Item Descriptions ............................................................................. 137
Table A-5: Calibration Menu Item Descriptions ....................................................................... 139
APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES ............................................. 143
APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART ..................... 147
APPENDIX D – DIMENSIONAL DRAWINGS ......................................................................... 149
APPENDIX E – PARTS LIST DRAWINGS .............................................................................. 151
APPENDIX F – PIPING DRAWINGS ...................................................................................... 173
APPENDIX G – C-MORE CONTROL PANEL VIEWS ............................................................. 187
APPENDIX H – C-MORE WIRING DIAGRAMS ..................................................................... 189
APPENDIX I – RECOMMENDED SPARES ............................................................................ 197
APPENDIX J – COMBUSTION CALIBRATION (KOREA ONLY) ............................................ 199
APPENDIX K – WARRANTY ................................................................................................. 203
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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 f urnished 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
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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Phrase, Abbreviation
or Acronym
A (Amp)
Ampere
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
BAS
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
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 Control Box
INN
Innovation Water Heater
INTLK (INTL’K)
Interlock
I/O
Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
FORWARD
Phrases, abbreviations and acronyms used in this manual are listed in the following table:
PHRASES, ABBREVIATIO NS AND ACRONYMS
Meaning
(signaling events) transmitted per second. It is not equal to bits per
DBB
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
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
Modbus®
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
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
RS232
(or EIA-232)
A standard for serial, f ull-duplex (FDX) transmission of data based on
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
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network in
order to prevent reflections that may cause invalid data in the
communication
FORWARD
PHRASES, ABBREVIATIO NS AND ACRONYMS – Continued
Meaning
PMC Board
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
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
Meaning
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 attent ion 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 PERSO NNEL 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 PRECAUTIONS
A DOUBLE-POLE SWITCH MUST BE INST ALLED ON T HE ELECT RI CAL
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
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 cannot 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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 Appr oved 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
AERCO Innovation Water 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
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
Ensure that the housekeeping pad does NOT extend
under the condensate assembly.
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.
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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.
Innovation Water Heaters Installation, Operation & Maintenance Manual
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 r equirements must also be taken
into consideration. All piping must include ample provisions for expansion.
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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. Refer to section 2.5.1 for installation
instructions prior to connecting inlet piping.
Innovation Water Heaters Installation, Operation & Maintenance Manual
P&T RELIEF
VALVE
COLD WATER INLET
DRAIN VALVE
EXHAUST MANIFOLD
AIR INLET
NATURAL GAS INLET
HOT WATER OUTLET
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.
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
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 f or 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:
WHM Ball Valve Installation
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
provided.
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure
2-3b.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
HEATER DRAIN VALVE
2” NPT UNION
BALL VALVE
2” NPT
CHAPTER 2 – INSTALLATION
WHM Ball Valve Installation – Continued
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 4-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 ACTUAT OR
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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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 recirculation pump that connects the upper hot water
outlet to the lower cold water inlet of t he 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
RECIRCULATION
HOT WATER OUTLET
P&T VALVE
RECIRCULATION
COLD WATER INLET
DRAIN VALVE
HEAT EXCHANGER
CHAPTER 2 – INSTALLATION
LOOP PIPING
PUMP
REAR VIEW – RIGHT-REAR PANEL & EXHAUST VENT 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/190°F is supplied with Alberta shipments.
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION
An ASME rated Pressure & Temperature (P&T) Relief Valve is factory installed on each
Innovation water heater on the hot water outlet at the top of the Recirculation Loop Assembly as
shown in Figure 2-5. With the exception of Alberta installations (see above Note), the valve
setpoint is 150 psig/190°F.
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 r elief valve should be piped to within
12 inches of the floor to prevent 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
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Innovation Water Heaters Installation, Operation & Maintenance Manual
COLD WATER
DRAIN VALVE
AIR INLET
EXHAUST MANIFOLD
CONDENSATE DRAIN
CHAPTER 2 – INSTALLATION
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 ordered
separately and packed 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
manifold drain port.
• The base of the condensate trap must be supported to ensure that it is level (horizontal).
• 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 Installat ion
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.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CAUTION
Housekeeping pad should not extend under the condensate assembly
HOUSEKEEPING
SUPPOR
EXHAUST
MANIFOLD
CONDENSATE
TRAP
TO
3/4”
NIPPLES
1” I.D.
ADAPTER
INTERNAL
CHAPTER 2 – INSTALLATION
If a floor drain is not available, a condensate pump can be used to remove the c ondensate to
drain. The maximum condensate flow rate is 10 GPH. The condensate drain trap, associated
fittings and drain line must be removable for routine maintenance.
Use PVC, stainless steel, aluminum or polypropylene for condensate drain
piping (Figure 2-7). DO NOT use carbon or copper components.
NOTE
Two different styles of condensate traps are currently in use. The functions
and connections provided are nearly identical however they look slightly
different.
WITH
HOSE &
CLAMP
FLOOR
DRAIN
LEFT SIDE VIEW
Figure 2-7. Sample Condensate Trap Installation
NOTE
As a general guideline, AERCO recommends use of its Condensate
Neutralizer Kit to raise the pH level of the condensate prior t o drainage. At
a minimum, the installation must be designed in accordance with local
codes that specify acceptable pH limits. For more information, see
Technical Instruction Document TID-0029, Condensate Neutralization Kit
and TID-0074 Condensate Neutralization Tank.
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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.
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.
NOTE
.
Innovation units contain a 1 inch NPT gas inlet connection on t he rear of the unit as shown in
Figure 2-3 (page 20).
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. The gas pressure applied to the unit should never 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 either 600,
800, 1060 or 1350 cfh while maintaining the gas pressure of 7“ W .C. for FM gas trains
operating at maximum capacity.
2.10.2 Manual Gas Shutoff Valve
A manual shut-off valve is factory-installed in the gas supply line at the unit, as shown in Figure
2-3a. Additionally, if a gas regulator is installed upstream of the unit, refer to Figure 2-8 to
determine the location of th e manual shut-off valve installation in relation to the r egulator. The
maximum allowable gas pressure to the Heater is 14” W.C.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
1” MANUAL
VALVE
NATURAL GAS
SUPPLY
DIRT TRAP
GAS PRESSURE
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 gas while maintaining a gas pressure of 8.0 ” W.C. minimum t o 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 g as utility
for detailed requirements concerning venting of the supply gas regulator.
SHUTOFF
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
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.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
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. Wiring 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 the wires thr ough one of
the four bushings provided.
Figure 2-11. Input/Output (I/O) Box Location – Partial Front View
Refer to the wiring diagram provided on the cover of t he I/O Box (Figure 2-12) when making all
wiring connections.
Since identical I/O Boxes are used with both AERCO gas-fired boilers and water heaters, some
of the input and output connections apply only to boilers while others are common to both
boilers and heaters. 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.
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CAUTION
CHAPTER 2 – INSTALLATION
DO NOT make any connections to the I/O Box terminals labeled “NOT
USED”. Attempting to do so may cause equipment damage.
Figure 2-12. I/O Box Terminal Strips
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.
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 abort t he ignit ion cycle. The controller will attempt up to three ignition cycles. If no
spark is present by the third try, the controller will shut down and display a fault message.
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CHAPTER 2 – INSTALLATION
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 voltage 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 switches.
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 VALVE FEEDBACK Terminals
The Valve Feedback terminals are used when the Sequencing Isolat ion Valve Feedback option
is selected. The Valve Feedback signal is connected to the “Valve Fdbk” terminals and is used
to confirm that the valve has properly opened or closed. If the Valve Feedback signal does not
match the Valve-Open or Valve-Close command for the t ime defined in the "Valve Fdbk timer"
entry, the controller will proceed as follows:
(a) If the valve fails with the Valve Stuck Open fault, the “Valve Stuck Open” message will be
displayed and the unit will remain active.
(b) If the valve fails with the Valve Stuck Closed fault, the “Valve Stuck Closed” message will
be displayed and the unit will shut down.
NOTE! If the Valve Feedback option is used, Shorting Jumper #JP2 on the I/O Boar d Must be
inserted.
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 voltag e output is used by the controller to modulate the
combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.12.11).
2. If “On Board” Water Heater Management is enabled, the Analog Output terminals are
used to drive the isolation valve, open and closed.
NOTE
When driving an isolation valve, shorting jumper #JP2 MUST be installed
on the I/O Board.
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CHAPTER 2 – INSTALLATION
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 +/-.
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
As of Firmware version 4.0 and above, these terminals are used only by factory-trained
personnel to monitor OnAER communications via a portable computer.
2.12.11 VFD/BLOWER Terminals
These terminals (0-10 & AGND) send an analog signal to control the blower speed. W hen 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 time 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
VENT PIPE
WORM-DRIVE HOSE CLAMP
EXHAUST CONNECTOR
1/4" CAP SCREW [4X]
1/4" FLAT WASHER [4X]
EXHAUST MANIFOLD
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 f ault 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 minimum of 1/4" per foot to avoid any condensate pooling and to allo w for
proper drainage. In addition, you must add a bead of high temperature red silicon sealant (such
as Permatex Hi-Temp Red RTV or Loctite Superflex Red High Temp RT V) between the exhaust
manifold and the mating flange of the exhaust connector, as shown in Figure 2-13.
CLEAN BOTH
SURFACES, THEN
APPLY HIGH TEMP
RED SILICON
SEALANT HERE
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Figure 2-13. Exhaust Vent Connection
Innovation Water Heaters Installation, Operation & Maintenance Manual
Selkirk Corporation - Heatfab Division
Watertown Supply
M. A. Peacard
www.mapeacard.com
Glover Sheet Meatal, Inc.
www.gloversheetmetal.com
CHAPTER 2 – INSTALLATION
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 or 0.81” W.C. with 6” piping.
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
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 free 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 Innovation Venting and Combustion Air
Guide, GF-5050.
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.
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CHAPTER 2 – INSTALLATION
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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CHAPTER 2 – INSTALLATION
(This Page Is Intentionally Blank)
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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
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CONTROL,
DISPLAY
Four Status LEDs indicate the current operating status as follows:
Lights when the valve position (fire rate) is being controlled using
mode of operation is for service
Lights when the unit is being controlled by an external signal from
Segment LED display continuously displays the outlet
LED next to the display lights to
indicate whether the displayed temperature is in degrees
Vacuum Fluorescent Display (VFD) consists of 2 lines each
capable of displaying up to 16 alphanumeric characters. The
RS232 Adaptor Cable
LED indicator lights when a boiler alarm condition
alarm is no longer valid. Lockout type alarms will be latched and
8
CHAPTER 3 – OPERATION
Table 3-1: Operating Controls, Indicators and Displays
ITEM
NO.
1
2
3
INDICATOR O R
FUNCTION
LED Status Indicators
COMM Lights when RS232 communication is occurring – see Item 4.
MANUAL
REMOTE
DEMAND Lights when there is a de ma nd f or heat .
OUTLET
TEMPERATURE
Display
VFD Display
the front panel keypad. This
technician use only.
an Energy Management System
3–Digit, 7–
water temperature. The °F or °C
Fahrenheit or degrees Cel sius. The °F or °C blinks when operating
in the Deadband Mode.
information displayed includes:
• Startup Messages
• Fault Messages
• Operating Status Messages
• Menu Selection
This port is used only factory-trained personnel to monitor OnAER
4
RS232 Port
communications, in combination with the
(P/N 124675).
FAULT Indicator
5
CLEAR Key
6
READY Indicator
7
ON/OFF Switch
LOW WATER L EVEL
TEST/RESET
9
Switches
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Red FAULT
occurs. An alarm message w il l app ear in t he VFD.
Turns off the FAULT indicator and clears the alarm message if the
cannot be cleared by simply pressing this key. Troubleshooting
may be required to clear these t ypes of alarms.
Lights when ON/OFF switch is set to ON and all Pre-Purge
conditions have been satisfi ed.
Enables and disables boi l er oper at ion.
Allows operator to test op er at ion of the water level monitor.
Pressing TEST opens the water level probe circuit and simulates a
Low Water Level alarm.
Pressing RESET resets t he water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
Innovation Water Heaters Installation, Operation & Maintenance Manual
Consists of 6 keys which provide the following functions for the Control Panel Menus:
CHAPTER 3 – OPERATION
Table 3-1: Operating Controls, Indicators and Displays – Continued
ITEM
NO.
10
CONTROL,
INDICATOR O R
DISPLAY
MENU
BACK
▲ (UP) Arrow
▼ (DOWN) Arrow
FUNCTION
MENU Keypad
Steps through the main menu categories shown in Figure 3-2.
The Menu categories wrap around in the order shown.
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 main menu
category.
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 the
selected setting.
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 selected setting.
CHANGE
ENTER
11
12
AUTO/MAN Switch
VALVE POSITION
Bargraph
Permits a setting to be changed (edited). When the 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 setting.
Saves the modified menu settings in memory. The display will
stop flashing.
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 disabled.
20 segment red LED bargraph continuously shows the
Air/Fuel Valve position in 5% increments from 0 to 100%
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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 key. 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
Menu is set to
CHAPTER 3 – OPERATION
INNOVATION WH.
The following sections provide brief descriptions of the options cont ained in
each m enu. 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
Innovation Water Heaters Installation, Operation & Maintenance Manual
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. It can therefore 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).
A full description of each item appears in Table A-1 of Appendix A – Innovation Menu Item
Descriptions.
Table 3-2: Operating Menu
Menu Item Display
1 Active Setpoint 40°F 190°F
2 Inlet Temp 30°F 240°F Calibration Menu
3 Air Temp -70°F 245°F
4 * Outdoor Temp -70°F 130°F Configuration Menu
5 Valve Position In 0% 100%
6 Exhaust Temp 40°F 560°F
7 Valve Position Out 0% 100% Calibration Menu
8 FFWD Temp 30°F 240°F Calibration Menu
9 Flame Strength 0% 100%
10 Oxygen Level -32% 32%
11 Ignition Time 0.00 10.00
12 SSOV Time to OPN 0.00 10.00
Available Choices or Limits
Minimum Maximum
Appears only if enabled
in the following menu:
13 Run Cycles 0 999,999,999
14 Run Hours 0 999,999,999
15 Fault Log 0 19
* 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).
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Minimum
Maximum
8
OnAER Mode
Ethernet or SD Card
Ethernet
9
Upload Timer
0
9999 Sec
0
10
Unit Alpha
E, G, H, R, N or A
A
11
Unit Year
0
99
0
12
Unit Serial #
0
9999
0
CHAPTER 3 – OPERATION
3.5 SETUP MENU
The Setup Menu 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 reentered when required. In addition to permitting
password entries, the Setup Menu is also used to enter date and time, and units of temperature
measurements. A view-only software version display is also provided to indicate the current
Control Box software version.
A full description of each item appears in Table A-2 of Appendix A – Innovation Menu Item
Descriptions.
Table 3-3. Setup Menu
1
Menu Item
Display
Password 0 9999 0
Available Choices or
Limits
Default
2 Language English English
3 Time 12:00 am 11:59 pm
4 Date 01/01/00 12/31/99
5 Unit of Temp Fahrenheit or Celsius Fahrenheit
6 Comm Address 0 127 0
7 Baud Rate 2400, 4800, 9600, 19.2K 9600
13 Software Ver 0.00 Ver 9.99 Current software version
3.6 CONFIGURATION MENU
The Configuration Menu permits adjustment of the Internal Setpoint (Setpt) temperature
regardless of whether the valid password has been entered. Setpt is required f or 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.
A full description of each item appears in Table A-3 of Appendix A – Innovation Menu Item
Descriptions.
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NOTE
The Configuration Menu settings shown in the table below are
Factory-Set in accordance with the requirements specified for
each individual order. Therefore, under normal operating
conditions, no changes will be required.
Innovation Water Heaters Installation, Operation & Maintenance Manual
Available Choices or Limits
Minimum
Maximum
4 – 20 mA/1 – 5V
CHAPTER 3 – OPERATION
Table 3-4. Configuration Menu
Menu Item Display
Default
1 Internal Setpt Lo Temp Limit Hi Temp Limit 130°F
2 Unit Type Innovation WH Innovation WH
3 Unit Size
600 MBH, 800 MBH, 1060 MBH,
1350 MBH
600, 800, 1060 or
1350 MBH
4 Fuel Type Natural Gas, Propane Natural Gas
Water Heater Mode
5
Remote Signal
6
(If Mode = Remote Setpoint,
Direct Drive or Combination)
Constant Setpoint,
Remote Setpoint,
0 -20 mA/0 – 5V
PWM Input (Legacy BMS),
Network
Constant Setpoint
4 – 20 mA,
1-5V
7 Outdoor Sensor Enabled or Disabled Disabled
System Start Tmp
8
(If Outdoor Sensor =Enabled)
Setpt Lo Limit 40°F Setpt Hi Limit 60°F
9
30°F 100°F 60°F
Setpt Hi Limit Setpt Lo Limit 190°F 150°F
10
11 Temp Hi Limit 40°F 200°F 160°F
Max Valve Position 40% 100% 100%
12
Pump Delay Timer 0 min. 30 min. 0 min.
13
14 Aux Start On Dly 0 sec. 120 sec. 0 sec.
Failsafe Mode Shutdown or Constant Setpt Shutdown
15
* Analog Output
16
Off, Setpoint, Outlet Temp, Valve Pos
4-20mA, valve Pos 0-10v
Valve Pos 0-10v
17 Low Fire Timer 2 sec. 600 sec. 2 sec.
18
19
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 0
20 Network Timeout 5 Sec 999 Sec 30 Sec
21
22
23
Shutoff Dly Temp 0 25 8
Demand Offset 0 25 5
Deadband High 0 25 0
24
Deadband Low 0 25 0
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Minimum
Maximum
CAUTION
CHAPTER 3 – OPERATION
Menu Item Display
Available Choices or Limits
Default
Minimum Maximum
25
26
IGST Version V2.00 or Lower V2.02 0
IGN Timing Setting 4 Sec 7 Sec -
* DO NOT CHANGE the Analog Output menu item from its Default
setting (Valve Position 0-10V).
3.7 TUNING MENU
The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change
these menu entries unless specifically requested to do so by Factory-Trained personnel.
A full description of each item appears in Table A-4 of Appendix A – Innovation Menu Item
Descriptions.
Table 3-5. Tuning Menu
Menu Item Display
1 Prop Band 1°F 200°F 30°F
2 Integral Gain 0.00 10.00 3.00
3 Derivative Time 0.00 min 2.00 min 0.20 min
4 Min Load Adj -50°F +50°F 0°F
Available Choices or Limits
Default
5 Max Load Adj -50°F +50°F 0°F
6 FFWD Temp 30°F 245°F Read Only Value
7 Outlet Feedback Yes (On) or No (Off) Yes (On)
8 Feedback Gain 0.01 1.00 0.10
Breakpoints – shown only if the Heatr Bkpt Dsp option in the Calibration Menu is Enabled (see
section 3-8). The Breakpoint values correspond to a 130°F default setpoint
9 Breakpt at 100% 30°F 240°F 85°F
10 Breakpt at 90% 30°F 240°F 86°F
11 Breakpt at 80% 30°F 240°F 87°F
12 Breakpt at 70% 30°F 240°F 88°F
13 Breakpt at 60% 30°F 240°F 89°F
14 Breakpt at 50% 30°F 240°F 90°F
15 Breakpt at 40% 30°F 240°F 94°F
16 Breakpt at 30% 30°F 240°F 103°F
17 Breakpt at 20% 30°F 240°F 118°F
18 Breakpt at 10% 30°F 240°F 134°F
19 Breakpt at 0% 30°F 240°F 136°F
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Available Choices or Limits
Minimum
Maximum
Verify 50%
CHAPTER 3 – OPERATION
WHM Items – the following item appear only if WHM is enabled
20 FDback Start Pos 0% 100% 30%
21 Fdback End Pos 0% 100% 60%
22 Max Feedback 0% 100% 30%
23 Fdback Value 0% 100% Read Only Value
24 Temp Gov Enable or Disable Enable
25 GOV Limit-5 0 100 30
26 GOV Limit-7 0 100 20
27 GOV Limit-10 0 100 15
28 GOV Limit-12 0 100 10
29 GOV Limit-15 0 100 5
Menu Item Display
Default
30 PID Output 0% 100% Read Only Value
31 P Output 0% 100% Read Only Value
32 I Output 0% 100% Read Only Value
33 D Output 0% 100% Read Only Value
34 Reset Defaults Yes No No
3.8 CALIBRATION MENU
The Calibration Menu is used by Factory Trained Service personnel to adjust or reset the
parameters listed below.
A full description of each item appears in Table A-5 of Appendix A – Innovation Menu Item
Descriptions.
Table 3-6: Calibration Menu
Menu Item Display
1
Stepper Fbk
Available Choices or Limits
Minimum Maximum
Cal 0%
Cal 100%
Default
Cal 0%
2 Purge Timer 5 sec. 60 sec Depends on unit type/size
3 Post Purge Timer 0 sec. 60 sec. 0 sec.
4 IGN Position 5% 60% Depends on unit type/size
5 FFWD Temp Disply Enabled or Disabled
6 Outlet Tmp Dsply Enabled or Disabled
7 Inlet Tmp Dsply Enabled or Disabled
8 Valv Pos Out Dsp Enabled or Disabled
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Minimum
Maximum
11
VP Down Rate
0.5
60.0
Depends on unit type/size
Analog In Adj
Flow In Adj
31
Skip Speed
5
20
5
CHAPTER 3 – OPERATION
Menu Item Display
9 Exhaust Tmp Dsp Enabled or Disabled
10 VP Up Rate 0.5 60.0 Depends on unit type/size
12 Purge Blwr Offst -1.0 8.0 Depends on unit type/size
13 4-20mA Purge Pct 60% 100% 70%
14 PWM In Adj -5.0% 5.0% 0.0%
Available Choices or Limits
Default
15
16
-5.0% 5.0% 0.0%
-5.0% 5.0% 0.0%
17 Supply Gas Pressure In Adj -5.0% 5.0% 0.0%
18 G as Plate dp In Adj -5.0% 5.0% 0.0%
19 mA Out Adj -1.0 mA 1.0 mA 0.0 mA
20 A/F Sensitivity 1% 5% 2%
21 Power Reset Automatic or Manual Automatic
22 Water Temp Reset Automatic or Manual Automatic
23 G as Press Reset Automatic or Manual Manual
24 Min Off Time 0 Min 15 Min 0 Min
25 Heatr Tuning Dsp Enabled or Disabled Disabled
26 Heatr Bkpt Dsp Enabled or Disabled Disabled
27 St op Level 0% Start Level 16
28 St ar t Level Stop Level 40% 20
29 Skip Range Cntr 10 95 40
30 Skip Range Span 0 3 0
32 O2 Gain 920 1126 1024
33 O2 Offset -3.0 +3.0 0
34 O 2 Sensor Enabled or Disabled Depends on unit type/size
35 Cal T emp Sensors Enabled or Disabled
36 FFWD Temp Offset -20 +20 0
37 Exhst Tmp Offset -20 +20 0
38 Outdr Air Offset -20 +20 0
39 Inlet Air Offset -20 +20 0
40 Inlet Wtr Offset -20 +20 0
41 Outlet Wtr Offset -20 +20 0
42 Spark Monitor
43 Min Spark Amps 0 Amps 2.5 Amps 0.1 Amps
44 Max Spark Amps 0 Amps 2.5 Amps 0.4 Amps
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Enabled or Disabled Depends on unit type/size
Innovation Water Heaters Installation, Operation & Maintenance Manual
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:
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 m ess ages will
be displayed and the unit will go into fault mode.
NOTE
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MOTOR
TO BLOWER
AIR IN
GAS INLET
MANUAL
SSOV
CHAPTER 3 – OPERATION
Start Sequence
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 shown)
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%.
PURGE
VALVE
POSITION
DIAL AT 100%
STEPPER
Figure 3-4. Air/Fuel Valve In Purge Position
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OUTLET TO BLOWER
TO BLOWER
AIR IN
CHAPTER 3 – OPERATION
Start Sequence – Continued
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
Figure 3-5. Blower Proof Switch
5. Upon completion of the purge cycle, the Control Box initiates an ignition cycle and the
following events occur:
VALVE
(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-injector 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
POSITION
DI AL AT
25% to 35%
STEPPER
MOTOR
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Figure 3-6. Air/Fuel Valve In Ignition Position
Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 3 – OPERATION
Start Sequence – Continued
6. Up to 7 seconds will be allowed for ignition to be detected. The igniter-injector relay will
be turned off one second after flame is detected.
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.
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 f or 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
Innovation Water Heater Model: Energy Input (BTU/Hr.)
INN600 INN800 INN1060 INN1350
80% 483,000 615,000 845,000 1,203,000
100% 600,000 800,000 1,060,000 1,350,000
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Innovation Water Heaters Installation, Operation & Maintenance Manual
WARNING
CHAPTER 4 – INITIAL START-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 c omplete all initial unit
start-up requirements.
An AERCO Gas Fired Startup Sheet, included with each Innovation Heater, m ust 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
MANUAL
SSOV
LEAK DETECTION
BALL VALVE
TO
HIGH GAS
PRESSURE
CHAPTER 4 – INITIAL START-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 Manom eter
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
1/4" NPT PLUG
(Install manometer here)
PRESSURE
SWITCH
SHUTOFF
VALVE
Figure 4-1. 1/4 Inch Gas Plug Location (INN600-1060 Gas Train Shown)
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CHAPTER 4 – INITIAL START-UP
4.2.3 Accessing the Analyzer Probe Port
The unit contains a 1/8” NPT port at the rear of the exhaust manifold. This port is located above
the condensate drain connection as shown in Figure 4-2. Prepare the port for the combustion
analyzer probe as follows:
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 J.
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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IGNITERINJECTOR
CLIP LEAD
#135
CLIP LEAD
MULTIMETER
BLOWER-SIDE
INTAKE MANIFOLD
CHAPTER 4 – INITIAL START-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
HARNESS
WIRE LEAD
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.
4.2.5 Recommendations for Temperature Calibration
Carefully follow the procedures of section 4.4 Temperature Control Calibration, below, to
properly set up the temperature control for the heater. Ignoring this commissioning step may
cause water temperature faults, poor water temperature control, and rapid cycling of the heater.
4.2.6 Recommendations for WHM (Water Heater Management) Operation
In case of multiple Innovation units, it is highly recommended to ALWAYS operate the system in
WHM mode. Operation in WHM mode ensures that the system flow will be divided between at
least 2 or more units as demand increases. In addition, WHM ensures that all units receive equal
run time and additional water heaters are activated based on the “NEXT ON” firing rate setting.
In case of pre-heated DHW systems with multiple Innovation units , it is highly recommended to
lower the “NEXT ON” setting to 30 - 40% (Default = 50%), so that subsequent Water Heaters are
engaged sooner to provide more rapid response and divide the system flow over additional units.
In case of DHW pre-heat systems, the required temperature rise through an individual unit can be
much lower to ensure that flow per unit does not exceed 50 GPM at any time.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
Innovation 1350
3.0” – 3.2” W.C.
Innovation 1060
2.6” – 2.8” W.C.
Innovation 800
1.5” – 1.7” W.C.
Innovation 600
1.2” – 1.4” W.C.
CHAPTER 4 – INITIAL START-UP
4.3 NATURAL GAS COMBUSTION CALIBRATION
Innovation Water Heaters are combustion calibrated at the factory prior to shipping. However,
recalibration is necessary as par t 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.
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. Enter the password 6817 to continue.
6. 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.
7. Adjust the air/fuel valve position to 0% by pressing the ▼ arrow key.
8. Ensure that the leak detection ball valve downstream of the SSOV is open.
9. Set the ON/OFF switch to the ON position.
10. Change the valve position to 30% using the ▲ arrow key. The unit should begin its start
sequence and fire.
11. Using the ▲ arrow key, increase the valve open position to 100% and then allow the valve
position to reach 100%.
12. Check that the gas pressure downstream of the SSOV is within the range listed below. If
gas pressure adjustment is required, remove the brass hex nut on the SSOV actuator (see
Figure 4-4) to access the gas pressure adjustment screw. Slowly rotate the screw, in
approximately 1/4-turn increments, clockwise to reduce t he oxygen level or
counterclockwise to increase the oxygen level, as needed, to reach the value listed below.
Allow the combustion analyzer to stabilize following each adjustment.
NATURAL Gas Pressure Range Downstream Of SSOV
Model Gas Pressure Range
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Valve
Position
Oxygen (O2)
%
Nitrogen Oxide
(NOx)
Carbon Monoxide
(CO)
BRASS HEX
CHAPTER 4 – INITIAL START-UP
NATURAL GAS Combustion Calibration - Continued
HEAD CAP
(Remove to access gas pressure
adjustment screw)
Figure 4-4. Gas Pressure Adjustment Screw Location
13. Replace the brass cap on the SSOV gas pressure adjustment if it was previously removed.
14. With the valve position at 100%, 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.
15. Compare the oxygen (O2) level, carbon monoxide (CO), nitrogen oxide (NOx) and flame
strength readings with the range
above this range to meet ultra-low NOx requirements or to avoid combustion tone issues.
shown in step 19, below. You may need to adjust O2%
16. Press the MENU key on the front panel of the C-More until Combustion Cal Menu appears
on the display.
17. Press the ▲ arrow key until SET Valve Position reads 100%. Press the ENTER key.
18. Press the CHANGE key and observe that CAL Voltage 100% is flashing.
19. The oxygen level at the 100% valve position should be as shown below. Also, ensure that
the nitrogen oxide (NOx), carbon monoxide (CO) and flame strength readings match the
following values:
Combustion Calibration Readings at 100% Valve Position
Flame µA
100% 6.0% ± 0.25% < 20 ppm < 100 ppm > 6 µA
20. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼
arrow keys. This will adjust the output voltage to the blower motor as indicated on the
display. Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼
arrow key decreases the oxygen level.
21. Once the oxygen level is within the specified range at 100%, press the ENTER key to store
the selected blower output voltage for the 100% valve position. Record all readings on the
Combustion Calibration Sheets provided.
22. Repeat steps 16 through 21 for the following valve positions (see NOTE below):
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• 80%, 60%, 40%, 30%, 24%, 20%, 16%
NOTE
If NOx readings exceed the target values shown (<20 ppm), increase the O2
level up to 25% higher than the listed calibration range shown in the table.
Record the increased O
value on the Combustion Calibration sheet.
2
Innovation Water Heaters Installation, Operation & Maintenance Manual
Valve
Position
Nitrogen
Oxide (NOx)
Carbon
Monoxide (CO)
Flame
µA
80%
6.5% ± 0.2%
<20 ppm
<100 ppm
> 6
> 6
> 6
> 6
> 5
> 4
16%
5.8% ± 0.2%
<20 ppm
<100 ppm
> 4
IDLE SCREW
CHAPTER 4 – INITIAL START-UP
NATURAL GAS Combustion Calibration – Continued
Combustion Calibration Readings
Oxygen (O2) %
60% 7.5% ± 0.2% <20 ppm <100 ppm
50% 8.0% ± 0.2% <20 ppm <100 ppm
40% 8.0% ± 0.2% <20 ppm <100 ppm
30% 8.3% ± 0.2% <20 ppm <100 ppm
20% 8.0% ± 0.2% <20 ppm <100 ppm
23. If the oxygen level at the 16% valve position is too high and the Blower voltage is at the
minimum value, you can adjust the idle screw (TAC valve), which is recessed in the top of
the Air/Fuel Valve. Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce the O
to the specified level. Recalibration MUST be performed again from 60% down to 16% after
making a change to the idle screw (TAC valve).
TAC VALVE
2
This completes the NATURAL GAS combustion calibration procedure.
4.4 PROPANE COMBUSTION CALIBRATION
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.
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Figure 4-5. TAC Valve Adjust (Idle Screw)
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 to run on Propane.
Innovation Water Heaters Installation, Operation & Maintenance Manual
Innovation 1350
2.0” – 2.2” W.C.
Innovation 1060
1.8” – 2.0” W.C.
Innovation 800
2.8” – 3.0” W.C.
Innovation 600
1.6” – 1.8” W.C.
Oxygen % ± 0.5
Carbon Monoxide
NOx
Flame Strength
6.0 %
<50 ppm
<15 ppm
>2.0 µA
CHAPTER 4 – INITIAL START-UP
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.
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.
PROPANE Gas Pressure Range Downstream Of SSOV
Model Gas Pressure Range
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
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carbon monoxide (CO), nitrogen oxide (NOx) and flame strength readings are within the
values shown.
Combustion Oxygen Level at 16% Valve Position
Innovation Water Heaters Installation, Operation & Maintenance Manual
Innovation 1350
2.0” – 2.2” W.C.
Innovation 1060
1.8” – 2.0” W.C.
Innovation 800
2.8” – 3.0” W.C.
Innovation 600
1.6” – 1.8” W.C.
50%,
CHAPTER 4 – INITIAL START-UP
PROPANE Combustion Calibration - Continued
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.
PROPANE Gas Pressure Range Downstream Of SSOV
Model Gas Pressure Range
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%,
• 60%,
• 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.
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CHAPTER 4 – INITIAL START-UP
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
Carefully follow the procedures below to properly set up the t emperature control for the heater.
Ignoring this commissioning step may cause water temperature faults, poor water temperature
control, and rapid cycling of the heater.
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: Min Load Adj and Max
Load Adj (minimum and maximum load adjustment). Adjustments to these sett ings 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.
When calibrating temperature control, observe the following:
Temperature Control Cal ibration
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.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 4 – INITIAL START-UP
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%.
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.
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CHAPTER 4 – INITIAL START-UP
4.6.3 Maximum Load Adjustment
Check the temperature control at maximum load as follows:
Maximum Load Adjustment
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%.
NOTE
It may be necessary to open the outlet valve if it was closed during m inimum
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.
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.
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.
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CHAPTER 4 – INITIAL START-UP
4.7 OVER-TEMPERATURE LIMIT SWITCHES
The unit contains both automatic and manual reset over-temperature limit switches, shown in
Figure 4-6. They can be accessed by opening the front panel door of the unit.
The manual reset switch is not adjustable and is permanently fixed at 190°F. This switch will shut
down and lock out the heater if the water temperature exceeds 190°F. Following an overtemperature condition, it must be manually reset by pressing the RESET button before the heater
can be restarted. The automatic reset over-temperature switch is adjustable and allows the unit to
restart, once the temperature drops below its temperature setting. Set the automatic overtemperature switch to the desired setting.
AUTOMATIC RESET
(ADJUSTABLE) OVER-
TEMPERATURE LIMIT
SWITCH
Figure 4-6. Over-Temperature Limit Switch Location
MANUAL RESET (NONADJUSTABLE) OVER-
TEMPERATURE LIMIT
SWITCH
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CHAPTER 4 – INITIAL START-UP
(This Page Is Intentionally Blank)
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WARNING
CHAPTER 5 – SAFETY DEVICE TESTING
CHAPTER 5. SAFETY DEVICE TESTING
5.1 INTRODUCTION
Periodic safety device testing is required to ensure that the control system and safety devices
are operating properly. The 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.
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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.
Innovation Water Heaters Installation, Operation & Maintenance Manual
MANUAL
SSOV
HIGH GAS
PRESSURE SWITCH
CHAPTER 5 – SAFETY DEVICE TESTING
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.
LEAK DETECTION
BALL VALVE
LOW GAS
PRESSURE SWITCH
1/4" NPT PLUG
(Install manometer here for
HIGH g as pressure test)
1/4" NPT PLUG
(Install manometer here for
LOW gas pressure test)
SHUTOFF
VALVE
TO AIR/FUEL VALVE
Figure 5-1. Low & High Gas Pressure Testing (INN600-1060 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:
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 s hould
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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High Gas Pressure Fault
Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 5 – SAFETY DEVICE TESTING
5.4 LOW WATER LEVEL FAULT TEST
To simulate a low water level fault:
Low Water Level Fault Test
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 button 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 Tes t
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-t em p er a t ur e swit ch setting is appr oximately 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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CHAPTER 5 – SAFETY DEVICE TESTING
NOTES
The manual (non-adjustable) Over Temp Limit switch is
calibrated to trip if the discharge water exceeds 190° F. Testing
of this device must be done by authorized personnel only.
AUTOMATIC RESET
(ADJUSTABLE)
TEMPERATURE OVER-
LIMIT SWITCH
MANUAL RESET (NONADJUSTABLE) OVER-
TEMPERATURE LIMIT
SWITCH
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 t he field 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
Remote Interlock
1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals (see
Figure 2-12).
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
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.
4. The unit should shut down and display INTERLOCK OPEN.
5. Once the interlock connection is reconnected, the INTERLOCK OPEN message should
automatically clear and the unit should restart.
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CHAPTER 5 – SAFETY DEVICE TESTING
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 FAULT 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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MANUAL
VALVE
SSOV
TO
HIGH GAS
CHAPTER 5 – SAFETY DEVICE TESTING
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.
LOW GAS
PRESSURE
SWITCH
SHUTOFF
Figure 5-3. Manual Gas Shut-Off Valve Location (INN600-1060 Gas Tr ain)
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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AIR/FUEL
VALVE
BLOCKED
INLET SWITCH
CHAPTER 5 – SAFETY DEVICE TESTING
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.
BLOWER PROOF
SWITCH
BLOWER
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PARTIAL FRONT VIEW
Figure 5-4. Blower Proof & Blocked Inlet Switch Locations
Innovation Water Heaters Installation, Operation & Maintenance Manual
EXHAUST
MANIFOLD
COLD WATER
INLET
DRAIN
VALVE
CHAPTER 5 – SAFETY DEVICE TESTING
AIR INLET
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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SSOV
COVER
CHAPTER 5 – SAFETY DEVICE TESTING
ACTUATOR
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, pr oc eed 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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AIR/FUEL VALVE
(Rotate CCW to
Ignition
Position
Purge
Switch
TO BLOWER
VALVE
POSITION
170
AIR/FUEL VALVE
BREAKOUT
AIR IN
CHAPTER 5 – SAFETY DEVICE TESTING
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.
COVER
Figure 5-7. Typical Air/Fuel Valve Cover Location
Position
SWITCH WIRING
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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Labor
Time
Igniter-Injector
Flame Detector
6.4
Combustion Calibration
*Check
Check
1 hr.
6.5
Testing of Safety Devices
Test
20 mins.
Inspect &
Clean
6.7
Waterside Inspection
*Inspect
Inspect
1 hr.
6.7
Anode Inspect
Replace
1 hr.
Inspect & Clean
6.9
Condensate Drain Trap
*Inspect
Inspect & Clean
-
30 mins.
Air Filter
Clean or
Low Water Cutoff (L WCO)
69126)
WARNING
CHAPTER 6 – MAINTENANCE
CHAPTER 6. MAINTENANCE
6.1 MAINTENANCE SCHEDULE
The Innovation Water Heater requires regular routine maintenance to ensure continued reliable
operation throughout the service life of the unit. For optimum operation, AERCO 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
6.6
6.8
6.10
6.13
(Kit # 58023)
(Kit P/N 24356-2)
Fireside Inspection
Heat Exchanger Cleaning
(P/N 59138)
Probe Capacitor (Kit P/N
*Inspect Inspect Replace
*Inspect Inspect Replace
(as required)
Replace
- Test
-
- 5 mins.
Replace &
Test
15 mins.
15 mins.
2 hrs.
2 hrs.
15 mins.
* Only performed after initial 6 month period after initial startup.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
FLAME
INTAKE
FLANGE
IGNITER-INJECTOR
FLAME DETECTOR
FLAME DETECTOR
(Kit P/N 24356-2)
BURNER FLANGE
OBSERVATION
PORT
IGNITER-INJECTOR
IGNITION
SOLENOID
CHAPTER 6 – MAINTENANCE
6.2 IGNITER-INJECTOR
The ig niter-injector is located on the flange of the blower-side intake manifold, at the bottom of the
unit’s heat exchanger. The igniter-injector (Kit P/N 58023) is the same for Natural Gas and
Propane units. Figure 6-1 shows the blower-side intake manifold (removed from the heater)
showing the location of the igniter-injector, flame detector and gasket (Kit P/N 24356-2) and
related components.
The igniter-injector may be hot, therefore, care should be exercised to avoid burns. It is easier to
remove the igniter-injector from the unit after the unit has cooled to room temperature.
DETECTOR
GASKET
MANIFOLD
(P/N GP-18899)
GASKET
(Kit P/N 24356-2)
(Kit P/N 58023)
Figure 6-1. Blower-Side Intake Manifold with Igniter-Injector & Flame Detector
Igniter-Injector 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-injector.
4. Refer to Figure 6-1. Disconnect the compression nut securing the gas injector tube of the
igniter-injector to the elbow of the ignition assembly. Disconnect the ignition assembly from
the igniter-injector.
5. Loosen and remove the igniter-injector from the burner plate.
6. Check the igniter-injector for evidence of erosion or carbon build-up. If there is evidence of
substantial erosion or carbon build-up, the igniter-injector 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.
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120°
ANGLE OF GAS
TUBE
FLAME
TERMINAL
IGNITER-
FLAME
PORT
CHAPTER 6 – MAINTENANCE
Igniter-Injector Inspection/Replacement – Continued
7. Prior to reinstalling the igniter-injector, apply a high temperature, conductive, anti-seize
compound to the threads.
NOTE
The igniter-injector replacement kit (P/N 58023) includes three clocking
(indexing) washers, which are used, as needed, so that when the igniterinjector is fastened in place, the gas injector tube is pointing outward, toward
the intake manifold perimeter.
8. Refer to Figure 6-2 and reinstall the igniter-injector on the intake manifold flange. Install one
to three clocking washers, as needed, to position the igniter-injector’s gas tube so that it is
pointing outward, toward the outer-edge of the intake manifold flange. Torque to 15 ft -lbs.
Do not over tighten.
DETECTOR
INJECTOR
INJECTOR
OBSERVATION
VIEWED FROM BELOW, LOOKING UP
Figure 6-2. Igniter-Injector & Flame Detector Mounting Details
9. Connect the ignition assembly to the gas injector tube of the igniter-injector by securing the
compression nut to the elbow of the ignition assembly.
10. Reconnect the igniter-injector cable and ground wire.
11. Reinstall the side and rear panels on the unit.
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CHAPTER 6 – MAINTENANCE
6.3 FLAME DETECTOR
Flame detector (Kit P/N 24356-2) is used on ALL Innovation Water Heater Models. The flame
detector is also located on the flange of the 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:
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
GP-18899 Burner Flange Gasket (Qty. = 2 )
81048 Flame Detector Gasket
81197 Shield Gasket
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 exhaust vent fr om the exhaust manifold. Use a scraper or blade to separate
the high temperature silicon sealant between the exhaust manifold and vent connect or and
remove all sealant from both surfaces in preparation for reassembly.
3. 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 needed to provide
clearance for pulling the burner.
4. Refer to Figures 6-3 and 6-4 to locate the blower-side intak e manifold at the bottom of the
unit's heat exchanger.
5. Disconnect the lead wire from the flame detector installed on the intake manifold flange
(Figure 6-2).
6. Remove the two (2) hex standoffs securing the flame detector to the intake manifold (see
Figures 6-1 and 6-2).
7. Remove the flame detector and gasket from the intake manifold flange.
8. Disconnect the cable from the ig niter-injector, loosen the compression nut and elbow from
the gas injector tube (Figure 6-1), and remove the entire ignition assembly (nut/elbow,
solenoid valve, hose nipple, and gas flex hose) from the manifold flange.
9. Loosen and remove the igniter-injector from the intake manifold f lange. Retain the clocking
washers (if present), for later reassembly.
10. 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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Innovation Water Heaters Installation, Operation & Maintenance Manual
CAUTION
EXHAUST
MANIFOLD
HEAT
EXCHANGER
BLOWER
5/16-18 HEX
CAP SCREWS
EXHAUST
SENSOR
CHAPTER 6 – MAINTENANCE
Fireside Inspection - Continued
SIDE INTAKE
MANIFOLD
NUTS (6)
1/4-20 X 7/8” LG. (4)
PARTIAL RIGHT-SIDE VIEW – SUPPORT BRACKET REMOVED FOR CLARITY
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.
11. 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.
12. Carefully lower and remove the blower side intake manifold, burner assembly and both
burner gaskets (P/N GP-18899). See Figures 6-3 and 6-4.
13. Disconnect the exhaust temperature sensor (Figure 6-3) by unscrewing it from the exhaust
manifold.
14. While supporting the exhaust manifold, remove the two (2) side nuts (Figure 6-5) securing
the manifold to the heat exchanger. Loosen, but do not remove the third nut nearest to the
front of the unit.
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15. Remove the exhaust manifold from the unit.
16. Inspect the exhaust manifold and burner assemblies for debris. Clean out debris as
necessary.
17. This completes the fireside inspection of the unit. Proceed to step 18 and reas semble the
unit as indicated.
Innovation Water Heaters Installation, Operation & Maintenance Manual
BURNER
INTAKE
CONDENSATE
BURNER GASKET
EXHAUST
5/16-18
SIDE NUTS
(2)
FRONT
EXHAUST
SHIELD GASKET
BURNER GASKET
CHAPTER 6 – MAINTENANCE
Fireside Inspection – Continued
ASSEMBLY
(P/N GP-18899)
SHIELD
(P/N 81197)
(P/N GP-18899)
NUT (1)
MANIFOLD
Figure 6-4.
Intake Manifold and Burner
SENSOR
MANIFOLD
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STUDS (6)
PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED
Figure 6-5. Intake and Exhaust Manifolds
Innovation Water Heaters Installation, Operation & Maintenance Manual
BURNER FLANGE GASKET
(P/N GP-18899)
BURNER
SHIELD
BURNER
ASSEMBLY
INTAKE MANIFOLD
EXHAUST
MANIFOLD
BURNER FLANGE GASKET
(P/N GP-18899)
SHIELD
CHAPTER 6 – MAINTENANCE
Fireside Inspection – Continued
CONDENSATE
GASKET
(P/N 81197)
BURNER, INTAKE AND EXHAUST MANIFOLDS – EXPLODED
Figure 6-6. Combustion Chamber Gasket Locations
IMPORTANT
During reassembly, apply high-temperature, anti-seize lubricant to the
threads of the igniter-injector and grounding screw. Also, ensure that the
igniter-injector are properly positioned and are not contacting other
components. Torque the igniter-injector to 15 ft-lbs.
18. Reinstall all components in the reverse order in which they were removed, beginning with
the exhaust manifold assembly removed in step 15.
WARNING
The manifold-to-heat exchanger gasket must be held in place with
High Temp RTV Silicone sealant. The exhaust manifold must be
carefully raised into place, centered, and leveled to insure the
gasket makes a good seal between the manifold and heat
exchanger.
19. Reinstall the exhaust vent onto the exhaust manifold using a High Temp Red RTV silicon
sealant, such as sealants available from Permatex or Loctite.
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CAUTION
CHAPTER 6 – MAINTENANCE
6.7 WATERSIDE INSPECTION
The waterside of the heating surfaces is inspected by removing the top heater head (see Figure
6-7). Prior to performing the inspection, ensure that the following replacement parts are available:
• GP-18556 Release Gasket
• GP-18532 Shell Gasket
• 24430 Anode Block Replacement Kit
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.
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.
4. Referring to see Figure 6-7, below, remove the 5/8-11 hex nuts and washers from the upper
head, and then remove the upper head, upper head-liner and gaskets.
5. Pull the baff le assembly out of the chamber, exposing the heat exchanger tubes.
6. Inspect and clean the heat exchanger tubes of scale and clean all gasket surfaces
thoroughly before reassembling the upper head. AERCO recommends that NEW gaskets
be used when reassembling.
7. Inspect the anode blocks f or corrosion. If they have corroded by more than 40% (original
dimensions are 7 1/4" X 4”), replace them, as described in the next section, before
completing the remaining instructions below to reassemble the upper head. Order the
Anode Replacement Kit from AERCO, part number 24430.
8. Place the shell gasket (P/N GP-18532) on top of the heat exchanger shell flange.
9. Replace the baffle assembly. If it includes threaded positioning rods, align the top surface of
the spindle caps with the top surface of t he head gasket. If the caps protrudes above the
top edge of the head gasket, it may damage the copper head liner
10. Place the head release gasket (P/N GP-18556) on top of the head gasket, aligning the
gasket holes with the bolts in the shell flange.
11. Place the copper upper head liner on, aligning the holes with the 5/8-11 X 3-3/4” studs.
12. Replace the nuts and washers on the 5/8-11 X 3-3/4” studs.
13. Cross tighten the nuts to approximately 75 ft.-lb. torque to obtain a uniform seating, then
14. Close the drain valve and reopen the inlet, outlet, and recirculation valve.
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progressively tighten the nuts to 200 ft.-lb.
Innovation Water Heaters Installation, Operation & Maintenance Manual
5/8-11 X 3-3/4”
STUD
5/8-11 HEX
UPPER HEAD
SHELL FLANGE
HEAT
EXCHANGER
UPPER HEAD LINER
HEAD RELEASE
SHELL GASKET
CHAPTER 6 – MAINTENANCE
(P/N 123077)
GASKET (P/N GP-18556)
(P/N GP-18532)
Figure 6-7. Heat Exchanger Head Configuration
6.7.1 Anode Replacement
If your inspection of the unit’s anode blocks reveal that they have shrunk by more than 40%
(original dimensions are 7 1/4" X 4”), refer to Figure 6-8 and complete the instructions below to
install the Anode Replacement Kit (P/N 24430).
Anode Block Replacement
1. Cut a doughnut shaped piece of cardboard that will fit snugly inside the heat exchanger
shell and around the combustion chamber head and fit it in place above the heat exchanger
tubes. This will act as a shield to prevent any hardware or debris from dropping into the
chamber during installation.
2. Referring to Figure 6-8, remove the four (4) 1/4–20 hex bolts holding the anode blocks to
the anode mounting bracket, and then remove both old anode blocks.
3. Position the four (4) ‘O’ rings (P/N 88019) in the circular recesses around the threaded
holes in the new anode blocks (P/N 44174). The ‘O’ rings keep water from entering the
threaded holes, preventing them from corroding, which would shorten the anode’s life.
4. Fasten one anode block to the mounting bracket with two (2) 1/4–20 hex flange seal bolts
(P/N 54108) and fully tighten them. Note that these are specialized bolts, with built-in ‘O’
rings – DO NOT substitute off-the-shelf bolts of the same size. DO NOT over-tighten
these bolts.
5. Repeat the previous step to attach the second anode block to the mounting bracket.
6. Remove any hardware or debris that may have fallen on the cardboard shield installed in
step 1 and then remove the shield from the chamber.
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CAUTION
CAUTION
3/8-16 HEX
(2 Each)
5/16-24 POSITIONING BOLT
1/4-20 HEX BOLT
COMBUSTION
COMBUSTION
LIFTING HOOK
SUPPORT
CHAPTER 6 – MAINTENANCE
(1 Each)
(4 Each)
BRACKET
BOLTS
Figure 6-8. Anode Assembly and Combustion Chamber Head
CHAMBER
HEAD
CHAMBER
HEAD
6.8 HEAT EXCHANGER CLEANING
For hard water installations, AERCO high recommends use of its Scale Reducer system. The
Scale Reducer, Model SR300, is strongly recommended for installations in areas with hard water
(>3.5 grains/gal). It provides an economical, maintenance free treatment of hard water without the
use of salt or any chemicals. The SR300 prevents new scale build-up and eliminates existing
build-up in water heaters, boilers and storage tanks, hot water piping, valves, recirculation lines
and pumps, mixing valves, showerheads and other plumbing fixtures. This eliminates the
associated heat exchanger overheating and lets the water heater continue to perform at its peak
efficiency (low-water heating cost). In addition to reduced inspection frequency, the periodic
maintenance to remove and flush the water heater for scale deposits is no longer necessary.
Alternatively, 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 distr ibuted by AERCO International, Inc. and is designed to dissolve the toug hest
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.
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HOSE
UNION
BACK-FLOW
CLOSE COLD
COLD
PUMP
CIRCULATION
HOT WATER
DRAIN
VALVE
CHAPTER 6 – MAINTENANCE
6.8.1 Pumping System Set-Up Instructions
A sample pumping set-up diagram is shown in Figure 6-9 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:
Set-Up Instructions
1. Turn off the water heater and close the inlet and outlet isolation valves.
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 6-9.
6. Install a “T”, ball valve and hose connection in the outlet piping of the heater (Figure 6-9).
Route the hose back to the top of the circulation bucket.
OUTLET
CONNECTION
CONNECTION
PREVENTOR
WATER
IN
BUCKET
WATE R INLET
Figure 6-9. 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 detai l s. 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 charting of a trend in the pH of the cleaning
solution.
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Innovation Water Heaters Installation, Operation & Maintenance Manual
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 6-10. Maintenance tasks for both styles
are almost 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 6-10.
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 6-10.
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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THUMB
(4)
CONDENSATE TRAP
FLOAT
THUMB
SCREW
O-RINGS
ADAPTOR
OPENING
3/4" NPT Port
3/4" NPT PORT
OUTLET
INLET
CHAPTER 6 – MAINTENANCE
(2)
Figure 6-10. External Condensate Trap– Cross-Sections
SCREWS
COVER O-RING
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 6-11.
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 6-11 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
CHAPTER 6 – MAINTENANCE
AIR/FUEL
VALVE
BLOWER
MOTOR
Figure 6-11. Air Filter Mounting Location
6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST
If the LWCO capacitor has failed, order the LWCO capacitor
and consult the Innovation 24 Month Maintenance Technical Instructions Document TID-0094 for
replacement instructions.
The LWCO capacitor should be tested for electrical shorts every 12 months and replaced,
then tested, every 24 months. The LWCO capacitor integrity test consists of two parts as
described in the next two sections. The first procedure explains how to test for electrical
shorting of the LWCO probe capacitor, while the second procedure instructs how to perform
the standard Low Water Cutoff test using the C-More controls.
On the Innovation series, the LWCO probe is located on the heat exchanger body on the left side
of the unit. Refer to Figure 6-12 for an illustration of the LWCO probe assembly and its
installation.
Kit, P/N 69126, from AERCO,
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LWCO Probe
Capacitor Assembly
Connector
Plastic Acorn Nut
LWCO
PARTIAL LEFT SIDE VIEW
CHAPTER 6 – MAINTENANCE
(Covered By Large
Shrink Tubing)
(to Shell Harness)
Probe
Terminal
Figure 6-12: LWCO Probe Location (INN 1350 Shown)
6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
This test determines if there is an electrical short between the LWCO capacitor and the heat
exchanger. Perform the capacitor electrical short test as described below.
LWCO Capacitor Electr ical Short Test
1.
Turn OFF AC power to the unit.
WARNING!
High voltages are used to power these units and so it is required
that power applied to t hese units is removed first before performing
the procedure described in this instruction. Serious personal injury
or death may occur if this warning is not observed.
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Unplug Shell
P5 Connector
Connect 1st Lead to LWCO
Connect 2nd Lead to PIN #6
19-Pin Shell Harness Cable
LWCO Probe Assembly
Ohmmeter
CHAPTER 6 – MAINTENANCE
LWCO Capacitor Electr ical Short Test – Continued
2.
Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the
rear panel of the C-More controller (see Figure 6-13).
Harness Cable
from
Figure 6-13: Removing Shell Harness Cable from P5 Conn. on C-More Rear Panel
3.
Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the
unit shell as sh ow n on l eft in Figure 6-14.
4.
Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed
from the C-More controller) as shown on right in Figure 6-14.
Figure 6-14: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable
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Connector
Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 6 – MAINTENANCE
LWCO Capacitor Integrity Test – Continued
5.
Confirm that the ohmmeter does NOT read a short.
NOTE
If the ohmmeter reads a short, the capacitor assembly needs to be replaced.
Refer to document TID-0094, provided with the 24-month maintenance kit,
for LWCO replacement instructions.
6.
Remove both ohmmeter probes and r econnect the Shell Harness connect or to the P5
connector on the rear of the C-More controller.
6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test
Perform the standard Low Water Cutoff test using the C-More controls as described below.
Standard Low Water Cutoff C -More Test
1.
Turn on the AC power to the unit.
Press the TEST switch on the C-More controller and confirm that the blinking "Low Water
2.
Level" message appears
Press the RESET key, followed by the Clear button, and confirm that the "Low Water
3.
Level" message is cleared.
on the C-More display within 4 seconds.
6.12 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.
6. Open the drain valve and drain all water from the unit.
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CHAPTER 6 – MAINTENANCE
6.13 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 installat io n 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. Perform safety device testing and scheduled maintenance procedures per Chapters 5 and
6 of this manual.
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CHAPTER 7 – TROUBLESHOOTING GUIDE
CHAPTER 7. TROUBLE SH O OTING GUIDE
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.
When a fault occurs in the unit, proceed as follows to isolate and correct the fault:
General Troubleshooting Inst ructions
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.
NOTE
The front panel of the C-More Control Box contains an RS232
port. This port is used only by factory-tr ained personnel to monitor
OnAER communications via a portable computer.
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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 TROUBLESHOOTING
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 TROUBLESHOOTING – 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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