AERCO Innovation 600, Innovation 800, Innovation 1060, Innovation 1350 User Manual

Innovation Water Heaters Installation, Operation & Maintenance Manual

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

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

USER MANUAL

Installation, Operation and Maintenance

INNOVATION Series

Gas-Fired Water Heaters

Latest Update: 11/25/2014

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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 this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

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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 CONFIGURATION 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 CALIBRATION .................................................................	57
4.4 PROPANE COMBUSTION CALIBRATION.........................................................................	59
4.5 REASSEMBLY....................................................................................................................	61
4.6 TEMPERATURE CONTROL CALIBRATION ......................................................................	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 DOWN 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 INSTRUCTIONS ....................................	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 & OPERATION .................................................	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 furnished with each unit. When the heater is ordered with a Sequencing Valve (SV), up to 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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		FORWARD
	INNOVATION POTABLE WATER HEATER MODELS
	Part Number	Description		Shipping
				Weight
	INN600	Innovation Potable Water Heater, 600,000 BTU/HR
	INN600P	Input, Natural Gas or Propane, FM Gas Train		1,060 lbs.
		Innovation Potable Water Heater, 600,000 BTU/HR
	INN600SV	Input, Natural Gas or Propane, FM Gas Train with WHM
	INN600SVP	Sequencing Valve		1,080 lbs.
		Innovation Potable Water Heater, 600,000 BTU/HR
	INN600DBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN600PDBB	(Formerly IRI) Gas Train		1,085 lbs.
		Innovation Potable Water Heater, 600,000 BTU/HR
	INN600SVDBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN600SVPDBB	(Formerly IRI) Gas Train with WHM Sequencing Valve		1,105 lbs.
	INN800	Innovation Potable Water Heater, 800,000 BTU/HR
	INN800P	Input, Natural Gas or Propane, FM Gas Train		1,080 lbs.
		Innovation Potable Water Heater, 800,000 BTU/HR
	INN800SV	Input, Natural Gas, or Propane FM Gas Train with WHM
	INN800SVP	Sequencing Valve		1,100 lbs.
		Innovation Potable Water Heater, 800,000 BTU/HR
	INN800DBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN800PDBB	(Formerly IRI) Gas Train		1,095 lbs.
		Innovation Potable Water Heater, 800,000 BTU/HR
	INN800SVDBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN800SVPDBB	(Formerly IRI) Gas Train with WHM Sequencing Valve		1,115 lbs.
	INN1060	Innovation Potable Water Heater, 1,060,000 BTU/HR
	INN1060P	Input, Natural Gas or Propane, FM Gas Train		1,100 lbs.
		Innovation Potable Water Heater, 1,060,000 BTU/HR
	INN1060SV	Input, Natural Gas or Propane, FM Gas Train with WHM
	INN1060SVP	Sequencing Valve		1,120 lbs.
		Innovation Potable Water Heater, 1,060,000 BTU/HR
	INN1060DBB	Input, Natural Gas, or Propane Double Block & Bleed
	INN1060PDBB	(Formerly IRI) Gas Train		1,115 lbs.
		Innovation Potable Water Heater, 1,060,000 BTU/HR
	INN1060SVDBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN1060SVPDBB	(Formerly IRI) Gas Train with WHM Sequencing Valve		1,135 lbs.
	INN1350	Innovation Potable Water Heater, 1,350,000 BTU/HR
	INN1350P	Input, Natural Gas or Propane, FM Gas Train		1,150 lbs.
		Innovation Potable Water Heater, 1,350,000 BTU/HR
	INN1350SV	Input, Natural Gas or Propane, FM Gas Train with WHM
	INN1350SVP	Sequencing Valve		1,170 lbs.
		Innovation Potable Water Heater, 1,350,000 BTU/HR
	INN1350DBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN1350PDBB	(Formerly IRI) Gas Train		1,165 lbs.
		Innovation Potable Water Heater, 1,350,000 BTU/HR
	INN1350SVDBB	Input, Natural Gas or Propane, Double Block & Bleed
	INN1350SVPDBB	(Formerly IRI) Gas Train with WHM Sequencing Valve		1,205 lbs.

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FORWARD

Phrases, abbreviations and acronyms used in this manual are listed in the following table:

			PHRASES, ABBREVIATIONS AND ACRONYMS
	Phrase, Abbreviation		Meaning
	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
			(signaling events) transmitted per second. It is not equal to bits per
			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		A control system developed by AERCO and currently used in all
	(or Control Box)		Benchmark, Innovation and KC1000 Series product lines.
	CO		Carbon Monoxide
	COMM (Comm)		Communication
	Cal.		Calibration
	CNTL		Control
	DBB		Double Block & Bleed. Used to define gas trains containing two
			SSOVs and a solenoid operated vent valve. Used interchangeably
			with IRI.
	DIP		Dual In-Line Package
	EMS		Energy Management System; often used interchangeably with BAS
	FM		Factory Mutual. Used to define boiler gas trains.
	GND		Ground
	HDR		Header
	HX		Heat Exchanger
	Hz		Hertz (Cycles Per Second)
	I.D.		Inside Diameter
	IGN		Ignition
	IGST Board		Ignition/Stepper Board contained in C-More 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

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		PHRASES, ABBREVIATIONS AND ACRONYMS – Continued
	Phrase, Abbreviation		Meaning
	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
	PMC Board		A Primary Micro-Controller (PMC) board is contained in the C-More
			Control Box used on all Benchmark units.
	PPM		Parts Per Million
	PTP		Point-to-Point (usually over RS232 networks)
	REF (Ref)		Reference
	RES.		Resistive
	RS232		A standard for serial, full-duplex (FDX) transmission of data based on
	(or EIA-232)		the RS232 Standard
	RS422		A standard for serial, full-duplex (FDX) transmission of data based on
	(or EIA-422)		the RS422 Standard
	RS485		A standard for serial, half-duplex (HDX) transmission of data based on
	(or EIA-485)		the RS485 Standard
	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

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				FORWARD
			PHRASES, ABBREVIATIONS AND ACRONYMS - Continued
		Phrase, Abbreviation		Meaning
		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
		µA		Micro amp (1 millionth of an ampere)

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(This Page Is Intentionally Blank)

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CHAPTER 1 – SAFETY PRECAUTIONS

CHAPTER 1. SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions. In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired heaters and ANSI/NFPASB for LP gas-fired heaters. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

See pages 15 and 16 for information on installations within the Commonwealth of Massachusetts.

IMPORTANT

This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.

IMPORTANT

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.

WARNING

DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

WARNING

FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES. CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE.

WARNING

ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS EQUIPMENT. THEREFORE 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.

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CHAPTER 1 – SAFETY PRECAUTIONS

WARNING

A DOUBLE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL SUPPLY LINE OF THE UNIT. THE SWITCH 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

Figure 1-1. Manual Gas Shutoff Valve

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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 requirements extracted 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 DETECTORS. 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

acrawl 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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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 OBSTRUCTIONS".

4.INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b)EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1.The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

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

(c)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1.Detailed instructions for the installation of the venting system design or the venting system components; and

2.A complete parts list for the venting system design or venting system.

(d)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1.The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2.The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e)A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

______________________________________

[End of Extracted Information From 248 CMR 5.08 (2)]

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CHAPTER 2 – INSTALLATION

CHAPTER 2. INSTALLATION

2.1 INTRODUCTION

This Chapter provides the descriptions and procedures necessary to unpack, inspect and install AERCO Innovation Water Heater Models INN600, INN800, INN1060 and INN1350.

2.2 RECEIVING THE UNIT

Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight is approximately 1200 pounds. The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage. The unit should be completely inspected for evidence of shipping damage and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed.

NOTE

AERCO is not responsible for lost or damaged freight. Each unit has a Tip- N-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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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 they do not interfere with the removal of any panels, or inhibit service or maintenance of the unit.

	50.9"	18"
SEQUENCING		97.25"
		75.25"
VALVE
18.6"

	24"
30"	24"
	24"

4" HIGH PAD

Ensure that the housekeeping pad does NOT extend under the condensate assembly.

Figure 2-1. Innovation Water Heater Clearances

WARNING

KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.

CAUTION

While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY.

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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 TWO LUGS TO LIFT AND MOVE THE UNIT. 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 off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad (required) in the desired location.

In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion.

LIFTING LUGS

Figure 2-2. Partial Top View Showing Installed Lifting Lugs

IMPORTANT

If the Innovation Water Heater is equipped for use with the C-More Water 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.

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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.

P&T RELIEF HOT WATER OUTLET VALVE

2” NPT

NATURAL GAS INLET 1” NPT

						COLD WATER INLET
						2” NPT
	AIR INLET
EXHAUST MANIFOLD
						DRAIN VALVE

Figure 2-3a. Water Inlet & Outlet Locations

2.5.1 WHM Actuator-Controlled Ball Valve Installation

If the Innovation Water Heater was ordered for use with the C-More Water Heater Management (WHM) system and the actuator-controlled ball valve is not already installed on the 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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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.

BALL VALVE

WITH ACTUATOR

2” NPT

2” NPT UNION

HEATER DRAIN VALVE

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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HOSE

CONNECTION

TEST

HOSE BIB

HOT

WATER

OUT

TO DRAIN

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 the unit’s heat exchanger. The purpose of this loop is to provide feed-forward (FFWD) temperature control by mixing a portion of the hot water outlet with the cold water inlet of the unit. Temperature sensors located in the hot water outlet and cold water inlet provide temperature data to the C-More Control System. The Control System utilizes this data to modulate the fire rate (Air/Fuel Valve position) to precisely maintain the hot water outlet temperature at the selected setpoint temperature.

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P&T VALVE

HOT WATER OUTLET

RECIRCULATION

LOOP PIPING

HEAT EXCHANGER

RECIRCULATION

PUMP

COLD WATER INLET

DRAIN VALVE

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 & temperature 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 relief 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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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 manifold at the rear 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.

AIR INLET

COLD WATER

INLET 2” NPT

EXHAUST MANIFOLD

CONDENSATE DRAIN	DRAIN VALVE
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 general 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 for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.

While observing the above guidelines, install the condensate trap as follows:

Condensate Trap Installation

1.Connect the condensate trap inlet to the exhaust manifold drain connection using the appropriate piping components (nipples, reducers, elbows, etc.) for the heater installation site

2.At the condensate trap outlet, install a 3/4” NPT nipple.

3.Connect a length of 1” I.D. polypropylene hose to the trap outlet and secure with a hose clamp.

4.Route the hose on the trap outlet to a nearby floor drain.

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If a floor drain is not available, a condensate pump can be used to remove the condensate to drain. The maximum condensate flow rate is 10 GPH. The condensate drain trap, associated fittings and drain line must be removable for routine maintenance.

CAUTION

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.

CONDENSATE	EXHAUST
TRAP	MANIFOLD

ADAPTER

WITH 1” I.D. INTERNAL HOSE &

CLAMP

TO

FLOOR

DRAIN 3/4”

NIPPLES

SUPPOR

HOUSEKEEPING

Housekeeping pad should not extend under the condensate assembly

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 to 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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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.

WARNING

NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

CAUTION

Many soaps used for gas pipe leak testing are corrosive to metals. Therefore, piping must be rinsed thoroughly with clean water after leak checks have been completed.

NOTE

All gas piping must be arranged so that it does not interfere with removal of any covers, inhibit service/maintenance, or restrict access between the unit and walls, or another unit.

Innovation units contain a 1 inch NPT gas inlet connection on the 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 the manual shut-off valve installation in relation to the regulator. The maximum allowable gas pressure to the Heater is 14” W.C.

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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 natural 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 to the unit.

•A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C.

2.10.3.1 Massachusetts Installations Only

For Massachusetts installations, a mandatory external gas supply regulator must be positioned as shown in Figure 2-8. The gas supply regulator must be properly vented to outdoors. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator.

2.10.3.2 All Installations (Except Massachusetts)

For all installations (other than Massachusetts) that EXCEED 7” W.C. gas pressure, a mandatory external gas supply regulator must be positioned as shown in Figure 2-8. No regulator is required for gas pressures below 7” W.C. of pressure. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator.

NATURAL GAS

SUPPLY

1” MANUAL

SHUTOFF

VALVE

	GAS PRESSURE	DIRT TRAP
	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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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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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 through 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 the 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

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 SPARK 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 the ignition 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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