RERCO Innovation Water Heaters Installation, Operation and Maintenance Manual [INN 600N, INN 800N, INN 1060N, NN 1350N]

RERCO Innovation Water Heaters Installation, Operation and Maintenance Manual [INN 600N, INN 800N, INN 1060N, NN 1350N]

FOREWORD

The AERCO Innovation Series Potable Water Heaters are tankless modulating units which represent a true industry advance that meets the needs of today’s energy efficiency and environmental concerns. Innovation’s compact size and robust venting capabilities allow maximum installation flexibility. The Innovation Series Heaters, with their load tracking controls can modulate up to 30:1 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 625,000 BTU/Hr. (183.2 kW) input to 1,350,000 BTU/Hr. (395.6 kW) input, all with Natural Gas gas trains. The available models are listed below.

TABLE F1: INNOVATION POTABLE WATER HEATER MODELS

Models: Description: Shipping Weight.
INN 600N: Innovation Potable Water Heater, 625,000 BTU/Hr. (183.2 kW) Input: 1,060 lbs. (480.8 kg.)
INN 800N: Innovation Potable Water Heater, 800,000 BTU/Hr. (234.5 kW) Input: 1,080 lbs. (489.9 kg.)
INN 1060N: Innovation Potable Water Heater, 1,060,000 BTU/Hr. (310.7 kW) Input: 1,100 lbs. (499.0 kg.)
INN 1350N: Innovation Potable Water Heater, 1,350,000 BTU/Hr. (395.6 kW) Input: 1,150 lbs. (521.6 kg.)

All Innovation models include Water Heater Management (WHM) software, which is built into the unit’s Edge Controller. When the heater is ordered with a Sequencing Valve (SV), up to 16 Innovation Water Heaters can be controlled by the WHM system utilizing RS485 Modbus protocol.
Units can be ordered with or without Sequencing Valves. Plants that have 2 or more units and have implemented WHM, sequencing valves are required for proper function.
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 (pending approval):

1. South Coast Air Quality Management District (SCAQMD), Rule 1146.2
2. Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117, Rule 117.465

Whether used in singular or modular arrangements, Innovation Water 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.

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

FORWARD
AERCO Technical Terminology Meanings

TERMINOLOGY: MEANING
A (Amp): Ampere
ADDR: Address
AGND: Analog Ground
ALRM: Alarm
ANSI: American National Standards Institute
ASME: American Society of Mechanical Engineers
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 (0.45 kg) of water 1° F (0.55 ° C).
BTU/Hr.: BTUs per Hour (1 BTU/Hr. = 0.29 W)
Edge Controller: A control system developed by AERCO and used in all Benchmark, Innovation and KC1000 Series product lines.
CO: Carbon Monoxide
COMM (Comm): Communication
Cal.: Calibration
CNTL: Control
CPU: Central Processing Unit
DBB: Double Block and Bleed, a gas trains containing 2 Safety Shutoff Valves (SSOVs) and a solenoid operated vent valve.
DIP: Dual In-Line Package, a type of switch
EMS: Energy Management System; often used interchangeably with BAS
FM: Factory Mutual. Used to define gas trains.
FRU: Field Replacement Unit
GF-xxxx: Gas Fired (an AERCO document numbering system)
GND: Ground
GPH: Gallons per Hour
HX: Heat Exchanger
Hz: Hertz (Cycles Per Second)
I.D.: Inside Diameter
IGN: Ignition
IGST: Board Ignition/Stepper Board, contained in Edge Controller
INN: Innovation Water Heater
I/O: Input/Output
I/O: Box Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000: Series products
IP: Internet Protocol
IRI: Industrial Risk Insurers. Used to define gas trains containing two
SSOVs: and a solenoid operated vent valve (See DBB above)
ISO: International Organization for Standardization
Lbs.: Pounds (1 lb. = 0.45 kg)
LED: Light Emitting Diode
LN: Low Nitrogen Oxide
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
OMM: Operation and Maintenance Manual
OnAER: AERCO’s on-line remote system monitoring system
PCB: Printed Circuit Board
PMC: Board Primary Micro-Controller (PMC) board, contained in the Edge Controller
P/N: Part Number
PPM: Parts per Million
PSI: Pounds per Square Inch (1 PSI = 6.89 kPa)
PTP: Point-to-Point (usually over RS232 networks)
P &T: Pressure and Temperature
ProtoNode: Hardware interface between BAS and a boiler or water heater
PVC: Poly Vinyl Chloride, a common synthetic plastic
PWM: Pulse Width Modulation
RES:. Resistive
RS232: (or EIA-232): A standard for serial, full-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
SETPT (Setpt) Setpoint: Temperature
SHLD (Shld):  Shield
SPDT: Single Pole Double Throw, a type of switch
SSD: Client to Client 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 to prevent reflections that may cause invalid data in the communication
Tip-N-Tell: A device that indicates if a package was tipped during shipping
UL: A business that tests and validates products
VAC: Volts, Alternating Current
VDC: Volts, Direct Current
VFD: Vacuum Fluorescent Display, also Variable Frequency Drive
W: Watt
WHM: Water Heater Management
W.C.: Water Column, a unit of pressure (1-inch W.C. = 249 Pa)
µA: Micro amp (1 millionth of an ampere)

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 Section 1.4, below, 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.

WARNINGS!

• Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.
• Fluids under pressure may cause injury to personnel or damage to equipment when released. Be sure to shut off all incoming and outgoing water shutoff valves and carefully decrease all trapped pressures to zero before performing maintenance.
• ELECTRICAL CURRENT OF 110 (OR 220 VOLTS FOR INTERNATIONAL MODELS) AND 24 VOLTS AC MAY BE USED IN THIS EQUIPMENT. The unit’s power box cover (located behind the front panel door) must therefore be installed at all times, except during maintenance and servicing.
• A switch must be installed on the electrical supply line of the unit, 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.
• 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.

Figure 1.2: Manual Gas Shutoff Valve

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended that the initial startup procedures in Chapter 4 and the safety device test procedures in Chapter 5 of this manual be performed to verify all systemoperating parameters. If there is an emergency, turn off the electrical power supply to the unit and close the manual gas valve located upstream of the unit. The installer must identify the emergency shut-off device.

1.4 FOR MASSACHUSETTS INSTALLATIONS

Water heater Installations within the Commonwealth of Massachusetts must conform to the following requirements:

• Heater must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
• 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 (1.2m) 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 (2.1m) 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 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 (2.4m) above grade directly in line
   with 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)]

CHAPTER 2. INSTALLATION

2.1 INTRODUCTION

This Chapter provides the descriptions and procedures necessary to unpack, inspect and install AERCO Innovation Water Heaters.

2.2 RECEIVING THE UNIT

Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight is shown in Table F1 in the Forward to this manual. 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 shipping container, which 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’s 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.
Each unit is shipped with the accessory kit ordered with the unit. The specific parts you receive depend on which accessory kit was ordered, but all kits include the following parts:

• Condensate Drain Trap (P/N 99259)
• Automatic Float Vent (P/N 99285) and Service Check Valve (P/N 99286)
• Ignitor Kit (P/N 58023)
• Flame Rod Kit (P/N 24356-2)
• Air Vent

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.
If optional accessories were 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.

2.4 SITE PREPARATION

Ensure that the site selected for installation of the Innovation Water Heater includes:

• Access to AC Input Power at either:
  o 110 VAC, Single-Phase, 60 Hz @ 20 Amps
  o 220 VAC, Single-Phase, 50/60 Hz @ 20 Amps – International Models only

• Access to a Natural Gas line with a minimum pressure of 4 inches W.C. (1.0 kPa) 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 2.4.1-1 (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 (0.61 m)
Front: 24 inches (0.61 m)
Rear: 30 inches (0.76 m)
Top: 18 inches (0.46 m)

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. Zero side clearance is also permissible.

Figure 2.4.1-1: 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.
FOR MASSACHUSETTS 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, Section 1.4, above.

2.4.2 Setting the Unit

The unit must be installed on a 4 to 6-inch (10.2 to 15.2 cm) level housekeeping pad to avoid base corrosion. Two lifting lugs are attached to the top of the heat exchanger. USE THESE TWO LUGS TO LIFT AND MOVE THE UNIT.
To use the lifting lugs, first remove the unit’s left side panel, then disconnect the wire track attached to the under-side of the top sheet metal panel by pushing it towards the center of the unit; its clips should slide off the top panel’s lip. You can then remove the top panel.

Figure 2.4.2: Partial Top View Showing 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 to 6-inch (10.2 to 15.2 cm) 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.

2.5 WATER INLET AND OUTLET PIPING

The locations of the 2″ (5.08 cm) NPT cold water inlet and hot water outlet piping connections are shown in Figure 2.5. Flow rates through the unit are limited to 50 gallons (189 Liters) per minute continuous.
Shut-off valves and union connections must be installed in the inlet and outlet lines for maintenance. The use of dielectric unions is recommended.
When connecting the hot water outlet and cold-water inlet to building piping, first make sure the threads are thoroughly clean. AERCO recommends using Teflon tape followed by RectorSeal® T+2 when plumbing the inlet and outlet water connections.

IMPORTANT!
If the Innovation Water Heater is equipped for use with the Edge Controller’s 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.
NOTE:
All piping must be arranged so that it does not interfere with the removal of any covers, inhibit service or maintenance, or prevent access between the unit and walls, or another unit.

Figure 2.5: Water Inlet & Outlet Locations

2.5.1 WHM Actuator-Controlled Ball Valve Installation

If the Innovation Water Heater was ordered for use with the Water Heater Management (WHM) system and the actuator-controlled ball valve is not already installed on the unit, as shown in Figure 2.5.1, it will be packed separately within the shipping container.

NOTE:
AERCO requires use of WHM sequencing valves in a multi-unit configuration. See Section 4.2.6: Recommendations for WHM Operation for more information.
If installation is required, proceed as follows:

WHM BALL VALVE INSTALLATION Instructions

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 2.5.1.
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.

Figure 2.5.1: Innovation Water Heater Equipped with Sequencing Valve

2.5.2 Automatic Float Vent Installation

All Innovation Water Heaters require an Automatic Float Vent connected to a Safety Check valve.
Both must be installed on all units, on the top of the heat exchanger dome, as shown below. Both valves are included in the Accessory Kit shipped with the unit.
AUTOMATIC FLOAT VENT Instructions

1. All units are shipped with a 1/4″ plug in the center of the heat exchanger dome, which protrudes through a hole in the center of the top enclosure panel. Remove this hex nut.
2. Fasten the Automatic Float Vent (P/N 99285) to top of the Service Check valve (P/N 99268), as shown below. Leave the red and black plastic caps in place on the Automatic Float Vent.
3. Install the Service Check valve and Automatic Float Vent in place of the 1/4″ plug removed in step 1.

Figure 2.5.2: Automatic Float Vent Installation

2.6 TEST HOSE CONNECTION

A test hose must be connected to the drain valve on the hot water outlet. This is required for startup and testing (Figure 2.6). The test hose diameter should be a minimum of 3/4″ (1.9 cm).

Figure 2.6: Test Hose Location

2.7 INTERNAL RECIRCULATION LOOP

The internal Recirculation Loop Assembly is located inside the unit enclosure at the rear of the unit. To access this assembly, the right-rear panel must be removed, as shown in Figure 2.7.
This assembly contains a recirculation pump that connects the upper hot water outlet to the lower cold-water inlet to the unit’s heat exchanger. 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 to the unit. Temperature sensors located in the hot water outlet and cold-water inlet provide temperature data to the Edge Controller. The Controller 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.

REAR VIEW – REAR PANEL & EXHAUST VENT REMOVED
Figure 2.7. Recirculation Loop

2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION

An ASME rated Pressure & Temperature (P&T) Relief Valve must be installed on each Innovation water heater, on the hot water outlet at the top of the Recirculation Loop Assembly as shown in Figure 2.7, above. The valve setpoint is 150 psig (1,034 kPa) at 210°F (98.9° C).
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 6 inches (15.2 cm) 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 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 2.9-
1). This drain port must be connected to the Condensate Trap (P/N 99259), which is packed within the unit’s shipping container.

PARTIAL REAR VIEW
Figure 2.9-1: Condensate Drain Connection Location

Sample Condensate Trap installation is shown in Figure 2.9-2. 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 must be level with, or lower than the exhaust manifold drain port.
• The base of the condensate trap can be supported to ensure that it’s level, but that’s not required.
• The trap must be removable for routine maintenance (see Section 6.9 for instructions).
• If a floor drain is not available, a condensate pump can be used to remove the condensate to a drain.
• The maximum condensate flow rate is 10 Gallons (37.85 L) per hour.

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

CONDENSATE TRAP INSTALLATION Instructions

1. Attach the 3/4” NPT nipple (P/N 94136) to the exhaust manifold’s drain port.
2. Loosen the condensate trap’s cap, then install it on the open end of the 3/4“ nipple.
3. Rotate the cap so the outlet faces towards the condensate drain, then tighten it.
4. Connect a length of 3/4” (1.91 cm) I.D. hose to the trap outlet. Use PVC, stainless steel, aluminum or polypropylene for condensate drain piping. DO NOT USE carbon or copper components
5. Route the hose from the trap outlet to a nearby floor drain and secure it with a hose clamp

Figure 2.9-2: Sample Condensate Trap Installation – Left Side View

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.

2.10 GAS SUPPLY PIPING

The minimum, nominal and maximum allowable gas pressures are listed in the Innovation-Edge Gas Supply Design Guide (TAG-0091, GF-5036). This guide must be consulted prior to designing or installing any gas supply piping.

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 Natural Gas inlet connection on the rear of the unit. The location of the gas inlet is shown in Figure 2.7, above.

Inlet Connection: Innovation Model
1.5 Inch (3.8 cm) Natural Gas: All INN models

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. (3.49 kPa). 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 is as follows:

• The maximum static pressure to the unit must not exceed 14” W.C. (3.49 kPa).
• The minimum pressure for Natural Gas is 4.0” W.C. (1.0 kPa).
• The gas supply pressure to the unit must be of sufficient capacity to provide the following
  while maintaining a recommended (nominal) gas pressure of 7“ W.C.(1.74kPa) with the
  unit operating at maximum capacity:
  o INN 600N: 625,000 BTU (183 kW)
  o INN 800N: 800,000 BTU (234 kW)
  o INN 1060N: 1,060,000 BTU (311 kW)
  o INN 1350N: 1,350,000 BTU (410 kW)

2.10.2 Manual Gas Shutoff Valve

A manual shut-off valve is factory-installed in the gas supply line at the unit, as shown in Figure 2.5. Additionally, if a gas regulator is installed upstream of the unit, refer to Figure 2.10.3.2 to determine the location of the manual shut-off valve installation in relation to the regulator. The maximum allowable gas pressure to the Water Heater is 14” W.C. (3.49 kPa).

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 50,000 BTU/Hr. to 3,180,000 BTU/Hr. (58.61 kW to 932.0 kW) of natural gas while maintaining a gas pressure of 8.0” W.C. (1.99 kPa) minimum to the unit.
• A lock-up style regulator is required when gas supply pressure exceeds 14” W.C. (3.49 kPa).

2.10.3.1 Massachusetts Installations Only

For Massachusetts installations, a mandatory external gas supply regulator must be positioned as shown in Figure 2.10.3.2, below. 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)

An external gas supply regulator is recommended for all installations (other than Massachusetts) that exceed 7” W.C. (1.74 kPa) gas pressure, positioned as shown in Figure 2.10.3.2. No regulator is required for gas pressures below 7” W.C. (1.74 kPa). Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator.

Figure 2.10.3.2: Manual Gas Shut-Off Valve Location

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.

2.11 AC ELECTRICAL POWER WIRING

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

POWER BOX LOCATIO N   – PO WER BOX WITH COVER REMOVED
Figure 2.11-1: Power Box Location – Partial Front View, Front Panel Removed

The Power Box contains the terminal block shown in Figure 2.11-2. A wiring diagram showing the required AC power connections is mounted on the front cover of the Power Box.

Figure 2.11-2: AC Terminal Block Configurations for 110 and 220 VAC Input

For International models only, units that connect to 220VAC power input must include a 220VAC to 120VAC transformer, shown in Figure 2.11-3. Connect the incoming 220VAC electrical line to the same terminals in the Power Box as the 120VAC line would be connected. The transformer is pre-wired to convert the power to 120VAC. No further steps are needed.

Figure 2.11-3: 220 VAC Transformer – Front and Side Panels Removed

2.11.1 Electrical Power Requirements

AERCO Innovation Heater built for the International market require the following input voltage:

• 120 VAC, single-phase, 50/60 Hz @ 20A
• 220 VAC, single-phase, 50/60 Hz @ 20A

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.

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 water heater 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.

2.12 FIELD CONTROL WIRING

Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the Edge Controller used with all Innovation current generation water heaters does allow for some control and monitoring features. Wiring connections for these features are made in the Input/Output (I/O) Box. The I/O Box is located to the left of the Controller’s front panel (Figure 2.12-1) behind the removable front panel door. To access the I/O Box terminal strips shown in Figure 2.12-2, 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 2.12-1: Input/Output (I/O) Box Location – Partial Front View

Refer to the wiring diagram provided on the cover of the I/O Box (Figure 2.12-2) 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 2.12-2 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.

CAUTION!
DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage.

Figure 2.12-2: 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 (+ & -) connect to the spark monitor (P/N 61034, also called “AC Current transducer”), which monitors the current going to the ignition transformer (P/N 65085, see Section 6.14). If the current is insufficient (too high or low) during the ignition sequence, the controller will abort the ignition cycle. The controller will attempt up to three ignition cycles. If the current is insufficient by the third try, the controller will shut down and display a fault message.

2.12.5 ANALOG IN Terminals

The ANALOG IN terminals (+ & -) are used when an external signal is used to change the unit’s setpoint or air/fuel valve position. There are four signal types:

• 4 to 20 mA
• 0 to 20 mA
• 1 to 5 VDC
• 0 to 5 VDC

The factory default setting is 4 to 20 mA , however this can be changed in the Remote Signal parameter in Main Menu → Advanced Setup → Unit → Application Configuration (note, Operating Mode must equal Remote Setpoint).
If voltage rather than current is selected as the drive signal, a DIP switch must be set on the Interface Board, located inside the Edge Controller. Refer to Appendix G – Edge [i] Controller Views for information on setting DIP switches. If Remote Signal is set to either 4 to 20 mA or 0 to 20 mA, DIP switch #4 in block SW1 must be set to mA. If Remote Signal is set to 1 to 5 VDC or 0 to 5 VDC , DIP switch #4 must be set to V.
All supplied signals must be floating (ungrounded) signals. Connections between the source and the Heater’s I/O Box must be made using twisted shielded pair of 18–22 AWG wire such as Belden 9841. Polarity must be maintained, and the shield must be connected only at the source end and must be left floating (not connected) at the unit’s I/O Box.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F (4.44 °C) to 240°F (115.6 °C) 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 Isolation 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 time 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 Board will be inserted at the factory.

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 two ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor Setpoint, Outlet Temperature, Valve Position 4-20 mA, Valve Position 0-10v or be set to OFF.
Default setting in the Edge Controller is Valve Position 0-10 v and settings behave as follows:

1. 0-10VDC must be selected for the voltage output 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.

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 Edge Controller’s 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 Edge 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. When any of the 4-20 mA options is selected for the Analog Outputs (Section 2.12.8), the output from the VFD/Blower terminals is disabled.

2.12.12 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 and DELAYED INTL’K IN in Figure 2.12-2). 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 REMOTE INTL’K Terminals

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 DELAYED INTL’K Terminals

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 (Auxiliary Delay) that holds the start sequence of the unitlong enough for a proving switch to make (close) can be programmed.
Should the proving switch not prove within the programmed time frame, the unit will shut down.
The Auxiliary Delay parameter (in Main Menu → Advanced Setup → Ancillary Device → Interlocks ) can be programmed from 0 to 240 seconds.

2.12.13 FAULT RELAY Terminals

The fault relay is a single pole double throw (SPDT) relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed. The Fault Relay connections are shown in Figure 2.12-2.

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 2.12-2 to locate the AUX RELAY terminals (N.C., COM, & N.O.) for wiring connections.

2.13 FLUE GAS VENT INSTALLATION

The Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056) must 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 (21 mm per m) to avoid any condensate pooling and to allow for proper drainage. In addition, you must add a bead of high temperature red silicon sealant (such as Permatex Hi-Temp Red RTV or Loctite Superflex Red High Temp RTV) between the exhaust manifold and the mating flange of the exhaust connector, as shown in Figure 2.13.

Figure 2.13. Exhaust Vent Connection

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 (42.7m) or 0.81” W.C. (201 Pa) with 6” (15.24 cm) 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. (-24.9 Pa). 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:

Selkirk Corporation – Heatfab Division
130 Industrial Blvd. Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
Watertown Supply
33 Grove St. Watertown, MA 02472
Phone: 617-924-2840
http://www.watertownsupply.com/
Glover Sheet Metal, Inc.
44 Riverdale Ave. Newton, MA 02485
Phone: 617-527-8178
www.gloversheetmetal.com
Emerson Swan Co
Engineering Products Department 300 Pond St. Randolph, MA 02368
Phone: 781-986-2555
Fax: 781-986-2027
www.emersonswan.com

2.14 COMBUSTION AIR

The Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056) must be consulted before any flue or inlet air venting is designed or installed.
Air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.
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 refrigerants. 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 next two sections, below.
For combustion air supply from ducting, see Section 2.15: Ducted Combustion Air, or consult the Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056).

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 sq. in. (6.45 sq. cm) for each 4000 BTUs (1.172 kW) input of the equipment or 250 sq. in. (1613 sq. cm) of free area. The free area must 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
sq. in. (6.45 sq. cm) per 1000 BTU (0.293 kW) of total input or 1000 sq. in. (6,451 sq. cm) of free area. The free area must take into account any restrictions, such as louvers.

2.15 DUCTED COMBUSTION AIR

See the Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056).
The AERCO Innovation Water Heater is UL listed for 100%-ducted combustion air. For ducted combustion air installations, the 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 considered when calculating the total maximum allowable venting run. When using the heater in a ducted combustion air configuration, each unit must have a minimum 6-inch (15.24 cm) diameter connection at the unit.

CHAPTER 3. OPERATION

3.1 INTRODUCTION

The information in this Chapter provides a guide to the operation of the Innovation Water Heater using the Edge Controller mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation 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.

CAUTION!
All the installation procedures in Chapter 2 must be completed before attempting to start the unit.
WARNING!
ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 110 OR 220 AND 24 VOLTS AC. IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS.
WARNING!
DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE. THIS SITUATION WILL VOID ANY WARRANTY.

3.2 EDGE CONTROLLER DESCRIPTION

The Innovation’s Edge Controller, shown in Figure 3.1, contains all the controls, indicators and displays necessary to operate, adjust and troubleshoot your Innovation Water Heater.
The Edge Controller contains a capacitive touchscreen, which is a highly sensitive device. It continuously checks for user interaction at a very high frequency.
Mechanical room environments are sometimes harsh, electromagnetically noisy and dirty, and can experience wide temperature ranges, and can be difficult for sensitive electronic components. Care should be taken to not damage the touchscreen or get any grease or pipe dough on the touchscreen.

Figure 3.2: Edge Controller Front Panel Layout

1. Multi-Function Bar, shows either:
   • Fire Rate
   • Valve Position

2. Parameter Indicator for both temperature read-outs:
   • LEFT: Inlet temperature or Setpoint temperature
   • RIGHT: Outlet temperature or System Header temperature

3. Temperature scale indicator: Fahrenheit or Celsius

4. Configurable temperature read-outs (2):
   • LEFT: Inlet or Setpoint temperature
   • RIGHT: Outlet or System Header temperature

5. Operation Mode Indicators (2):
   • LEFT: Demand or Manual
   • RIGHT: Manager (BST only), COMM when communicating

6. Edge Controller Touchscreen: see Section 1.8, below

7. Soft Keys: see table below

8. onAER Indicator Light Fault Indicator Light

9. Ready Light

10. Enable/Disable Switch

11. Low Water Level Test buttons (2):
    • TEST: Initiates Low Water test
    • RESET: Resets unit after Low Water test

The Soft-Keys on the Controller’s front face function as follows:

TABLE 3.2: Controller Front Panel Controls

Icon: Name: Description

:Previous: Takes you to the previous screen.
:Home: Takes you to the touchscreen’s Main Menu (see Figure 1.2). If pressed during a procedure, it aborts the procedure.
:Up/Down: These buttons activate a selection box that can then be moved sequentially through the editable/selectable parameters starting from top left (not the title bar with home/previous icons) and moving right and then down as in reading a book.
:Edit: This button allows the editing of the parameter that is currently selected through use of up/down arrows.
:Enter: This button allows you to finalize a selection (for instance, a selected from a menu or from a pop-up (for example, password entry input completion).
Note, all alphanumeric data entry is entered in the touchscreen.
: Fault: A red light Indicates that the Controller is in a Fault condition.
: Clear: Clears a fault – the red Fault light goes out.

If the touchscreen becomes non-responsive at any time, simply press the CLEAR button; this resets the touchscreen and should clear the problem.

3.2.1 Touchscreen Button Functionality

Some of the same Soft-Key controls, as well as some additional controls, appear within the Controller’s touchscreen. They function as follows:

TABLE 3.2.1: Touchscreen Controls

Icon: Name: Description

: Previous: Takes you to the previous screen.
: Home: Takes you to the touchscreen’s Main Menu (see Figure 3.3). If pressed during a procedure, it aborts the procedure.
: Left Right: The LEFT arrow moves to previous point in the array or list and RIGHT arrow moves to next point in the array or list.
: Up/Down: The UP arrow increases a value, DOWN decreases value.
: Page Left:  The arrows on left and right edges of the touchscreen scroll Page Left or
Page Right: Page Right in a round-robin sequence.
: Page Up Page Down: moves up and down the pages.
: Abort: The Abort button appears when a process may need to be exited prior to completion.
: Next: Pressing Next takes you to the next screen in a multi-step procedure. Some
procedures have a Proceed button instead.
: Save
1. Pressing SAVE on a pop-up screen saves the entered data and returns you to the previous screen.
2. Pressing SAVE on a non-popup screen saves the entered data and takes you to the next screen.
: Retry: Pressing Retry takes you to the previous screen and re-attempts the process
step that caused the notification message to appear.
: Help: Takes you to a Help screen specific to the subject.

3.2.2 Logging In

The Edge Controller user interface is protected by password levels to prevent unauthorized use.
The Level 1 password, which allows some basic setting changes, is 159. Higher level passwords (appropriate for AERCO Trained Technicians), are distributed on an individual basis when after technicians have complete AERCO certified training.
Complete the instructions below to log in to the Edge Controller.

LOGGING IN Instructions

1. Go to the Main Menu, press Advanced Setup, then press the Access button. The Enter Password screen appears.
   
   Figure 3.2.2: Enter Password Screen

2. Use the number keypad to enter the password (each number appears as a X), then press Save.

3. You are now directed to the Main Menu (see Figure 3.3) or returned to the last screen opened before the unit timed out. You have access to the functionality associated with your password level.

3.3 MENU STRUCTURE

The Main Menu give you access to all Edge Controller user functionality. There are four major divisions within the menu structure.

Figure 3.3: The Edge Controller Main Menu

3.3.1 Unit Status Menu
The Unit Status menu contains the following sections and parameters. Unlike other Edge menus, navigation starts at the Unit Status screen and proceeds from there by scrolling to the right.

Main Menu → Unit Status

Target Fire Rate: Read Only: The target Fire Rate (0% to 100%).
Current Fire Rate: Read Only: The current Fire Rate (0% to 100%).
Flame Strength: Read Only: The current Flame Strength (0% to 100%).
Feed Forward: Read Only: The current Feed Forward temperature.
Inlet Temp: Read Only: The current Inlet Water temperature
Air Inlet: Read Only: The current Air Inlet temperature.
Setpoint: Read Only: The unit’s current Setpoint.
Outlet: Read Only: The current Outlet temperature.
Exhaust: Read Only: The current Exhaust temperature.

Main Menu → WHM Cascade Status

Avg Fire Rate: Read Only: The average Fire Rate (0% to 100%).
Units Online: Read Only: The number of units in the WHM cascade online.
Setpoint: Read Only: The WHM cascade’s current Setpoint.
Units Available: Read Only: The number of units in the WHM cascade.
Avg Outlet: Read Only: The average outlet temperature.
Units Firing: Read Only: The number of units in the WHM cascade firing.

Main Menu → Runtime Statistics

Average Cycles Per Hour: Read Only: The unit’s average number of cycles per hour.
Run Hours: Read Only: The number of hours the unit has run since startup.
Cycle Count: Read Only: The number of cycles during unit run hours.

Main Menu → Unit Event History

Event: Read Only: Lists the unit’s warning and fault events.

Main Menu → Plant Event History

Event: Read Only: Lists the plant’s warning and fault events

3.3.2 Calibration Menu

The Calibration menu contains the following sections and parameters:

Main Menu → Calibration → Combustion Calibration

NOx Requirement Select Select the unit’s NOx requirement: None, <= 20 or <= 9 PPM.
Valve Position – Target Read Only The unit’s target Valve Position.
Valve Position – Reading Read Only The unit’s actual Valve Position.
Blower Voltage – Target Read Only Target blower voltage for current Valve Position.
Blower Voltage – Reading Read Only The unit’s actual blower voltage.
O2% – Target Read Only The unit’s target O2% in the exhaust.
O2% – Reading Numeric Entry The unit’s actual O2% in the exhaust.
CO – Target Read Only The target CO amount in the exhaust, in ppm.
CO – Reading Numeric Entry The actual CO amount in the exhaust, in ppm.
NOx – Target Read Only The target NOx amount in the exhaust, in ppm
NOx – Reading Numeric Entry The actual NOx amount in the exhaust, in ppm.
Flame Strength – Reading Numeric Entry The unit’s Flame Strength, from Multimeter
Air Temperature – Reading Read Only The current air temperature.
Downstream Gas pressure Numeric Entry Appears only when fire rate = 100%.
Blower Voltage Adjust Adjust as needed to match targets to actual readings

3.3.2.1 Main Menu → Calibration → Input/Output

Main Menu → Calibration → Input/Output → Temperature Sensors

Sensor Select Select: Feed Forward, Exhaust, Outside Temp, Air
Inlet, Lower Inlet, Outlet.
Offset Numeric Entry Optional offset applied to current Sensor
Current Reading Read Only Current sensor’s current reading. (Flow In Adj & Flow Rate removed) .

Main Menu → Calibration → Input/Output → Analog Inputs

Analog Name Select Select: Flow or Remote Analog In.
Offset Numeric Entry A correction value to selected input, if needed.
Current Reading Read Only Current reading of selected input.

Main Menu → Calibration → Input/Output → Analog Outputs

Analog Name Read Only The name Analog Output.
Level Numeric Entry Set the output’s level (0.00 to 20.00 mA)
Offset Numeric Entry A correction value to the analog output, if needed (-2.00 to 2.00).
Feedback Read Only Displays feedback from Analog Output.

3.3.2.2 Main Menu → Calibration → Subsystems

Main Menu → Calibration → Subsystems → Air Fuel Valve

Valve Position Manual Adjust Set to desired Valve Position.
A/F Sensitivity Numeric Entry Set Air/Fuel Valve sensitivity (1% to 5%)

Main Menu → Calibration → Subsystems → Spark Monitor

Spark Monitor Enabled/Disabled Enables/Disables the Spark Monitor.
Min Spark Numeric Entry Minimum spark. (0.00 to 0.29 amps)
Max Spark Numeric Entry Maximum spark. (0.30 to 2.50 amps)

3.3.2.3 Main Menu → Calibration → Combustion Summary

Main Menu → Calibration → Combustion Summary

Valve Position Read Only Displays combustion calibration valve steps.
O2 Read Only Displays combustion calibration O2 results.
NOx Read Only Displays combustion calibration NOx results.
CO Read Only Displays combustion calibration CO results.
Flame Strength Read Only Displays combustion calibration flame strength.

3.3.3 Diagnostics Menu
The Diagnostics menu contains the following sections:

3.3.3.1 Main Menu → Diagnostics → Manual Run

Main Menu → Diagnostics → Manual Run

Manual Mode Enable/Disable Enables/disables running in Manual Mode.
Fire Rate Adjust Manual fire rate adjustment, 0 to 100%
Flame Strength Read Only The flame strength sensed in the burner, 0 to 100%

3.3.3.2 Main Menu → Diagnostics → Front Panel

Main Menu → Diagnostics → Front Panel

Touchscreen Display Test On/Off Starts the Touchscreen Display Test.
Touchscreen Test On/Off Starts the Touchscreen Test.
Status Light Test On/Off Starts the Status Light Test.
Keypad and Switch Test On/Off Starts the Keypad and Switch Test.

3.3.3.3 Main Menu → Diagnostics → Analog Outputs and Relays

Main Menu → Diagnostics → Analog Outputs and Relays → Relays

Ignition Relay Enable/Disable Enables/Disables the Ignition Relay.
Blower Relay Enable/Disable Enables/Disables the Blower Relay.
Pump Relay Enable/Disable Enables/Disables the Pump Relay.
Aux Relay Enable/Disable Enables/Disables the Aux Relay.
Fault Relay Enable/Disable Enables/Disables the Fault Relay.

Main Menu → Diagnostics → Analog Outputs and Relays → Analog Outputs

Valve Read/Adjust Adjustable display of the A/F valve Position.
Blower Read/Adjust Adjustable display of the Blower.

3.3.3.4 Main Menu → Diagnostics → Subsystems

Main Menu → Diagnostics → Subsystems → Air Fuel Valve Stepper Motor

Auto Stroke Toggle Initiates A/F cycle, 0 to 100 to 0%
Valve Position In Adjust Manual adjustment of A/F Valve 0 to 100%.

Main Menu → Diagnostics → Subsystems → Blower

Profile Select Select the profile to run (default = Profile 1).
Profile Run Enable/Disable Enables running the selected profile.
Blower Numeric Entry Manually adjust the Blower’s voltage.

Main Menu → Diagnostics → Subsystems → Ignition

Ignition Spark Enable/Disable Enables testing the unit’s ignition spark.
Spark Current Read Only The current Spark Current.

3.3.3.5 Main Menu → Diagnostics → System

Main Menu → Diagnostics → System → Pre-Start Up

Pre-Start Up Mode Enable/Disable Enables Pre-Start Up Mode, a test of various system components without firing the unit.
Valve Position Out Read Only The current A/F valve position.
Blower (voltage) Read   Only The current Blower voltage.
Blower (RPM) Read Only The current Blower RPM.
Spark Current Read Only The current Spark Current.

Main Menu → Diagnostics→ System → Versions

Serial Number Read   Only The unit’s serial number.
Software Version Read Only The Controller’s software version.
Graphic Data Version Read Only The Controller’s graphic version.
Display Version Read Only The Controller’s display version.
I/O Board Version Read Only The I/O board version.
Touch Version Read Only The touch screen version.
Bluetooth Version Read Only The Bluetooth version.
Framework Version Read Only The Framework version.
Bootloader version Read Only The Bootloader version.
Display BL Version Read Only Display Bootloader version.
I/O PCB BL Version Read Only I/O Board PCB Bootloader version.

3.3.3.6 Main Menu → Diagnostics → Comm & Network

Main Menu → Diagnostics → Comm & Network → IP Network

Unit IP Address Read Only The unit’s IP address.
Subnet Mask Read Only The unit’s subnet mask address.
Gateway IP Address Read Only The unit’s gateway IP address.
DSN 1 Read Only The unit’s DSN 1 address.
DSN 2 Read Only The unit’s DSN 2 address.
Unit MAC Address Read Only The unit’s MAC address.
Network Status Read   Only The unit’s current network status.

Main Menu → Diagnostics → Comm & Network → BAS

BAS Read Only The Building Automation System protocol.
Communication Address Read Only The unit’s BAS address.
Device Instance Read Only The unit’s Device Instance within BAS.
Unit IP Address Read Only The unit’s IP address on the network.
Unit MAC Address Read Only The unit’s MAC address within BAS.
Last Command Received Read   Only The last command received by the unit.
BAS IP Read Only If Security is enabled, this is the IP of the BAS system that the unit can only communicate with.
Network Status Read Only The unit’s BAS network’s current status.

Main Menu → Diagnostics → Comm & Network → onAER

Unit IP Address Read Only The unit’s IP address.
Upload Time Read Only Frequency at which the unit transmits data to onAER
Test Setup Enable Initiates test o onAER functionality.
Test Heartbeat Enable Initiates test of the onAER heartbeat.

Main Menu → Diagnostics → Comm & Network → USB Storage

Status Read Only Status of the USB device.
Serial Number Read Only The serial number of the USB device.
Size Read Only The size of the USB device.
Available Space Read Only The amount of free space on the USB device.

3.3.3.7 Main Menu → Diagnostics → Input/Output Summary

Main Menu → Diagnostics → Input/Output Summary

Air Inlet Read Only Displays the current air inlet temperature.
Exhaust Read Only Displays the current exhaust temperature.
Outlet Read Only Displays the current outlet water temperature.
Lower Inlet Read Only Displays the current lower inlet temperature.
Feed Forward Read Only Displays the current Feed Forward temperature.
Blower Read Only Displays the current Blower voltage.
Remote Ain Read Only Displays the value of Remote Analog In.
Cascade Valve Read Only Displays the state of the Cascade Valve.
Cascade Vlv Fdbk Read Only Displays the Cascade Valve feedback.
Outside Temp Read Only Not in use.

3.3.4 Advanced Setup Main

The Advanced Setup menu contains the following sections:

Main Menu → Advanced Setup → Access

Password Numeric Entry Enter 159 or your password, then press Save.

3.3.4.1 Main Menu → Advanced Setup → Unit

Main Menu → Advanced Setup → Unit → Unit Settings

Unit Serial # Entry The unit’s factory-set serial number. Do NOT change except when replacing the Controller.
Unit Type Enter Displays unit’s product and model. Do NOT change except when replacing the Controller.
Unit Size Select Displays the unit’s sizes. Do NOT change except when replacing the Edge Controller.
Date Numeric Entry Allows you to set the current date.
Time Format Toggle Choose the 12 Hour or 24-Hour time format.
Time Numeric Entry Allows you to set the current time. Vent Type Select Choose the vent material: PVC, cPVC, Polypro, Stainless Steel.
Exhaust Safety Enable/Disable Depending on exhaust temperature and value of Vent Type, triggers an exhaust temperature warning, reduced fire rate or unit shutoff.
Fuel Type Toggle Choose Natural Gas
Control Type Read Only Displays the controller type: Edge [i]. Language Select Choose the language of the Controller’s display: English, Spanish, French.
Unit of Measurement Toggle Choose unit of measure: Metric or English.
Temperature Sensor Read Only Displays the sensor type in use: Balco.
Standby Pump On Time Numeric Entry The amount of time internal recirculation pump runs when unit is in standby. Pump has a continual operation.
Standby Pump Off Time Numeric Entry The amount of time internal recirculation pump is disabled during unit standby. Pump is continually cycled during standby (0 to 30 min.).
Post-Fire Pump Time Numeric Entry The amount of time internal recirculation pump runs after unit has entered standby mode (0 to 30 min.).
Beeper Toggle Enables/disables the audible fault alarm.
Run Cycles Numeric Entry Displays number of run cycles since last system reset. Can be reset to 0 or any number.
Run Hours Numeric Entry Displays the number of run hours since the last system reset. Can be reset to 0 or any number.
Reset All Settings Select Yes/No Press Yes to restore all settings to default values.
Clear Fault Log Select Yes/No Press Yes to clear the Unit Event History.

Main Menu → Advanced Setup → Unit → Front Panel Configuration

Upper Left Display Select Choose Setpoint or Water Inlet.
Upper Right Display Select Choose Water Outlet or System Header.
Multi-Function Bar Select Choose the Multi-Function Bar display: Fire Rate or Valve Position.
Brightness Numeric Entry Adjusts Touchscreen brightness.
Screensaver Password Enable/Disable If set to Enabled, all access to the Controller requires a Password.
Screen Timeout Minutes Numeric Entry Specifies touchscreen timeout in minutes (Screensaver Password = Enabled).
Screen Timeout Now Toggle Choose Yes to put Controller into sleep mode. (Screensaver Password = Enabled).

Main Menu → Advanced Setup → Unit → Settings Transfer

Restore All Settings Select Restores all settings to the factory default.
Restore Common Settings Select Restores common settings to the factory default.
Save All Settings Select Saves all settings to USB or onboard memory.

Main Menu → Advanced Setup → Unit → Fault Management

Power Reset Toggle Choose if power fault reset mode, Manual or Automatic.
Water Temp Reset Toggle Choose water temperature fault reset mode, Manual or Automatic.
Gas Pressure Reset Toggle Choose if gas pressure fault reset mode, Manual or Automatic.

Main Menu → Advanced Setup → Unit → Freeze Protection

Freeze Protection Enable/Disable Enables/disables Freeze Protection functionality.
Pump On Temperature Numeric   Entry If enabled, ambient temperature below this value triggers the system pump to start (20 to 245°F , Freeze Protection = Enabled).
Unit On Temperature Numeric Entry Ambient temperature below this value triggers the unit to
fire (20 to 245°F , Freeze Protection = Enabled).
Stop Temperature Numeric   Entry Ambient temperature above this value returns system to normal operation (20 to 245°F, Freeze Protection = Enabled).

Main Menu → Advanced Setup → Unit → Unit Application Configuration

Unit Application Select Select unit’s application: DHW
Operating Mode Toggle Choose either Constant or Remote Setpoint.
Setpoint Numeric Entry Sets the unit’s setpoint (Operating Mode = Constant Setpoint).
Setpoint Low Limit Numeric Entry Sets the minimum setpoint.
Setpoint High Limit Numeric Entry Sets the maximum setpoint.
Remote Signal Select Select the source of the (Operating Mode = Remote Setpoint).
Unit Address Toggle Specifies the unit’s Modbus address (Operating Mode = Remote Setpoint, Remote Signal = Network)).
Cascade Baud Rate Numeric Entry Specifies Modbus baud rate (Operating Mode = Remote Setpoint, Remote Signal = Network).

Main Menu → Advanced Setup → Unit → Maintenance

12 Month Maintenance Complete? Yes/No Specifies 12 Month Maintenance completed.
Fire Side Inspection Yes/No Specifies Fire Side Inspection completed.
Optical Burner Inspection Yes/No Specifies Optical Burner Inspection completed
Water Side Inspection Yes/No Specifies Water Side Inspection completed. CSD-1 Safety Device
Inspection Yes/No Specifies CSD-1 Safety Device inspection completed.
Combustion Calibration Check Yes/No Specifies Combustion Calibration Check completed.

3.3.4.2 Main Menu → Advanced Setup → WHM Cascade

Main Menu → Advanced Setup → WHM Cascade → Cascade Configuration

WHM Unit Mode Select Specifies Unit Mode: Off, WHM Client or WHM Manager.
Auto-Manager Transfer Enable/Disable Allows WHM Manger functionality to be transferred to another unit if the WHM Manger malfunctions (WHM Unit Mode = WHM Manager).
Auto-Manager Timer Numeric Entry Specifies duration of WHM Manger malfunction that triggers Auto-Manager Transfer (10 to 120, WHM Unit Mode = WHM Manager).
Auto-Manager Addr Read Only The address of the WHM Manger (0 to 16, WHM Unit Mode = WHM Manager).
Backup Manager Addr Numeric Entry The address of the unit designated as the Backup WHM Manger (0 to 16) (WHM Unit Mode = WHM Manager).

Main Menu → Advanced Setup → WHM Cascade → Cascade Communication

Unit Address Numeric Entry The unit’s address in the WHM cascade.
Min Address Numeric Entry The minimum address in the WHM cascade (1 to 16, WHM Unit Mode = WHM Manager).
Max Address Numeric Entry The maximum address in the WHM cascade (1 to 16, WHM Unit Mode = WHM Manager).
Cascade Baud Rate Select The communication baud rate in the cascade.
Network Timeout Numeric Entry The timeout before a Modbus Fault is declared (5 to 999 sec.).
Error Threshold Numeric Entry The number of Modbus Comm errors allowed before invoking a Modbus comm fault (1 to 9).
Comm Error 1-8 Read Only The number of comm errors on ports 1 – 8.
Comm Error 9-16 Read Only The number of comm errors on ports 9 – 16.
SSD Address Numeric Entry The Client/Client Device address (0 to 250).
SSD Temp Format Toggle Choose either Points or Degrees (WHM Unit Mode = WHM Manager).
Unit/Plant Failsafe Mode Toggle The unit or plant’s operating mode if communication is lost: Shutdown or Constant Setpoint.
Unit/Plant Failsafe Setpoint Numeric Entry The unit or plant’s setpoint if communication is lost (Unit Failsafe Mode = Constant Setpoint).
Time & Date Sync Enable/Disable If Enabled, all Client units in the Cascade will synchronize time and date with the WHM Manager (WHM Unit Mode = WHM Manager).
WHM Min Units Numeric Entry The minimum number of units in the WHM cascade (1 to
16, WHM Unit Mode = WHM Manager).
WHM Max Units Numeric Entry The maximum number of units in the WHM cascade (1 to 16, WHM Unit Mode = WHM Manager).
WHM On Timeout Numeric Entry Specifies the time the WHM Manager must wait for a backup Client unit to turn on (15 – 300, WHM Unit Mode = WHM Manager).

Main Menu → Advanced Setup → WHM Cascade → WHM Application Configuration

Application Read Only The WHM Cascade’s application: DHW.
Operating Mode Read Only The WHM Cascade’s operating mode, Constant Setpoint.
WHM Setpoint Numeric Entry The WHM Cascade’s Setpoint (Operating Mode = Constant Setpoint).

Main Menu → Advanced Setup → WHM Cascade → Operating Controls

Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Sequencing Controls

Low Flow Threshold Numeric Entry Specifies the valve position below which the plant enters this mode (10% to 35%).
Next On Valve Pos Numeric Entry The valve position that triggers the next unit to come on
line (16% to 100%).
Next Off Valve Pos Numeric Entry The valve position that triggers the next unit to go off line (16% to 100%).
WHM Max Units Numeric Entry The maximum number of units that will fire (1 to 16, WHM Unit Mode = WHM Manager).
Valve Close Delay Numeric Entry The time an open Isolation Valve will remain open once a unit cycles off (0 to 15 min., WHM Unit Mode = WHM Manager).

Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Anti- Cycling Control

On Delay Enter Minimum length of time a unit must stay off after shutting down/going standby (30 to 300 sec.).
WHM Off Delay Numeric Entry Specifies the amount of time full shut down will be delayed (30 to 300 sec).
Shutoff Delay Temp Numeric Entry The temperature above setpoint the unit may rise to during delay shutdown (0°F to 25°F).

Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Valve Configuration

Select Output Read Only Displays Standard Setup.
Output Signal Type Toggle Select the output signal type of the selected output: Current or Voltage.
Control Mode Read Only Displays On/Off.
Valve Feedback Enable/Disable Choose Enabled or Disabled.
Valve Feedback Status Read Only Displays the selected valve’s current status (Valve Feedback = Enabled).

Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Lead/Lag

Lead/Lag Setting Select Select: Run Hours, Unit Size or Select Lead Lag.
Hours Numeric Entry The number of hours after which the Lead unit is rotated (25 – 225 hours, Lead/Lag Setting = Run Hours).
Lead Unit Numeric Entry Specify the address of the Lead unit (0 to 16, (Lead/Lag Setting = Select Lead Lag).
Lag Unit Numeric Entry Specify the address of the Lag unit (0 to 16, Lead/Lag Setting = Select Lead Lag).

3.3.4.3 Main Menu → Advanced Setup → Com & Network 

Main Menu → Advanced Setup → Comm & Network → BAS 

BAS Select To enable communication with a BAS, select Off, BACnet IP or Modbus TCP.
Communication Address Numeric Entry Specify the network address of the Edge Controller on the BAS network (0 – 127)
Node Offset Numeric Entry The starting address range for AERCO units (for BACnet IP only).
Device Instance Read Only The unit’s Device Instance within BAS (for BACnet IP only).
Port Number Numeric Entry Specify the BAS port to which the unit will communicate. (Range: 47808 to 47823) (for BACnet IP only).
Local IP Address Read Only Displays the local IP address of the Edge Controller.
Status Read Only Displays the status of BAS communications.
BAS Comm Timeout Numeric Entry Specifies the period for BAS Communication timeout (1-10 min)
BAS Temp Format Toggle Choose: Fahrenheit or Celsius
Security Enable/Disable Set to Enabled to enable BAS security
BAS IP Numeric Entry Specifies the IP address of the BAS server (appears if Security = Enabled).
BAC MAC Numeric Entry Specifies the MAC address of the BAS server (appears if Security = Enabled).

Main Menu → Advanced Setup → Comm & Network → onAER

onAER Mode Select To enable onAER, select the communication method: Ethernet, Wi-Fi or Wiznet (for units where the Edge Controller replaced a C-More).
Unit Upload Time Numeric Entry Determines how frequently unit data is uploaded to the
server (30 to 9999 sec.).
Cascade Upload Time Numeric Entry Determines how cascade data is uploaded to the server
(60 to 9999 sec.).
Status Read Only The communication interface status.

Main Menu → Advanced Setup → Comm & Network → Ethernet
DHCP Enable/Disable Enables/disables DHCP (Dynamic Host Configuration Protocol).
IP Address Numeric Entry The static IP address of the unit (DHCP = Disabled).
Subnet Numeric Entry The subnet address of the network (DHCP = Disabled).
Gateway Numeric Entry The IP address of the Gateway (DHCP = Disabled).
DNS1 Numeric Entry The IP address of DNS Server 1 (DHCP = Disabled).
DNS2 Numeric Entry (The IP address of DNS Server 2 DHCP = Disabled).
ICMP PING Enable/Disable Allows the unit to be pinged.

Main Menu → Advanced Setup → Comm & Network → Communication Failsafe

Unit Failsafe Mode Toggle Choose how the unit will operate when either the Manager communication or a Remote Signal is lost: Constant Setpt or Shutdown.
Unit Failsafe Setpoint Numeric Entry The unit’s default setpoint when communication fails (60 to 150°F, Unit Failsafe Mode = Constant Setpt).

3.3.4.4 Main Menu → Advanced Setup → Ancillary Devices

Main Menu → Advanced Setup → Ancillary Device → Interlocks
Remote Interlock Name Select Choose the Remote Interlock: Flow, Damper, Louver, Other.
Remote Interlock Use Read Only Displays what will shut down if the selected Remote Interlock is open: Unit Shutdown.
Delayed Interlock Name Select Choose the Delayed Interlock: Valve 1, Valve 2, Louver 1 or Louver 2.
Auxiliary Delay Numeric Entry Select the Delayed Interlock’s delay (0 to 240 sec.).

3.3.4.5 Main Menu → Advanced Setup → Performance

Main Menu → Advanced Setup → Performance → Temperature Control

Main Menu → Advanced Setup → Performance → Temperature Control → PID Setting

Proportional Band Numeric Entry Generates a fire rate based on the error that exists between the setpoint and the actual outlet temperature. If the error is less than Proportional Band, fire rate will be less than 100%. If the error is equal to or greater than proportional band, the fire rate will = 100% (1°F to 120°F).
Integral Band Numeric Entry Specifies the fraction of the output, due to setpoint error, to add or subtract from the output each minute to move towards the setpoint. (0.00 to 5.00)
Derivative Band Numeric Entry Specifies the time that this action advances the output; it responds to the rate of change of the setpoint error (0.00 to 2.00 min.).
Warm-up Prop Band Numeric Entry
Warm-up Integral Band Numeric Entry
Warm-up Derivative Band Numeric Entry These three parameters eliminate Temperature Overshoots during the “Warmup” period of a cold ignition cycle by temporarily modifying the PID Gain parameter during warmup.
Restore Defaults Yes/No Choose Yes to reset all parameters to the factory default.

Main Menu → Advanced Setup → Performance → Temperature Control → Temperature Conformance

Deadband High Numeric Entry These two settings create an “outlet temperature zone” (between Active Setpoint + Deadband High and Active
Deadband Low Numeric Entry Setpoint – Deadband Low) in which no Valve Position corrections are attempted. (0 to 25°F for both)
Temperature High Limit Numeric Entry The unit’s maximum allowable working temperature. If the unit reaches this limit, it will fault and shut down (40 to 210 °F).

Main Menu → Advanced Setup → Performance → Temperature Control → Setpoint Range

Setpoint Low Limit Numeric Entry Determines the upper and lower limit within which the
setpoint can vary. Setpoint High Limit Numeric Entry
Setpoint Limiting Enable/Disable Enables/disables Setpoint Limiting functionality.
Setpoint Limit Band Numeric Entry Sets the number of °F below Setpoint High Limit the unit’s outlet temperature must fall before the unit restarts (0 to 10°F, Setpoint Limiting = Enable).
Setback Schedule Enable/Disable Enables/disables Setback Schedule functionality
Setback Setpoint Numeric Entry The Setpoint that will be in effect during the Setback period. (60°F to 245°F, Setback Schedule = Enabled).
Setback Start Time Numeric Entry The Setback period’s start time (Setback Schedule = Enable).
Setback Stop Time Numeric Entry The Setback period’s end time (Setback Schedule = Enable).

Main Menu → Advanced Setup → Performance → Temperature Control → FFWD Settings

FFWD Temp Read  Only Displays the current FFWD temperature.
PID Output Read Only Displays the calculated PID output.
FFWD Output Read Only Displays the current FFWD output.
Min Load Adj Numeric Entry Adjusts the output by adding an offset to the breakpoint chart at minimum flow. This is used to fine tune FeedForward (FFWD) output at low flow levels. (-50 – + 50°F)
Max Load Adj Numeric Entry Adjusts the output by changing the scaling of the breakpoint chart at maximum flow. (-50 – +50°F)
Outlet Feedback Yes/No Enables Outlet Feedback functionality.
Feedback Gain Numeric Entry The percentage of feedback from the water outlet sensor the algorithm factors to determine fire rate (0.01 – 1.00).
Fdback Start Pos Numeric Entry The Feedback start position (0 – 100%).
Fdback End Pos Numeric Entry The Feedback end position (0 – 100%).
Max Feedback Numeric Entry Specifies the maximum Feedback position (0 – 100%).
Fdback Value Read Only Displays the current feedback value.
Breakpt at 100 to Breakpt at 0 Numeric Entry Allows breakpoint temperature settings to be entered for 100% to 0% in 10% increments (60 – 260°F).
Temp Gov Enable/Disable Enables temperature governor limiting functionality, which aggressively reduces the effective Fire Rate as the Outlet Temperature approaches the High Temperature Limit.
GOV Limit-5 – GOV Limit-15 Numeric Entry When the Outlet Temperature exceeds the Temperature Hi Limit by 5 to 15°F, the effective Fire Rate will be reduced by the value entered in GOV Limit-5 through GOV Limit-15 (0 – 100°F).
Above 70F Val Numeric Entry If the inlet water temp is above 70°F, an algorithm adds an offset provided by this item to all 11 breakpoints (“breakpoint at 100” – “breakpoint at 0”), (-10 – +10°F).
Below 70F Val Numeric Entry If the inlet water temp is below 70F, algorithm adds offset provided by this item to all the 11 breakpoints (“breakpoint at 100” – “breakpoint at 0”), (-10 – +10°F).
No FFWD Above FR Read Only No Feed Forward above this fire rate.
No FFWD Feature Read Only No Feed Forward above fire rate feature status.

Menu → Advanced Setup → Performance → Fire Control

Main Menu → Advanced Setup → Performance → Fire Control → Purge Control

Purge Blower Voltage Numeric Entry Sets the blower speed (blower output voltage) during the Purge cycle (2.0 to 10.0 V).
Purge Timer Numeric Entry Allows adjustment of the pre-ignition purge time (5 to 60 sec.).
Post Purge Timer Numeric Entry Allows adjustment of the post purge time before the unit shuts down (0 to 60 sec.).

Main Menu → Advanced Setup → Performance → Fire Control → Ignition Control

Ignition Position Numeric Entry Sets the air fuel valve position at which the unit will operate during the ignition sequence (5% to 60%).
Ignition Blower Voltage Read Only Displays the actual blower voltage during ignition.
Ignition Voltage Offset Numeric Entry Allows an adjustment to the blower voltage during ignition (-5.00 to 5.00).
Low Fire Timer Numeric Entry Specifies how long to remain in the low fire position after
ignition, before going to the desired output (2 to 600 sec.).
Ignition Hold Timer Numeric Entry Sets the length of time the unit stays in ignition position (0 to 60 sec.).
IGN Time Setting Read Only Displays the maximum time between confirmation of gas
valve opening (POC) and a stable flame detected.

Main Menu → Advanced Setup → Performance → Fire Control → Operating Control

Start Valve Position Numeric Entry Specifies the valve position at Start Level (0 to 40%).
Stop Valve Position Numeric Entry Specifies the valve position at Stop Level (0 to 40%).
Max Valve Position Numeric Entry The maximum valve position for unit (40 to 100%).
Standby Blower Voltage Numeric Entry Specifies the blower voltage in Standby Mode, during which the blower motor remains “ON” at low speed, to limit power cycles. AERCO recommends keeping the default, however, may set this between 2.00 and 0 volts on individually vented units in positive pressure mechanical rooms to compensate (0.0 to 10.0V).
Air Compensation Enable/Disabled Innovation Only! Vlv Position Change Rate Numeric Entry Defines the rate at which the valve position will progress from one step to the next (0.5 to 60 sec.).
Skip Range Cntr Numeric Entry
Skip Range Span Numeric Entry
Skip Speed Numeric Entry Together, these 3 parameters define an optional Fire Rate the Controller will skip-over (Skip Range Cntr = center of the range). These can be used to reduce objectionable noise at a certain Fire Rate, if there is no other remedy.

Main Menu → Advanced Setup → Performance → Fire Control → Anti-Cycling Control

On Delay Numeric Entry Sets the minimum time a unit must stay off after shutting down or going into standby (0 to 600 sec.).
Shutoff Delay Temp Numeric Entry Specifies the number of degrees above setpoint that the outlet temperature can rise without triggering a unit shut down (0°F to 25°F)

3.4 START SEQUENCE

When the Edge Controller’s Enable/Disable switch is set to the Enable position, it checks all prepurge 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

NOTE:
The Blocked Inlet and downstream Blower Proof switches are not checked prior to starting the pre-purge.

If all the above switches are closed, the READY light above the ON/OFF switch will light and the unit will be in the Standby mode.
When there is a demand for hot water, the following events will occur:
NOTE:
If any of the Pre-Purge safety device switches are open, the appropriate fault message will be displayed. Also, if the required conditions are not observed at any point during the start sequence, appropriate messages will be displayed and the unit will go into fault mode.

START SEQUENCE Instructions

1. The DEMAND LED status indicator 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 3.4-1 for SSOV location.
   
   Figure 3.4-1: SSOV Location (INN 600N–INN 1060N Gas Train shown)__

3. With all required safety device switches closed, a purge cycle is initiated and the following events will occur:

a. The Blower relay energizes and turns on the 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 3.4-2) will read 100 to indicate that it is full-open (100%).
c. The VALVE POSITION bargraph will show 100%

Figure 3.4-2: Air/Fuel Valve in Purge Position

4. Next, the Blower Proof switch on the Air/Fuel Valve (Figure 3.4-3) closes. The display will show Purging and indicate the elapsed time of the purge cycle in seconds.

Figure 3.4-3: Blower Proof Switch

5. Upon completion of the purge cycle, the Edge Controller initiates an ignition cycle and the following events occur:
a. The Air/Fuel Valve rotates to the low-fire ignition position and closes the Ignition switch. The dial on the Air/Fuel Valve will read between 25 and 35 (Figure 3.4- 4) to indicate that the valve is in the low-fire position.
b. The igniter-injector relay is activated and provides ignition spark. Current to the igniter or igniter-injector is monitored by the spark monitor (P/N 61034).
c. The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve.

START SEQUENCE Instructions

Figure 3.4-4: 25% Air/Fuel Valve Ignition Position

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 Edge Controller will turn off the SSOV gas valve, the blower relay will be deactivated, the Air/Fuel Valve will be closed and the Controller will display Standby.

3.5 START/STOP LEVELS

The ignition position (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:

Fuel: Model: Stop Level: Ignition Position
Natural Gas: All: 20%: 35%

Normally, these settings should not require adjustment.
Note that the energy input is not linearly related to the Air/Fuel Valve position. Refer to Table 3-5 for the relationship between the energy input and Air/Fuel Valve position for units running on natural gas.

TABLE 3-5. Relationship Between Air/Fuel Valve Position and Energy Input

Valve Position ( % ): INN 600N BTU/Hr. kWh: INN 800N BTU/Hr. kWh: INN 1060N BTU/Hr. kWh: INN 1350N BTU/Hr. kWh.

20: 50,000 14.65: 50,000 14.65: 50,000 14.65: 50,000 14.65
30: 93,000 27.26: 99,000 29.01: 108,000 31.65: 124,000 36.34
40: 161,000 47.18: 210,000 61.54: 222,000 65.06: 260,000 76.20
50: 272,000 79.72: 344,000 100.82: 372,000 109.02: 445,000 130.42
60: 367,000 107.56: 478,000 140.09: 563,000 165.00: 637,000 186.69
70: 446,000 130.71: 586,000 171.74: 686,000 201.05: 845,000 247.65
80: 500,000 146.54: 660,000 193.43: 823,000 241.20: 1,050,000 307.72
90: 591,000 173.20: 768,000 225.08: 981,000 287.50: 1,259,000 368.98
100: 625,000 183.17:   800,000 234.46: 1,060,000 310.66: 1,350,000 395.65

CHAPTER 4. INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

The requirements for the initial start-up of the Innovation Water Heater consists of the following:

• Complete installation (Chapter 2)
• Set proper controls and limits (Chapter 3)
• 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 complete all initial unit start-up requirements.
An AERCO Gas Fired Startup Sheet, included with each Innovation Heater, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at:

AERCO International, Inc.
100 Oritani Drive
Blauvelt, New York 10913
(FAX: 845-580-8090)

WARNING!
DO NOT ATTEMPT TO DRY FIRE THE HEATER. Starting the unit without a full water level can seriously damage the unit and may result in injury to personnel or property damage. this situation will void any warranty.

4.2 TOOLS & INSTRUMENTS 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:

• Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1 PPM.
• 16-inch W.C. (4.0 kPa) manometer or equivalent gauge and plastic tubing.
• Multimeter (Capable of measuring 0 – 10 µA)
• 1/4-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 used to verify that the upstream gas pressure is within the allowable range, and it is then installed on the downstream side of the SSOV to measure gas pressure during the combustion calibration process.

INSTALLING GAS SUPPLY MANOMETER Instructions

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 upstream side of the Safety Shut Off Valve (SSOV) (see Figure 4.2.2).

4. Install an 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. (4.0 kPa) manometer.
   
   Figure 4.2.2: 1/4 Inch Gas Plug Location (INN 600N – INN 1060N Gas Train Shown)

6. Open the manual gas supply shut-off valve, then start the unit and raise the fire rate to 100%.

7. Check that the manometer reading is within the allowable gas pressure range, 4.0” W.C. and 14” W.C. If it is outside that range, you must take whatever steps necessary to correct this issue. Proceed to the next step only if the gas pressure is within the allowable range.

8. Shut off the unit and close the main manual gas supply shut-off valve.

9. Remove the manometer from the upstream port and replace the 1/4” plug.

10. Remove the 1/4” plug from the downstream ball valve and install the manometer on that port. It will remain in this position until combustion calibration is complete.

4.2.3 Accessing the Analyzer Probe Port

The unit contains a 1/8” NPT port at the rear of the exhaust manifold. This port is located above the condensate drain connection as shown in Figure 4.2.3. Prepare the port for the combustion analyzer probe as follows:

ACCESSING ANALYZER PROBE PORT Instructions

1. Refer to Figure 4.2.3 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.

Figure 4.2.3: Analyzer Probe Hole Location

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 intake manifold flange as shown in Figure 4.2.4.
Proceed as follows to set up the multimeter to measure the flame strength current:

CONNECTING MULTIMETER TO MEASURE FLAME STRENGTH
Instructions

1. Refer to Figure 4.2.4 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 4.2.4.
3. Ensure that the multimeter is set to the µA scale.

Figure 4.2.4: Flame Strength Set-Up Using Multimeter – Rear View

IMPORTANT!
The unit is shipped from the factory set up for Natural Gas, as specified by the Style Number on the Sales Order. Perform the Combustion Calibration procedure in Section 4.3.

4.2.5 Recommendations for Temperature Calibration

Carefully follow the procedures of Section 4.6 Temperature Control Calibration, below, to properly set up the temperature control for the unit. Ignoring this commissioning step may cause water temperature faults, poor water temperature control, and rapid cycling of the unit.

4.2.6 Recommendations for WHM Operation

Installations with multiple Innovation units must operate in Water Heater Management (WHM) mode (see Section 2.5.1 for instructions on installing the actuator-controlled ball valve). Operation in WHM mode ensures that the system flow will be divided between at least 2 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 gal. (189 L) per minute at any time.

4.3 COMBUSTION CALIBRATION

Innovation Water Heaters are combustion calibrated at the factory prior to shipping. However, recalibration is necessary as part of initial start-up due to changes in the local altitude, gas BTU (kW) content, gas supply piping and supply regulators. It is important to perform the combustion calibration procedure, as it provides optimum performance and keep readjustments to a minimum.
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.
The unit is shipped from the factory set up for Natural Gas or Propane, as specified by the Style Number on the Sales Order.
If you press the Back or Home buttons at any time before completion, the calibration operation is disabled and normal operation resumes.
Complete the instructions below to perform combustion calibration.

Combustion Calibration Instructions

1. Ensure that the Controller’s Enable/Disable switch is set to Disable.

2. Ensure that external AC power to the unit is ON.

3. Ensure that the water supply and return valves to the unit are open and that the system pumps are running.

4. Open the main manual gas supply shut-off valve upstream of the unit.

5. On the Controller, go to: Main Menu → Calibration → Combustion.

6. The first Combustion Calibration screen appears lists the three steps that must be completed before continuing. Complete these steps then press Next to continue.
   
   Figure 4.3-1: First Combustion Calibration Screen
   • Verify that the incoming (upstream) gas pressure to the unit is within the allowable range, either 4.0 to 14 in. W.C. for Natural Gas, or 11 to 14 in. W.C. for Propane.
   • Install the following devices on the unit:
   o A gas pressure manometer downstream of the SSOV (see Section 4.2.2).
   o A combustion analyzer probe in the exhaust manifold (see Section 4.2.3).
   o A multimeter to read flame strength and combustion analysis (see Section 4.2.4).
   • Ensure the unit has sufficient heat dissipation at full fire to avoid over-temperature conditions. If demand is low, you can reduce the amount of heat that needs to be dissipated, either by completing combustion calibration quickly or using a hose attached to the drain valve on the hot water outlet to generate additional flow.
   

7. Choose the Nitrogen Oxide NOx requirement for the unit. For Natural Gas, choose either None or <= 20 PPM, but for Propane, choose None ( < = 20 PPM is for Natural Gas only).
   
   Figure 4.3-2: Choose NOx Requirement

8. The main Combustion Calibration screen now appears. It provides two methods to ramp the unit’s valve position up or down:
   • Method 1: Toggle through the pre-set calibration points till you reach the desired valve position, then press Go to go to that point (left image below).
   • Method 2: Enable Fine VP Step, then manually press the + or – buttons once per 1% to bring the unit to the desired valve position (right image below).
   PRE-SET CALIBRATION STEPS
   
   PRESET CALIBRATION POINTS METHOD** FINE VALVE POSITION CONTROLS
   FINE VP STEP METHOD
   _ Figure 4.3-3: Combustion Calibration Screens**_

9. Set the Controller’s Enable/Disable switch to Enable.

10. Change the valve position to 30%, press the Go button, then verify that the unit has ignited and is operating as expected.

11. Use the (Right) arrow key to change the valve position to 100%, then press Go.

12. Verify that the gas pressure on the downstream side of the SSOV is within the required range shown in Table 4.3-1. If it isn’t, remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw (Figure 4.3-4). Make adjustments using a flattip screwdriver, slowly rotating the gas pressure adjustment (in 1/4-turn increments) clockwise to increase gas pressure or counterclockwise to reduce it. The resulting gas pressure reading on the downstream manometer should fall in the range listed below.

Combustion Calibration Instructions

TABLE 4.3-1: Gas Pressure Downstream of SSOV

Models: Natural Gas : Propane

INN 600N: 1.9 ± 0.2” W.C. (473 ± 50 Pa): 1.8 ± 0.2” W.C. (448 ± 50 Pa)
INN 800N: 1.7 ± 0.2” W.C. (423 ± 50 Pa): 2.2 ± 0.2” W.C. (548 ± 50 Pa)
INN 1060N: 1.9 ± 0.2” W.C. (473 ± 50 Pa): 2.3 ± 0.2” W.C. (573 ± 50 Pa)
INN 1350N: 1.9 ± 0.2” W.C. ( 473 ± 50 Pa): 3.7 ± 0.2” W.C. (922 ± 50 Pa)

Figure 4.3-4. SSOV Gas Pressure Adjustment Screw Location

13. With the valve position still at 100%, and the combustion analyzer probe in the exhaust manifold probe opening (see Section 4.2.3):
a. Allow enough time for the combustion analyzer reading to stabilize.
b. Note the combustion analyzer’s oxygen (O2) reading.
c. If it doesn’t match the value in the O2 Target cell, adjust the Blower Voltage using either the + or – controls, or press on the field and type the value directly, until the O2 value matches the O2 Target.
d. Once it matches the O2 Target, press the O2 Reading cell and enter the value.
14. Enter the downstream manometer’s gas pressure reading in the Downstream Gas Pressure field. Note, this field appears only when Valve Position = 100%.
15. Enter the Flame Strength, NOx and CO readings from the Combustion Analyzer and
multi-meter in the Reading cells.
16. Enter the same values, plus the O2 value, on the Combustion Calibration Data Sheet provided with the unit.
17. Compare the NOx and carbon monoxide (CO) values in the Reading and Target columns. If NOx readings exceed the target values in Table 4.3-2, below, repeat Step 13c to increase the O2 level up to 1% higher. You must then record the increased O2 value on the Combustion Calibration sheet (repeat Step 16).

NOTE:
These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C).

Combustion Calibration Instructions

18. Lower the Valve Position to the 80% calibration point using either the  (Left) arrow key or the Fine Valve Position – (Minus) key, then repeat step 13 and 17 at that valve position.
The O2, NOx and CO should stay within the ranges shown in these tables. If they are not in the ranges shown, check the following:

• Verify that the gas supply conforms to the requirements in the Innovation-Edge Gas Supply Design Guide (TAG-0091, GF-5036).
• Verify that the regulator (if one is used) is properly sized.
• Verify that there was no sudden drop in gas pressure or that gas pressure is steady, with no variations or pulsations.
• Verify that venting is conforms to the requirements in the Innovation-Edge Venting and Combustion Air Design Guide (TAG-0090, GF-5056).
• Verify that condensate is draining properly.

19. Repeat the previous step for the remaining valve positions in Table 4.3-2a for Natural Gas units, or Table 4.3-2b for Propane units. This table applies to all Innovation models.

TABLE 4.3-2a: Combustion Calibration Readings – NATURAL GAS

Valve Position: Oxygen (O2) %: Nitrogen Oxide (NOx): Carbon Monoxide (CO): Flame µA
100% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
90% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
80% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
60% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
50% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
40% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
30% 6.0% ± 0.2% < 20 ppm <100 ppm > 7
20% 5.5% ± 0.2% < 20 ppm <100 ppm > 4

TABLE 4.3-2b: Combustion Calibration Readings – PROPANE

Valve Position: Oxygen (O2) %: Nitrogen Oxide (NOx): Carbon Monoxide (CO): Flame µA
100% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
90% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
80% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
60% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
50% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
40% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
30% 5.0% ± 0.2% < 30 ppm <100 ppm > 7
20% 5.0% ± 0.2% <30 ppm <100 ppm > 4

20. If the oxygen level at the lowest valve position is too high, and the Blower voltage is at the minimum value, you can adjust the TAC screw, which is recessed in the bottom of the Air/Fuel Valve. Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce the O2 to the specified level. Recalibration MUST be performed again from 60% or 50% down to the lowest valve position after making a change to the TAC screw.

VIEWED FROM BELOW, LOOKING STRAIGHT UP
Figure 4.3-5: TAC Screw Location

21. Once combustion calibration has been completed, you can view the results by going to Main Menu → Calibration → Combustion Summary. This screen will remain accessible and unchanged until the next time combustion calibration is performed.

Figure 4.3-6: Combustion Calibration Complete Screen

4.4 REASSEMBLY

Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation.

Reassembly

1. Set the Controller’s Enable/Disable switch to the Disable 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” (3.18 mm) 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.

4.5 TEMPERATURE CONTROL CALIBRATION

Carefully follow the procedures below to properly set up the temperature control for the unit. Ignoring this commissioning step may cause water temperature faults, poor water temperature control, and rapid cycling of the unit.
The unit normally comes factory set and calibrated for a 130°F (54.4°C) setpoint (default value).
However, if a different setpoint temperature is desired, it can be changed using the procedure in Section 4.6.1. Temperature control calibration should be performed each time the setpoint is changed.
There are two primary adjustments for performing temperature calibration: Min Load Adj and Max Load Adj (minimum and maximum load adjustment). Adjustments to these settings are made at minimum and maximum load conditions and should be made in small increments, from 1 to 3 degrees F (0.55 to 1.65 degrees C). 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 controls, observe the following:

• The unit must be in the Auto mode of operation.

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

• Monitor the outlet temperature displayed on the Controller and Valve Position bar-graph to set load conditions and observe the effect of adjustments.

• Calibration is performed the using the Edge Controller’s Tuning Menu.

• Make small adjustments and allow time between adjustments for the outlet water temperature to stabilize.

• Maintain water flow as constant as possible during these adjustments.

• Ensure that recirculation loops are operational while the calibration is being performed.

• Upon completion of calibration, set the Outlet Feedback back to ENABLE.

Temperature control calibration is accomplished by first performing the procedure in Section 4.5.2:
Minimum Load Adjustment. Once that is complete, you can then perform the procedure in Section 4.5.3: Maximum Load Adjustment, below.

4.5.1 Setting the Outlet Water Temperature Setpoint

If the setpoint is already set to the correct values for the site, skip this step and proceed to Section 4.5.2. However, if necessary, the current setpoint can be changed using the instructions below.

Setting Outlet Water Temperature Setpoint – Standalone Unit

1. On a standalone unit, go to: Main Menu → Advanced Setup → Unit → Application Configuration.
2. Set the Setpoint parameter to the desired setpoint.

Setting Outlet Water Temperature Setpoint – WHM Manager Units

1. On the WHM Manager unit, go to: Main Menu → Advanced Setup → WHM Cascade → Application Configuration.
2. The Setpoint for the WHM Cascade can be a constant, or received from a remote source,
   such as a BAS (building automation system).
   • If Operating   Mode = Constant Setpoint: Set WHM Setpoint to the desired setpoint.
   • If Operating Mode = Remote Setpoint: Choose the source of the remote setpoint:
   o 4-20mA
   o 1-5V
   o Network
   o 0-20mA
   o 0-5V
   o BAS

4.5.2 Minimum Load Adjustment

With the unit in operation, check the temperature control at minimum load as described below.

Minimum Load Adjustment

1. Go to: Main Menu → Advanced Setup → Performance → Temperature Control → FFWD Settings.
   
   Figure 4.5.2: FFDW Settings Screens
   

2. Set the Outlet Feedback parameter to No.

3. 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 drain valve on the hot water outlet
   pipe (see Figure 2.6) to simulate a minimum load condition.

4. Wait several minutes to allow the outlet temperature to stabilize under load conditions.

5. Once stabilized, the outlet temperature displayed on the Controller should read no more than 2 to 3 °F (1.1 to 1.65 °C) above the unit’s setpoint.

6. If the outlet temperature is stabilized, proceed to Section 4.5.3: Maximum Load Adjustment.
   If the temperature is not stabilized, proceed to step 7.

7. Raise or lower the Min Load Adj by one or two degrees (increasing it will increase outlet water temperature), then allow time for the system to stabilize.

8. Repeat step 7 as needed until the temperature is stabilized at no more than 2 to 3 °F (1.1 to 1.65 °C) above the unit’s setpoint.

9. Return the Outlet Feedback parameter to Yes.

4.5.3 Maximum Load Adjustment

Check the temperature control at maximum load as follows:

Maximum Load Adjustment

1. Go to: Main Menu → Advanced Setup → Performance → Temperature Control → FFWD Settings (see Figure 4.5.2, above).
2. Set the Outlet Feedback parameter to No.
3. 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%.
4. Wait several minutes to allow the outlet water temperature to stabilize under load conditions.
5. Once stabilized, the outlet temperature displayed on the Controller should read no more than 2 to 3 °F (1.1 to 1.65 °C) below the unit’s setpoint.
6. If the outlet temperature is stabilized, no adjustment is necessary. If the temperature is not stabilized, proceed to step 7.
7. Raise or lower Max Load Adj (increasing it will increase outlet water temperature), then allow time for the system to stabilize.
8. Repeat step 7 as needed until the temperature is stabilized 2 to 3 °F (1.1 to 1.65 °C) below the unit’s setpoint.
9. If the outlet temperature does not maintain setpoint after a reasonable amount of time and adjustment, contact your local AERCO representative.
10. Set the Outlet Feedback parameter back to Yes.

4.6 OVER-TEMPERATURE LIMIT SWITCHES

The unit contains both Automatic Reset 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 Over-Temperature Limit switch is not adjustable and is permanently fixed at 190°F (87.7°C). This switch will shut down and lock out the unit if the water temperature exceeds 190°F (87.7°C). Following an over- temperature condition, it must be manually reset by pressing the RESET button before the unit can be restarted.
The Automatic Reset Over-Temperature Limit switch is adjustable and allows the unit to restart, once the temperature drops below its temperature setting. Set the Automatic Reset Over-Temperature Limit switch to the desired setting.

Figure 4.6: Over-Temperature Limit Switch Location

CHAPTER 5. SAFETY DEVICE TESTING

5.1 INTRODUCTION

Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The unit control system comprehensively monitors all combustion-related safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.
Operating controls and safety devices should be tested on a regular basis or following service or replacement. All testing must conform to local codes.

NOTES:
Manual and Auto modes of operation are required to perform the following tests. It will also be necessary to remove the front door and side panels from the unit to perform the following tests.

WARNING!
ELECTRICAL CURRENT OF 110 OR 220 AND 24 VOLTS AC MAY BE USED IN THIS EQUIPMENT. POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.

5.2 LOW GAS PRESSURE FAULT TEST

To simulate a low gas pressure fault, refer to Figure 5.2 and proceed as follows:

Low Gas Pressure Fault Test Instructions

1. Refer to Figure 5.2 and ensure that the leak detection ball valve located at the Low Gas Pressure switch is closed.
2. Remove the 1/4“ plug from the ball valve at the Low Gas Pressure switch.
3. Install a 0 – 16“ W.C. (0 – 4.0 kPa) manometer (or a W.C. gauge) where the 1/4″ plug was removed.
4. Slowly open the ball valve near the Low Gas Pressure switch.
5. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled.
6. Adjust the air/fuel valve position (% open) between 25 and 30%.
7. While the unit is firing, slowly close the external manual gas shut-off valve.
8. The unit should shut down and display a Low Gas Pressure fault message at approximately 2.6” W.C. (648 Pa). The FAULT indicator should also start flashing.
9. Fully open the external manual gas shut-off valve and press the CLEAR button on the Controller.
10. The fault message should clear, and the FAULT indicator should go off. The unit should restart.
11. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4“ plug removed in step 2.

Low Gas Pressure Fault Test Instructions

Figure 5.2: Low & High Gas Pressure Testing (INN600N–800N Gas Train Shown)

5.3 HIGH GAS PRESSURE FAULT TEST

To simulate a high gas pressure fault, refer to Figure 5.2 and proceed as follows:

High Gas Pressure Fault Instructions

1. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled.
2. Remove the 1/4“ plug from the leak detection ball valve located at the High Gas Pressure switch (see Figure 5.2).
3. Install a 0 – 16” W.C. (0 – 4.0 kPa) manometer (or W.C. gauge) where the 1/4” plug was removed.
4. Slowly open the leak detection ball valve
5. Start the unit at a valve position (firing rate) of 25%.
6. Slowly increase the gas pressure using the adjustment screw on the SSOV.
7. The unit should shut down and display a High Gas Pressure fault message when the gas pressure exceeds the setting on the high gas pressure switch. The FAULT indicator should also start flashing. The switch should be set for 1” W.C. more than the “Manifold Pressure Setpoint” written on the Manifold Gas Pressure Setting tag. For example: if the tag states that the unit was set up at 1.9” W.C. full input rate as the factory calibration, then the high gas pressure switch will be set for 2.9” W.C. (1.0 kPa).
8. Reduce the gas pressure back to the original setting listed on the tag.
9. Press the CLEAR button on the Controller to clear the fault.
10. The fault message should clear, the FAULT indicator should go off and the unit should restart.
11. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4“ plug removed in step 2.

5.4 LOW WATER LEVEL FAULT TEST

To simulate a low water level fault:

Low Water Level Fault Test Instructions

1. .Set the Controller’s Enable/Disable switch to the Disable 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. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting Manual Mode to Enabled.
6. Start the unit and raise the valve position above 30%.
7. Set the Enable/Disable switch to the Enable 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 the fault to qualified service personnel.
8. Close the drain and pressure relief valve used in draining the unit.
9. Open the water shut-off valve in the return piping to the unit.
10. Open the water supply shut-off valve to the unit to refill.
11. After the shell is full, press the Low Water Level Reset button to reset the low water cutoff.
12. Press the CLEAR button to reset the FAULT LED and clear the displayed error message.
13. Set the Enable/Disable switch to the Enable 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 Reset OverTemperature Limit switch on the front of the unit (see Figure 5.5).

Water Temperature Fault Test Instructions

1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint.
2. Lower the adjustable Automatic Reset Over-Temperature Limit switch setting to match the outlet temperature displayed on the Controller.
3. Once the Automatic Reset Over-Temperature Limit switch setting is approximately at, or just below, the actual outlet water temperature, the unit should shut down. The FAULT indicator should start flashing and a High-Water Temp Switch Open fault message should be displayed. It should not be possible to restart the unit.
4. Reset the adjustable over-temperature switch to its original setting.
5. The unit should start once the Automatic Reset Over-Temperature Limit switch setting is above the actual outlet water temperature.

NOTE:
The (non-adjustable) Manual Reset Over-Temperature Limit switch is calibrated to trip if the discharge water exceeds 190° F (87.8° C). Testing of this device must be done by authorized personnel only.

Figure 5.5: Over-Temperature Limit Switch Setting

5.6 INTERLOCK TESTS

The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock.
Terminal connections for these circuits are located in the I/O Box (Figure 2.12-2) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumpered (closed).
However, each of these interlocks may be utilized in the 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 Instructions

1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals (see Figure 2.12-2).
2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then 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.

5.6.2 Delayed Interlock

Delayed Interlock Instructions

1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals (see Figure 2.12-2).
2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the 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, disconnectone  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 Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position.

2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then 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 5.7).

4. Set the Controller’s Enable/Disable switch to the Enable position to start the unit.

5. The unit should shut down after reaching the Ignition cycle and display Flame Loss During Ignition.

6. Open the valve 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 manual gas shut-off 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.

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 closed in step 8.

12. Press the CLEAR button. The unit should restart and fire.

Figure 5.7: Manual Gas Shut-Off Valve Location (INN600N-800N Gas Train Shown)

5.8 AIR FLOW FAULT TESTS

These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5.8-2.

Air Flow Fault Tests Instructions

1. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position to 25%.

2. Disable the blower output drive voltage as follows:
   (a) Go to: Main Menu → Diagnostics → Analog Outputs and Relays → Analog Outputs.
   (b) Press the Manual button, then press the Zero button. The Blower slider now read 0.00.
   
   DEFAULT MODE MANUAL MODE
   
   DEFAULT MODE MANUAL MODE
   Figure 5.8-1: Analog Outputs Screen

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.

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) Go to: Main Menu → Diagnostics → Analog Outputs and Relays → Analog Outputs.
   (b) Press the Manual button; the Blower is now operational again.
   (c) Press the CLEAR button; the unit should restart.

6. Once the unit has proved flame, turn off the blower again by repeating Step 1.

7. The Blower Proof switch will open and the blower should stop. The unit should shut down and display Airflow Fault During Run.

8. Re-enable the blower output drive voltage by repeating Step 5, then press the CLEAR button; the unit should restart.

9. Next, check the operation of the Blocked Inlet switch located on the inlet side of the Air/Fuel Valve (Figure 5.8-2).

10. Ensure that the sheet metal panels are securely installed on the water heater and the unit is running.

11. At the rear of the unit, partially block the air inlet (Figure 5.8-3) with a plywood sheet or metal plate.

12. The unit should shut down and again display Airflow Fault During Run.

13. Unblock the air inlet and press the CLEAR button. The unit should restart.

Air Flow Fault Tests Instructions

PARTIAL FRONT VIEW
Figure 5.8-2: Blower Proof & Blocked Inlet Switch Locations

PARTIAL REAR VIEW
Figure 5.8-3: Water Heater Rear View Showing Air Inlet Location

5.9 SSOV PROOF OF CLOSURE SWITCH

The SSOV shown in Figure 5.9 contains the Proof Of Closure switch. The Proof Of Closure switch circuit is checked as follows:

SSOV Proof of Closure Switch Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position.
2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.
3. Locate the SSOV (see Figure 5.9) and remove its cover by loosening the Actuator Cover screw, then lifting the cover off to access the terminal wiring connections.
4. Disconnect wire #148 from the SSOV to “open” the Proof Of Closure switch circuit.
5. The unit should fault and display SSOV Switch Open.
6. Replace wire #148 and press the CLEAR button.
7. Set the Controller’s Enable/Disable switch to the Enable position.
8. Remove the wire again when the unit reaches the purge cycle and Purging is displayed.
9. The unit should shut down and display SSOV Fault During Purge.
10. Replace the wire on the SSOV and press the CLEAR button. The unit should restart.

Figure 5.9: SSOV Actuator Cover Location

5.10 PURGE SWITCH OPEN DURING PURGE

The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch,
proceed as follows:

Purge Switch Open During Purge Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position.
2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.
3. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it (see Figure 5.11-1).
4. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5.11-2).
5. Initiate a unit start sequence.
6. The unit should begin its start sequence, then shut down and display PRG Switch Open During Purge.
7. Replace the wire on the Purge switch and depress the CLEAR button. The unit should restart.

5.11 IGNITION SWITCH OPEN DURING IGNITION

The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:

Ignition Switch Open During Ignition Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position.
2. Put the unit in Manual Mode by going to the Main Menu → Diagnostics → Manual Run and setting the Manual Mode toggle to Enabled, then set the valve position between 25% and 30%.
3. Remove the Air/Fuel Valve cover (see Figure 5.11-1) 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 5.11-2).
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.

Figure 5.11-1: Typical Air/Fuel Valve Cover Location
Figure 5.11-2: Air/Fuel Valve Purge and Ignition Switch Locations

5.12 SAFETY PRESSURE RELIEF VALVE TEST

Test the safety Pressure Relief Valve in accordance with ASME Pressure Vessel Code, Section VI.

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 requires 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.

WARNING!
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 BREAKER.
• SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT-OFF VALVE PROVIDED WITH THE UNIT
• ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING

6.2 WATER QUALITY GUIDELINE

To keep your water heater operating efficiently over a long lifetime, it is critical to make sure the chemical composition of incoming water is not harmful to the heater. To prevent corrosion, fouling, and other harmful effects on the heater, the following water quality guideline should be adhered to:

TABLE 6-2: Water Quality Guideline

Total Dissolved Solids: 500 ppm
Hardness (CaCO3): See Table 6-8, Section 6.8.1
Chlorides: 250 ppm
Free Chlorine: 0.5 ppm

Total dissolved solids are a measure of overall risk of water corrosivity/hardness/salinity/color. The EPA recommends keeping a level below 500 ppm. For calcium hardness limits, see Table 6-8 in Section 6.8.1, below. The allowable calcium hardness depends on temperature set point as well as concentration.
Many water systems also carry orthophosphate chemicals for corrosion protection. These chemicals form orthophosphate scale. Conventional water softening techniques that treat calcium scale may not treat orthophosphate scale. If the system contains orthophosphates, the unit must be inspected every 6 months and cleaned as needed. Systems may also contain polyphosphates that sequester and mitigate water hardness. Over time, these chemicals break down in the system to form orthophosphates. Therefore, any water entering the water heater that contains polyphosphates warrants that the heat exchanger be inspected every 6 months and cleaned as needed.
Chloride limits are set to prevent corrosion of the heat exchanger. The EPA also recommends levels lower than 250 ppm for potable systems.
Free chlorine is added to systems to protect from harmful microbes. Most public water supplies have been treated to a safe level, but care must be taken when building owners perform supplemental treatment. Batch feeding or poorly controlled methods will cause free chlorine spikes that will damage any equipment in the system. When added in excess, free chlorine is a powerful oxidant that can cause corrosion. Inlet water fed to the heater should always be below 0.5 ppm free chlorine, regardless of where in the system the chemical feed pump is positioned.

6.3 IGNITER-INJECTOR

The igniter-injector (Kit P/N 58023) is located on the flange of the intake manifold, at the bottom of the unit’s heat exchanger. Figure 6.3-1 shows the intake manifold (removed from the unit) showing the location of the igniter- injector (Kit P/N 58023), flame detector and gasket (Kit P/N 24356-2) and other 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.

Figure 6.3-1: Intake Manifold with Igniter-Injector & Flame Detector

Igniter-Injector Inspection/Replacement Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position, then 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. Referring to Figure 6.3-1, 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 buildup 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.
7. Prior to reinstalling the igniter-injector, apply a high temperature, conductive, anti-seize compound to the threads.
8. Install the igniter-injector on the intake manifold flange. Use the number of clocking washers required to rotate the Ignitor-Injector so that the injector tube is inside the approximately 60° arc shown in Figure 6.3-2.

Igniter-Injector Inspection/Replacement Instructions

Figure 6.3-2: Igniter-Injector & Flame Detector Mounting Details

9. Torque the ignitor-injector to 15 ft-lbs. Do Not Over Tighten
10. 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.
11. Reconnect the igniter-injector cable and ground wire.
12. Reinstall the side and rear panels on the unit.

6.4 FLAME DETECTOR

Flame detector (Kit P/N 24356-2) is used on ALL Innovation Water Heater models. The flame detector is also located on the flange of the intake manifold as shown in Figures 6-1 and 6-2. The flame detector may be hot. Allow the unit to cool sufficiently before removing the flame detector.
To inspect or replace the flame detector:

Flame Detector Inspection/Replacement Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position, then 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.

6.5 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.

6.6 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 requirements 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.

6.7 FIRESIDE INSPECTION

Fireside inspection of the Innovation Water Heater includes removing the exhaust manifold, intake manifold, and the burner assembly from the unit.
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.
Since the fireside inspection will include removal of the exhaust manifold, burner assembly and intake manifold from the Innovation Water Heater, the following replacement gaskets will be necessary for reassembly upon completion of the inspection:

Part Number: Quantity: Description

GP-18899: 2: Burner Flange Gasket
81048: 1: Flame Detector Gasket
81198: 1: Intake Manifold Flange Gasket
GP-122537: 1: Manifold-To-Heat Exchanger Gasket

The intake manifold may be hot. Therefore, allow the unit to cool sufficiently before starting the removal process described in the following steps.

Fireside Inspection Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position. Disconnect AC power from the unit and turn off the gas supply.

2. Remove the exhaust vent from the exhaust manifold. Use a scraper or blade to separate the high temperature silicon sealant between the exhaust manifold and vent connector 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. Locate the intake manifold at the bottom of the unit’s heat exchanger (see Figure 6.7-1 and 6.7-2).

5. Disconnect the lead wire from the flame detector installed on the intake manifold flange (Figure 6.3-1).

6. Remove the two (2) hex standoffs securing the flame detector to the intake manifold (see Figure 6.3-1 and 6.3-2).

7. Remove the flame detector and gasket from the intake manifold flange.

8. Disconnect the cable from the igniter-injector, loosen the compression nut and elbow from the gas injector tube (Figure 6.3-1), 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 flange. Retain the clocking washers (if present), for later reassembly.

10. Refer to Figure 6.7-1. Loosen and remove the four (4) 1/4-20 cap screws securing the blower side of the intake manifold (P/N 44106). DO NOT REMOVE the two 1/4-20 screws and nuts securing the manifold support bracket.
    
    PARTIAL RIGHT-SIDE VIEW – BASE & SUPPORT BRACKET REMOVED FOR CLARITY
    Figure 6.7-1: Intake Manifold & Exhaust Manifold Locations
    CAUTION!
    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 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 intake manifold, burner assembly, two burner gaskets (P/N GP-18899), and the intake manifold flange gasket (P/N 81198). See Figures 6-3 and 6-4.

13. Disconnect the exhaust temperature sensor (Figure 6.7-3) by unscrewing it from the exhaust manifold.

14. While supporting the exhaust manifold, remove the two (2) side nuts (Figure 6.7-3) securing the manifold to the heat exchanger. Loosen, but do not remove the third nut nearest to the front of the unit.

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 to reassemble the unit.
    
    Figure 6.7-2: Intake Manifold and Burner – Cross-Section, Exploded
    
    PARTIAL RIGHT-SIDE VIEW WITH SUPPORT REMOVED
    Figure 6.7-3: Intake and Exhaust Manifolds
    
    BURNER, INTAKE AND EXHAUST MANIFOLDS
    Figure 6.7-4: Combustion Chamber Gasket Locations
    IMPORTANT!
    During reassembly, apply high-temperature, anti-seize lubricant to the threads of the igniterinjector and grounding screw. Also, ensure that the igniter-injector is properly positioned and not contacting other components. Torque the igniter-injector to 15 ft/lbs. (20.3 Nm).

18. Reinstall all components in the reverse order in which they were removed, beginning with the exhaust manifold assembly removed in step 15.

19. When attaching the intake manifold to the exhaust manifold (removed in step 11), torque the six 5/16 hex nuts to 146 in/lbs. (16.5 Nm).
    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.

20. Reinstall the exhaust vent onto the exhaust manifold using a High Temp Red RTV silicon sealant, such as sealants available from Permatex or Loctite.

21. Start the unit and fire it for approximately 20 minutes, to bring it up to working temperature, then shut it down and repeat Step 19, re-torqueing the six 5/16 hex nuts attaching the intake manifold to the exhaust manifold to 146 in/lbs. (16.5 Nm).

6.8 WATERSIDE INSPECTION AND CLEANING

6.8.1 Waterside Inspection-Cleaning Schedule

For units installed at sites with hard water (>3.5 grains/gal, >59.9 mg/L), AERCO strongly recommends use of Watts OneFlow® anti-scaling system (note, this system does not protect against orthophosphates, which can also cause scale deposits). It provides an economical, chemical free treatment of hard water, allowing the water heater to perform at its peak heat transfer efficiency, thereby reducing heating cost.
AERCO requires that the unit’s heat exchanger be inspected per the schedule in Table 6-8, below.
If scale deposits are observed at the top inspection port (the most likely area for scale deposits), the heat exchanger must be cleaned, as described in Section 6.8.3.
The frequency of cleaning can be determined at each site based on inspection results, performance of the unit, and/or experience with similar equipment. The cleaning frequency may be affected by the quality of the inlet water (see Section 6.2: Water Quality Guideline), but it generally follows the inspection schedule shown in Table 6-2.
If the inlet water contains orthophosphates, the unit must be inspected every 6 months and cleaned as needed.

6.8.2 Waterside Inspection

Inspection of the heat exchanger tubes and tubesheet area is done using the two 2” NPT inspection ports, in the upper and lower sections of the shell, as shown in Figure 6.8.2.

Waterside Inspection Instructions

1. Disconnect the electrical power to the unit.
2. Close the water inlet, water outlet, and recirculation shut-off valves to the unit.
3. Open the upper drain valve, to allow air to enter the chamber, then open the lower drain valve and allow all water to drain from the shell.
4. Remove the lower 2” NPT plug (a little additional water may flow from the port).
5. Use a boroscope, or a camera and flashlight, to inspect and take photos of the visible tubes and tubesheet area.
6. If sediment and deposits exist on the lower tubesheet, and/or there is a buildup of scale deposits, follow instructions (Section 6.8.3) for descaling and flushing the unit to remove excess debris.
7. Remove the upper NPT plug and repeat the inspection, looking for signs of scale buildup or other damage in the upper portion of the shell.

Figure 6.8.2: Waterside Inspection Port Locations

6.8.3 Waterside Heat Exchanger Cleaning

If the inspection of the waterside components revealed sediment and/or scale buildup, complete the instructions below to flush the shell with a cleaning solution.
To clean the heat exchanger, AERCO recommends using a cleaning solution of Rydlyme Chemical Descaler (or equivalent) and clean water. This product, available from Apex Engineering Products Corp., is designed to dissolve water scale, lime scale, calcium and rust. To obtain this product, or for specifications and instructions for its use contact Apex Engineering Products, or call AERCO Technical Service at 800-526-0288.

6.8.3.1 Pumping System Set-Up Instructions

A sample pumping set-up diagram is shown in Figure 6.8.3.1. The heat exchanger is cleaned by pumping the cleaning 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 unit. Set up the pumping system as follows:

Pumping System Set-Up Instructions

1. Turn off the water heater.

2. Close the hot water outlet and cold water inlet isolation valves.

3. Open the drain valve at the rear of the unit and drain at least half of the heat exchanger waterside volume. When full, Innovation models hold the approximately gallons of water listed below. Drain at least the amount of water shown, depending on the model.
   Model: Capacity: Volume to be Drained
   INN 600N: 24.5 gallons (92.7 L): 12.25 gallons (46.37 L)
   INN 800N: 24.5 gallons (92.7 L): 12.25 gallons (46.37 L)
   INN 1060N: 23.0 gallons (87.01 L): 11.5 gallons (43.53 L)
   INN 1350N: 20.6 gallons (77.97 L): 10.3 gallons (38.98 L)

4. Close the lower drain valve and connect a suitable size bucket and pump to the lower drain.
   **Pumping System Set-Up Instructions

Figure 6.8.3.1: Sample Heat Exchanger Cleaning Set-Up**

5. Install a hose to the upper drain valve and route it back to the top of the circulation bucket.

6.8.3.2 Cleaning Procedure

Cleaning Procedure Instructions

1. Prepare a cleaning solution of Rydlyme Chemical Descaler and clean water according to manufacturer’s instructions. The amount of the solution should be approximately equal to the full volume of water that the heat exchanger holds.

2. Slowly add the prescribe amount of the cleaning solution to the circulating bucket.

3. Open the upper and lower drain valves, and then 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.

4. Check the cleaning circuit to ensure that the cleaning solution is flowing from the circulation bucket, through the pump and the unit and back to the top of the top of the bucket.

5. Return discharge foaming indicates an active cleaning solution and the presence of mineral deposits in the equipment.

6. Additional cleaning solution and/or water may be required to maintain circulation and to prevent the pump from cavitating.

7. 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, cleaning solution strength is depleted (two pounds of deposits removed per gallon used) or the equipment is free from calcium and other water-formed mineral deposits.

8. Periodically test the solution for effectiveness to determine if more cleaning solution is needed. Refer to “Testing Cleaning Effectiveness” in the next section for details. If the cleaning solution is expended before circulation time is up, additional cleaning solution will
   be needed and circulation time may be extended to complete the cleaning.
   9. 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. Rydlyme Chemical Descaler 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.

6.8.3.3 Testing Cleaning Effectiveness

There are two methods of testing the effectiveness of the cleaning solution during cleaning: the calcium carbonate spot test of the circulating solution and the charting of a trend in the pH of the cleaning solution.

Calcium Carbonate Spot Test
A calcium carbonate spot test is performed by exposing a form of calcium carbonate to the cleaning solution. Samples of the deposit, a Tums or Rolaids tablet, or bare concrete can be used. Observe the reaction of the cleaning 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 cleaning solution will be required to complete the job. If the solution is still active at the end of the time, all the scale has been dissolved.
pH Trend Charting
The initial pH of the cleaning solution will measure between 1-3 (See pH sheet on Rydlyme Chemical Descaler packaging). 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

Innovation Water Heaters are shipped with a condensate trap (P/N 99259). The trap must be installed external to the unit and attached to the exhaust manifold’s condensate drain port, as described in Section 2.9 (see Figure 2.9-1 and 2.9-2). This trap should be inspected and, if necessary, cleaned according to the schedule in Table 6-1 to ensure proper operation.
To inspect and clean the trap, proceed as follows:

Condensate Trap Inspection and Cleaning Instructions

1. Disconnect the condensate trap by loosening and then removing connections on the inlet and outlet sides of the trap (see Figure 6.9).
2. Unscrew and remove both the top and bottom caps.
3. Run water through the body of the trap to thoroughly clean the inside of the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap.
4. Replace the caps and tighten them.
5. Reassemble all piping and hose connections to the condensate trap inlet and outlet.

Figure 6.9: Condensate Trap P/N 99259

6.10 AIR FILTER REPLACEMENT

The Innovation heater is equipped with an air filter (P/N 59138), which should be cleaned or replaced according to the schedule in Table 6-1. The air filter is attached to the air fuel valve.
To inspect/replace the air filter, proceed as follows:

Air Filter Replacement Instructions

1. Set the Controller’s Enable/Disable switch to the Disable position. Disconnect AC power from the unit
2. Remove the side panels from the unit.
3. Refer to Figure 6.10 and locate the air filter attached to the air/fuel valve inlet.
4. Using a flat-tip screwdriver or 5/16 nut driver, loosen the clamp securing the filter to the inlet flange of the air/fuel valve. Remove the filter and clamp.
5. Each replacement air filter is equipped with its own clamp. Therefore, simply install the replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat-tip screwdriver or 5/16 nut driver.
6. Replace the side panels on the unit and return heater to service use.

Figure 6.10: Air Filter Mounting Location

6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST

If the LWCO capacitor has failed, order the LWCO capacitor Kit, P/N 69126, from AERCO, 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 Edge Controller.
The LWCO probe is located on the front of the heat exchanger body near the top. Figure 6.11 shows its location and components.

Figure 6.11: LWCO Probe Location (INN 1350 Shown)

6.11.1 Low Water Cutoff (LWCO) – Capacitor Electrical Short Test

This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger. Perform the capacitor electrical short test as described below.

LWCO Capacitor Electrical Short Test Instructions

1. Turn OFF AC power to the unit.
   WARNING!
   VOLTAGES OF 220 OR 110 AND 24 ARE USED TO POWER THESE UNITS, SO POWER APPLIED TO THESE UNITS MUST BE REMOVED BEFORE PERFORMING THE PROCEDURE DESCRIBED BELOW. SERIOUS PERSONAL INJURY OR DEATH MAY OCCUR IF THIS WARNING IS NOT OBSERVED.

2. Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the rear panel of the Edge Controller (see Figure 6.11.1-1).

Figure 6.11.1-1: Removing Shell Harness Cable from P5 Connector on Rear Panel

3. Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure 6.11.1-2.

4. Connect the second ohmmeter probe to Pin #6 of Shell Harness Connector (removed from the Edge Controller) as shown on right in Figure 6.11.1-2.
   
   Figure 6.11.1-2: Connecting Ohmmeter – LWCO Probe & Shell Harness Cable

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 reconnect the Shell Harness connector to the P5 connector on the rear of the Edge Controller.

6.11.2 Low Water Cutoff (LWCO) – Standard Test

Perform the standard Low Water Cutoff test using the Edge Controller as described below.

Standard Low Water Cutoff Edge Test Instructions

1. Turn on the AC power to the unit.
2. Press the TEST switch on the Edge Controller and confirm that the blinking Low Water Level message appears on the Edge display within 4 seconds.
3. Press the RESET key, followed by the Clear button, and confirm that the Low Water Level message is cleared.

6.12 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME

If the unit is to be taken out of service for an extended period of time (one year or more), complete the following instructions.

1. Set the Controller’s Enable/Disable switch to the Disable position to shut down the unit’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.
7. If the temperature in the storage location will ever get below freezing, for even a short time, you must drain all water from the unit before the temperature falls below freezing.
   Step 6 is not sufficient, as it leaves some water in the bottom of the heat exchanger chamber. You must then use a suction pump inserted through the inspection port to remove all water from the bottom of the heat exchanger chamber and base assembly.

6.13 PLACING THE UNIT BACK IN SERVICE AFTER A PROLONGED SHUTDOWN

After a prolonged shutdown (one year or more), the following procedures must be followed:

Placing Heater Back In Service After Prolonged Shutdown Instructions

1. Review installation requirements included in Chapter 2.
2. Inspect all piping and connections to the unit.
3. Inspect exhaust vent, air duct (if applicable).
4. Perform initial startup per Chapter 4.
5. Perform safety device testing and scheduled maintenance per Sections 5 and 6, above.

6.14 SPARK MONITOR (AC CURRENT TRANSDUCER)

The spark monitor (P/N 61034) evaluates the strength of the current between the ignition transformer (P/N 65085) and igniter or igniter- injector (see Figure 6.14-2).

Figure 6.14-1: Spark Detector Sensor (AC Current Transducer) Location

The monitor’s wires are connected to the I/O board’s Spark Signal terminals (see Section 2.12.4). Wire# 140 is connected to the ignition transformer. It passes through the spark monitor’s orifice. If an adequate AC current is not detected in the wire during ignition, the unit automatically shuts down.

Figure 6.14-2: Spark Detector Sensor Wiring

If the spark monitor needs to be replaced, open the monitor’s orifice by pulling on the tab at the side, remove Wire# 140, disconnect the monitor’s wires are from the I/O board, remove the old monitor from its position, install a new monitor in its place, route wire# 140 through the new sensor orifice, and connect the wires to the I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-).

CHAPTER 7. TROUBLESHOOTING GUIDE

7.1 INTRODUCTION

This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in an Innovation Water Heater. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action. 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 Instructions

1. Observe the fault messages displayed in the Edge Controller 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 unit’s I/O board contains an RS232 port. This port is used only by factory-trained personnel to monitor OnAER communications via a portable computer.

TABLE 7-1. WATER HEATER TROUBLESHOOTING

FAULT INDICATION:
PROBABLE CAUSES:
CORRECTIVE ACTION.

AIRFLOW FAULT DURING IGNITION:

1. Blower stopped running due to thermal 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 Edge Controller.

12. .Defective Air-Fuel Valve potentiometer.:

13. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices.

14. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

15. Remove the Blower Proof switch and inspect for signs of blockage, clean or replace as necessary.

16. Remove the Blocked-Air Inlet switch and inspect for signs of blockage, clean or replace as necessary.

17. 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.

18. 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.

19. 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.

20. Refer to item 7, above, and verify that the voltage conforms to the values shown in Appendix C.

21. Check wire connection from I/O Box 0-10V signal to the Blower Motor.

22. Measure voltage at the I/O box 0-10V output. A voltage of 8.2V equates to a 100% open valve position.

23. Check that the blower Analog Out terminal on the I/O board has a corresponding signal for the A/F valve.

24. Check Air/Fuel Valve position at 0%, 50% and 100% open positions. The positions on the VALVE POSITION bargraph should match the dial readings on the Air/Fuel Valve dial.

AIRFLOW FAULT DURING PURGE:

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 Edge Controller.

6. PROBABLE CAUSES from AIRFLOW FAULT DURING IGNITION above, items 3 to 12, applies to this fault.:

7. 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.

8. Start the unit. If the blower runs, check the airflow switch for continuity. Replace the switch if there is no continuity.

9. Remove the air flow switch and inspect for signs of blockage, clean or replace as necessary.

10. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

11. Measure for 24 VAC during start sequence from each side of the switch to ground. If 24 VAC is not present refer to qualified service personnel.

12. See CORRECTIVE ACTIONS from AIRFLOW FAULT DURING IGNITION above, items 3 to 12.

AIRFLOW FAULT DURING RUN:

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 AIRFLOW FAULT DURING IGNITION above, items 3 to 12, applies to this fault.:

7. Check combustion blower for signs of excessive heat or high current draw that may trip thermal or current overload devices.
   

8. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.
   

9. Remove the airflow switch and inspect for signs of blockage, clean or replace as necessary.
   

10. 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.
    

11. Run unit to full fire. If the unit rumbles or runs rough, perform combustion calibration.
    

12. See CORRECTIVE ACTIONS from AIRFLOW FAULT DURING IGNITION above, items 3 to 12.

DELAYED INTERLOCK OPEN:

1. Delayed Interlock Jumper not installed or removed.

2. Device proving switch hooked to interlocks is not closed.:

3. Check for a jumper properly installed across the delayed interlock terminals in the I/O box.

4. If there are 2 external wires on these terminals, check to see if an end switch for a device such as a pump, louver, etc. is tied these interlocks. Ensure that the device and or its end switch are functional. (Jumper may be temporarily installed to test interlock.).

STEPPER MOTOR FAILURE:

1. Air/Fuel Valve out of calibration.

2. Air/Fuel Valve unplugged.

3. Loose wiring connection to the

4. stepper motor.

5. Defective Air/Fuel Valve stepper motor.

6. Defective Power Supply Board or fuse.

7. Defective IGST Board.:

8. Perform Stepper Test per GF-112 (section 6.3.5) to ensure stepper motor rotates properly from 0% (fully closed) to 100% (fully open) positions. Verify VALVE POSITION bargraph and dial on the Air/Fuel Valve track each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (GF-112, section 6.2.1).

9. 2. Check that the Air/Fuel Valve is connected to the Edge Controller.

10. Inspect for loose connections between the Air/Fuel Valve

11. motor and the wiring harness.

12. Replace stepper motor.

13. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

14. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

WARNING EXHAUST TEMP HIGH (Flashing WARNING):

1. Poor combustion calibration.

2. Heat exchanger has scale.

3. The gasket between the exhaust manifold and combustion chamber is not properly sealing.:

4. Check combustion calibration using procedures in Chapter 4.

5. Clean heat exchanger using procedures in Chapter 6.

6. Check the gasket between the exhaust manifold and combustion chamber.

7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Refer to Table 7-2 to troubleshoot faults which may occur without a specific fault message being displayed.

TABLE 7-2. WATER HEATER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED

OBSERVED INCIDENT: PROBABLE CAUSES: CORRECTIVE ACTION

Fluctuating Gas Pressure:
1. Gas pressure going into unit is fluctuating.:
1. Stabilize gas pressure going into unit. If necessary, troubleshoot Building Supply Regulator.

Figure 7.2-1: Innovation Gas Train Component Locations (600N & 800N P/N 22332 shown)

Figure 7.2-2: Intake Manifold

Figure 7.2-3: SSOV Actuator with Gas Pressure Adjustment

CHAPTER 8. WATER HEATER MANAGEMENT

NOTE:
Some of the descriptions and procedures provided in this Chapter may duplicate information provided in previous Chapters of this manual. This is done to organize all WHM related information into a single Chapter, thus minimizing referencing back to these descriptions and procedures. It is assumed that the user is familiar with the basic Edge Controller’s menu processing procedures used throughout this manual.

The On-Board-Water-Heater Management system II (WHM II) is a feature integrated in the Edge Controller, designed to stage and coordinate multiple AERCO Innovation water heaters while maximizing operational efficiency. The WHM software code resides in each Edge Controller that is part of the system. The WHMII can control up to eight (8) water heaters in parallel. Each water heater controlled by the WHM must be equipped with an Actuator-Controlled Sequencing Valve (P/N 92123). These valves are installed on the cold-water inlet on each water heater in the WHM network (see Figure 8.1).

8.1 GENERAL DESCRIPTION

The Edge Controller’s Water Heater Management System (WHM) is designed to ensure that all water heaters in the system operate at maximum efficiency. This is accomplished by monitoring the Air/Fuel Valve position (VP) of all water heaters that have their sequencing valves open. Units with open sequencing valves are called enabled units. Units with closed sequencing valves are called disabled units. Units which are unable to function, due to a fault or user intervention, are called offline units. When there is minimal or no demand for hot water, the sequencing valve for one unit will be open. As system load increases, the WHM will open the sequencing valves on additional heaters. A simplified block diagram of multiple water heaters connected to a WHM is shown in Figure 8.1.

Figure 8.1: Simplified Block Diagram – Water Heater Management (WHM)

8.2 WHM PRINCIPLES OF OPERATION

The WHM system communicates with the plant water heaters via a RS485 network utilizing Modbus RTU protocol (8-bit, 9600 baud, no parity). All Modbus networks are implemented using a “Manager” /  Client” scenario where only one device, the Manager, can initiate a communication sequence. All other Edge Controller equipped units on the network are called Clients. However, since the WHM software code resides in each Edge Controller that is part of the system, any one of the Edge Controllers can be selected to control the system.
The WHM Manager monitors the Air/Fuel Valve position (VP) of all enabled units. When this valve position (% open) exceeds a user-selectable limit (Next On Valve Pos), the WHM will open the sequencing valve of another water heater in the system. Conversely, when the valve positions of all enabled units have dropped below a different user-selectable limit (Next Off Valve Pos) threshold, the WHM Manager will close the sequencing valve on a unit. The philosophy behind this approach is to maintain the fire rates (Air/Fuel Valve % open) at a level that maximizes heater efficiency.
In addition to collecting Air/Fuel Valve position data, the controlling Manager also monitors the total accumulated operating time for each unit on the system and attempts to balance the system so that all units operate for approximately the same number of hours.

8.3 NEW AERCO WHM FEATURES

The following sections describe new Water heater Management features.

8 .3.1 Valve Feedback

The Valve Feedback feature is designed to confirm that the Neptronic Valve has successfully executed either a Valve-Open or Valve-Close command from the Edge Controller. The Valve Feedback signal from the Neptronic Valve is connected to the Edge Controller via the I/O box. When the Edge Controller issues either a Valve-Open or Valve-Close command to the valve, the Valve Feedback signal is monitored to confirm that the Neptronic Valve has successfully opened or closed. If there is a mismatch between the Valve Feedback signal and the Valve-Open or Valve-Close command for a period of time exceeding the value entered in “Valve Fdbk timer” a fault is invoked.
This feature can be enabled or disabled in the Valve Feedback parameter (see Main Menu →
Advanced Setup → WHM Cascade → Operating Controls → Valve Configuration).

8.3.2 Valve Supervisor

This feature periodically monitors the Neptronic valve status (On or Off) and compares it to the
Valve command. If there is a mismatch, a fault is displayed and the unit will react as follows:

1. If the Valve is Stuck Open, it displays the VALVE STUCK OPEN fault message but continue with the unit operation (do not shut the unit down).
2. If the Valve is Stuck Closed, it shuts down the unit and displays the VALVE STUCK CLOSED fault message.

8.3.3 Valve Control

The Valve Control logic has been redesigned to assure proper valve operation. Critical valve positioning (On or Off) is assured by the development of two independent valve control functions, with one function monitoring the results of the other.

8.3.4 Temperature Sensor Calibration

The Temperature Sensors screens allows you calibrate the unit’s temperature sensors to achieve optimal performance. Complete the following to calibrate the temperature sensors.

Figure 8.3.4: Temperature Sensors Screen

Temperature Sensor Calibration Instructions

1. Go to: Main Menu → Calibration → Input/Output → Temperature Sensors.

2. Press the Sensor parameter and select the temperature sensor you want to calibrate.
   The following sensors are available for calibration:
   • Feed Forward
   • Outside Temp
   • Lower Inlet
   • Exhaust
   • Air Inlet
   • Outlet

3. The selected sensor’s current reading appears in the Current Reading field.

4. If there is an independent way to measure the temperature, and it differs from the Current Reading, enter an appropriate value in the Offset parameter.

8.3.5 Manual Mode Password Required

To prevent unauthorized or inadvertently setting the unit in Manual Mode of operation, entering a valid password is required to set the Edge in Manual Mode. Any level password will enable Manual Mode.

8.3.6 Auto-Manager Transfer

The Auto-Manager Transfer feature, once enabled, automatically transfers WHM Manager functionality to a new unit if the current WHM Manager fails or loses power.
To use this feature (default = Disabled), go to: Main Menu → Advanced Setup → WHM Cascade → Cascade Configuration on the unite designated as the WHM Manager and set Auto Manager Transfer to Enabled, then choose address of the backup unit in the Backup
Manager Addr parameter. You can also specify a delay before transferring manager functionality in the Auto-Manager Timer parameter.

8.3.7 Run Hours and Run Cycles

Run hours and run cycles are monitored to select the Lead unit and Lag unit (next on unit) in a WHM Cascade. In the event an Edge or PMC board is exchanged in the field, this feature will allow the user to increase but not decrease the run hours or run cycles. Once a user hits enter,
the changes made will be permanent and this feature will not allow changing to the previous value.
Only AERCO personnel are permitted to change this menu item. To increase the Run Hours or Run Cycles, go to Main Menu → Advanced Setup → Unit → Unit Settings.

8.3.8 High Temperature Governor

The High Temperature Governor is a feature that aggressively prevents the outlet temperature from exceeding the “Temperature High Limit”. The High Temperature Governor is independent of the system PID and Feed-Forward control methodology and independently modulates the Valve
Position (Fire Rate) if the outlet temperature dangerously approaches the Temperature Hi Limit parameter.
This feature has 5 separate temperature bands for more precise control.
This feature is enabled by the TEMP GOV parameter in Main Menu → Advanced Setup → Performance → Temperature Control → FFWD Settings. Once enabled, the 5 “governor” items, GOV Limit-5 to GOV Limit-15 are available. When the Outlet Temperature exceeds the value of the Temperature Hi Limit parameter (in Main Menu → Advanced Setup → Performance → Temperature Control → Temperature Conformance ) the effective Fire Rate will be reduced by the value entered in GOV Limit-5 through GOV Limit-15.

8.4 WHM STATUS DISPLAYS

The following WHM status information will be displayed to inform the user of critical WHM realtime operating conditions:
Once a unit is defined as the WHM Manager, the green Manager light appears on the Controller’s front face. In addition, the flowing status information appears on the WHM Cascade Status screen:
MANAGER-DISABLED – The Manager has been disabled and is not available
MANAGER-STANDBY – The Manager is “Cycled Off” and is available to be lit off
MANAGER-IGNITED – The Manager is ignited
On unit’s defined as WHM Clients, the flowing status information will be displayed on the Unit Status screen:
CLIENT-DISABLED – The Client has been disabled and is not available
CLIENT-STANDBY – The Client is “Cycled Off” and is available to be lit off
CLIENT-IGNITED – The Client is ignited

8.5 WATER HEATER MANAGEMENT ALTERNATING STATUS DISPLAYS

Manager Status Displays:
On both WHM Manager units, the following status information will alternate, and be displayed on the WHM Cascade Status screen:

Figure 8.5: WHM Cascade Status Screen

The following messages can appear on this screen:

FAILSAFE ACTIVE – The Client Failsafe Mode has been activated
All Heaters On – All available heaters are ignited
All Heaters Off – All available heaters are off
Enabling First – The first heater is allowed to ignite and its valve is opened
Enabling Next – The next heater is allowed to ignite and its valve is opened
Wtr Htr Inactive – This Client unit is inactive; its valve is closed and can’t ignite
Wtr Heatr Active – This Client unit is active; its valve is opened and it can ignite
REMOTE SIG FAULT – Remote signal fault
WHMS FAILSAFE – WHMS is in Failsafe Mode

8.6 WHM PARAMETERS

The WHM parameters are all in the various screens under Main Menu → Advanced Setup → WHM Cascade. However, these parameters can only be viewed if the Unit Type option in the Main Menu → Advanced Setup → Unit → Unit Settings screen is set to Innovation WH.
Many of the options in this menu are preset at the factory and cannot be altered by the user.

NOTE:
Some of the WHM parameters appear only if they are enabled, either in the WHM Cascade screens or by a specific menu item.

8.7 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS

The following sections provide the basic installation and set-up instructions for implementing a Water Heater Management System (WHM) to control up to 16 AERCO Innovation Water Heaters.
Some of the descriptions and procedures included in Chapter 2 are repeated here to avoid unnecessary referencing.

8.7.1 Installation Notes

AERCO requires a WHM sequencing valve in multi-unit Innovation configurations. When WHM is employed, Modbus communication with BAS is available via Modbus TCP (go to Main Menu → Advanced Setup → Comm & Network → BAS).
If you are installing a WHM system that also includes a ProtoNode SSD, you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the WHM system.

a) Do NOT install the ProtoNode Device at the outset of the installation. If the ProtoNode Device is already installed, you must physically disconnect it from the Modbus network in I/O board.
b) Make sure that the Modbus load and bias resistors are properly configured for the system to operate without the ProtoNode installed.
c) Temporarily set the WHM system for Constant Setpoint mode of operation (see below).
d) Turn on and completely test the installation to verify that it is operating proper.
e) Once the installation is working properly as a WHM system, install the ProtoNode Device.
f) Make sure that the Modbus load and bias resistors are properly configured for the system to operate with the ProtoNode installed.
g) Set the WHM system for desired mode of operation (Setpoint mode).
h) Test the system completely with the ProtoNode installed.

8.7.2 Hardware Installation

All Innovation Water Heaters which will be controlled by a WHM Manager must be equipped with an actuator-controlled sequencing valve (P/N 92123). If this valve is not already installed on the cold-water inlet, proceed as follows:

WHM Hardware Installation

1. Remove the sequencing valve from its stowed location.
2. Refer to Figure 8.7 and attach 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 8.7.
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 sequencing valve is properly positioned.
6. Connect the 4-pin Molex connector on the sequencing valve to the mating connector on the Innovation harness at the rear of the unit.
7. This completes the sequencing valve installation.

Figure 8.7.2: Innovation Water Heater Equipped with Sequencing Valve

8.7.3 WHM Modbus Network Wiring

As previously mentioned, all units being controlled by the WHM will be connected to a RS485 Modbus Network. All Modbus networks are wired in a daisy- chain configuration using a Manager/Client scenario as shown in Figure 8.7.3.

Figure 8.7.3: Typical Daisy-Chain Modbus/RS485 Network

NOTE:
The WHMS Manager does not necessarily have to be on either end of the Daisy- Chain loop.

Any one of the Edge WHM units included in the Modbus network can be the Manager. However, it is recommended that you decide which unit will be the Manager and which will be the last unit on the daisy-chain prior to performing the wiring connections. This will simplify wiring connections and Modbus address assignments.
Modbus network wiring connections must be made using shielded twisted-pair wiring, (18 – 24 AWG) such as Belden #9841, #3105A, #8760, or equivalent. The Modbus wiring connections are made at the RS485 COMM terminals on the I/O board included with each Edge Controller.
Connect the Modbus wiring as follows:

Modbus Network Wiring

1. Starting at the first unit, connect the twisted, shielded pair cable to the RS485 Comm plus (+) and minus (-) terminals on the left side I/O board as shown in Figure 8.7.4.
2. At the I/O board of the first unit in the daisy chain (not necessarily Manager), activate the DIP switch labeled “MODBUS TERM” by placing it in the up position. This will connect a termination resistor across the terminals at the source end.
3. Refer to Figure 8.7.4 and run the shielded cable to the next unit in the daisy-chain and connect the + and – wire leads (+ to +, – to -). DO NOT terminate the shield of the RS485 Comm leads to the SHIELD terminal at the Client. Instead, connect the shields of the incoming and outgoing RS485 leads together.
4. Continue connecting the + and – wire leads and shields for the remaining units as described in step 3 for the remaining Client units in the chain.
5. At the end unit in the chain, activate the DIP switch labeled “MODBUS TERM” by placing it in the up position. This will ensure that the termination resistors are activated at both ends of the loop.

8.7.4 Control and Power Wiring
Control and power wiring connections to the sequencing valves associated with each Edge WHM unit is accomplished by simply ensuring that the 4-pin Molex connectors on the units are connected to the corresponding connectors on the valves.

Figure 8.7.4-1: WHM Network Wiring Diagram

Figure 8.7.4-2: WHM Network Wiring Diagram

Figure 8.7.4-3: WHM Network Wiring Diagram

8.8 WHM PROGRAMMING & START-UP

All required hardware installation and network wiring must be completed before configuring the WHM parameters into the WHM Manager and Client units. In addition, the required menu entries must be determined based on the descriptions in the previous sections.
AERCO recommends that the WHM Manager be set up first. By doing so, the Manager will “push” most of the operating parameters to each WHM Client when they are brought on-line. For clarity, the instructions below assume that the WHM Manager and Clients will be consecutively numbered, starting at 1 (WHM Manager), although that’s not required.
Complete the instructions below on the unit designated as the WHM Manager :

1. Go to: Main Menu → Advanced Setup → WHM Cascade → Cascade Configuration , then configure the following parameters:
   a. Set the WHM Unit Mode to WHM Manager.
   b. You have the option of designating one of the units in the WHM Cascade as a Backup Manager. If the WHM Manager fails, manager functionality will automatically transfer to the designated Backup Manager. To use this functionality, enable the AutoManager Transfer parameter, then specify the address of the Backup Manager in the Backup Manager Addr parameter. You can also enter a delay before transferring manager functionality in the Auto- Manager Timer parameter.

2. Go to: Main Menu → Advanced Setup → WHM Cascade → Application Configuration.

3. Set the WHM Setpoint parameter to the desired temperature.

4. Go to: Main Menu → Advanced Setup → WHM Cascade → Cascade Comm and configure the following parameters:
    
   _ Figure 8.8: WHM Manager Cascade Communication Screens
   a. Specify the address of the WHM Manager in the Unit Address parameter.
   b. Specify the minimum and maximum address in the Cascade in the Min Address and Max Address parameters (typically 1 to the maximum number of units in the cascade).
   c. Set the communication parameters in the Cascade Baud Rate, Network Timeout and Error Threshold parameters.
   d. Specify the Plant Failsafe Mode, which determines what the entire plant does if the WHM Manager loses communication with the WHM Client units.
   e. _Check that the Manager LED is lit on the Controller’s front face.

5. Go to: Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Sequencing Control. The Next On Valve Pos parameter specifies the valve position that will trigger the next unit to come on line, and the Next Off Valve Pos parameter specifies the valve position that will trigger the next unit go off-line.

6. The Controller includes a Setback option, which can be used to adjust the setpoint temperature, start and end time, for operation during periods of low demand. To specify the setback time and temperature, go to: Main Menu → Advanced Setup → Performance → Temperature Control → Setpoint Range and configure the following parameters:
   _ a. Set the Setpoint Limiting parameter to Enabled.
   b. Configure the Setpt Low Limit and Setpt High Limit parameters, which together determine the temperature range within which the setpoint can vary. You can also configure the Setpoint Limit Band parameter, which allows you to set the number of degrees below Setpoint High Limit the unit’s outlet temperature must fall before the unit restarts.
   c._ Configure the Setback Start Time and Setback End Time, which together define when the Setback period will be in effect.

7. If you want to change the Lead/Lag Hours, go to: Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Lead/Lag, set Lead/Lag Settings to Select Lead/Lag, then select the Lead and Lag units in the Lead Unit and Lag Unit fields.

Complete the instructions below on each unit designated as a WHM Client:

WHM Client Programming & Start-Up Procedure 

1. Go to: Main Menu → Advanced Setup → WHM Cascade → Cascade Configuration and set the WHM Unit Mode to WHM Client.

2. Go to: Main Menu → Advanced Setup → WHM Cascade → Cascade Comm.
   _ a. Enter the Client unit’s address in the Unit Address parameter,
   b. Set the communication parameters in the Cascade Baud Rate, Network Timeout and Error Threshold parameters.
   c. _Specify the Unit Failsafe Mode, which determines what happens if a WHM Client units loses communication with the WHM Manager.

3. If you want to change the Lead/Lag Hours, go to: Main Menu → Advanced Setup → WHM Cascade → Operating Controls → Lead/Lag, set Lead/Lag Settings to Select Lead/Lag, then select the Lead and Lag units in the Lead Unit and Lag Unit fields.

8.9 TROUBLESHOOTING

Faults which may occur during WHM operation include the items listed in Table 8-9.

TABLE 8-9: WHM Troubleshooting

FAULT INDICATION:
PROBABLE CAUSE:
CORRECTIVE ACTION.

Manager LEDs are flashing on 2 Controllers:

1. Two Edge Controllers have their WHM Mode menu option set to WHM Manager.:

2. Check the WHM Mode entries in the units which have their displays flashing. Change one of the WHM Mode settings to WHM Client.

MANAGER LED on one or more WHM units is Off.:

1. Improperly connected or faulty RS485 Modbus wiring.

2. Improper Comm address.

3. Unit Comm address is not unique.:

4. Check the polarity of the RS485 Comm connections on the I/O board of the affected unit. Also, ensure that all Modbus wiring connections to the unit are secure.

5. Verify that the address of the affected unit is within the allowable range (1 thru 16).

6. Check to ensure that none of the units have the same Comm address.

Actuator-controlled sequencing valve does not open:

1. Control cable not connected to valve actuator.

2. 24 VAC power not being supplied to valve actuator.

3. Defective valve actuator:

4. Ensure that the control cable from the unit’s I/O Box is connected to the valve actuator.

5. Remove the enclosure cover from the valve actuator and verify that 24 VAC is present at Terminal 2 of the actuator.

6. Replace valve actuator. Following replacement, the actuator stroke will have to be calibrated to ensure it fully opening and closing.

8.10 SEQUENCING VALVE DESCRIPTION & OPERATION

Brief descriptions of Actuator-Controlled Sequencing Valve (P/N 92123) and its operating characteristics are provided below in Sections 8.11.1 and 8.11.2, respectively. The installation of the valve itself is described in Chapter 2, Section 2.5.1.

8.10.1 Sequencing Valve Description

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

• 2” Brass Ball Valve
• Actuator Linkage
• Actuator Housing
• Valve Shaft Handle

Figure 8-10.1-1: Actuator-Controlled Sequencing Valve (P/N 92123)

The Actuator Housing contains a cover which is removed by simply loosening a single captive screw. Removing the cover provides access to a PC Board containing wiring connections and control circuitry components as shown in Figure 8.10.1-2.
The components on the PC board include DIP switches which are preset at the factory and should not be changed unless instructed to do so.

Figure 8.10.1-2: Actuator PC Board Components

NOTES:

1. DO NOT press Auto-Stroke (Reset) button. Doing so may alter actuator calibration.
2. Depress and hold brass clutch button to manually rotate valve.

CAUTION!
Power must be removed from the Actuator prior to attempting to disengage the clutch. Failure to observe this precaution may damage the Actuator.

The PC board also contains a brass button which is used to disengage the clutch and permit the ball valve to be manually rotated. To disengage the clutch, proceed as follows:

Actuator Clutch Disengagement Instructions

1. Disconnect the 4-pin connector on the Actuator to ensure that 24 VAC power is not being supplied
2. Press and hold the brass CLUTCH button shown in Figure 8.10.1-2.
3. With the CLUTCH button depressed, the ball valve can be manually rotated from the fully open (90°) to the fully closed (0°) position.

8.10.2 Sequencing Valve Operating Characteristics

The Sequencing Valve is powered by 24 VAC which is supplied from a step-down transformer located in the Power Box of the Innovation Water Heater. The 24 VAC power output and a 2 to 10 VDC control signal from the I/O Box of the Water Heater are routed to the Sequencing Valve via a 4-pin Molex connector.
During normal Water Heater Management (WHM), a control signal of less than (<) – 2 VDC will rotate the valve to the fully open (90°) position. Conversely, a control signal above 8 VDC will rotate the valve to the fully closed (0°) position. The sequencing valve will send a status of the Valve (open/close) as a feedback signal (2 – 10 VDC) to the Edge Controller.

Figure 8.10.2: Sequencing Valve Wiring

APPENDIX A – Startup, Status and Fault Messages

All Startup, Status and Fault messages are included in Section 8 of the Edge [i] Controller Manual for Benchmark Boilers and Innovation Water Heaters, OMM-0141, GF-213.

APPENDIX B – Temperature Sensor Resistance/Voltage Chart

TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART (BALCO)

TEMPERATURE
°F:            °C  :RES (OHMS): VOLTS*

-40: -40: 779.0: 1.93
-30: -34.4: 797.5: 1.96
-20: -28.9: 816.3: 1.99
-10: -23.3: 835.4: 2.02
0: -17.2: 854.8: 2.05
10: -12.2: 874.6: 2.07
20: -6.7: 894.7: 2.10
30: -1.1: 915.1: 2.12
40: 4.4: 935.9: 2.15
50: 10: 956.9: 2.17
60:15.5: 978.3: 2.20
70: 21.1: 1000.0: 2.23
80: 26.7: 1022.0: 2.25
90: 32.2: 1044.4: 2.27
100: 37.8: 1067.0: 2.30
110: 43.3: 1090.0:  2.32
120: 48.9: 1113.3: 2.34
130: 54.4: 1137.0: 2.36
140: 60: 1160.9: 2.39
150: 65.6: 1185.2: 2.41
160: 71.1: 1209.5: 2.43
170: 76.7: 1234.7: 2.45
180: 82.2: 1260.0: 2.47
190: 87.8: 1285.6: 2.50
200: 93.3: 1311.4: 2.52
210: 98.9: 1337.7: 2.54
220: 104.4: 1364.2: 2.56
230: 110: 1391.0: 2.58
240: 115.6: 1418.2:
250: 121.1: 1445.7:

APPENDIX D – Dimensional Drawings

Drawing Number: AP-A-1054 rev A

Drawing Number: AP-A-1054 rev A

APPENDIX E – Parts List Drawings

Innovation Parts List – 28735-TAB rev B – On Top

Item: Qty.: Part #: Description.

1: 1: 22246: DYNAMIC LOAD ANTICIPATOR ASSY.
2: 1: 80090: INNOVATION SHELL INSULATION – Ø16.00.
3:
1: 24648-1: AIR-FUEL DELIVERY COMPONENTS, INN 600N
1: 24648-2: AIR-FUEL DELIVERY COMPONENTS, INN 800N
1: 24648-3: AIR-FUEL DELIVERY COMPONENTS, INN 1060N
1: 24648-4: AIR-FUEL DELIVERY COMPONENTS, INN 1350N
4 *: 4: 123449: SENSOR, TEMPERATURE
5: 1: 34061: BASE FORMED 26 X 40
6: 1: 92060: VALVE, 3/4” DRAIN
7: 1: 44085-1 6″: EXHAUST MANIFOLD – INNOVATION
8: 1: 93410: COUPLING, 1/8 NPT 304 SST 150 PSI
9: 1: 93357: PLUG, 1/8 NPT HEX PIPE 304 STAINLESS
10: 1: 80088: EXHAUST MANIFOLD SEAL

Innovation Parts List – 28735-TAB rev B

Item: Qty.: Part #: Description

1: 1: 25074: ENCLOSURE, FRAME ASSY
2: 5: 59133: LATCH, COMPRESSION
3: 1: 37096: FRONT PANEL ASSEMBLY
4: 1: 37098: TOP PANEL

Innovation 1060N, 1350N PROPANE Gas Train – P/N 22386 rev A, 2/6/2020

Item: Qty: Part #: Description

1: 1: 95026 1.25″: NPT 125#: THREADED FLANGE
6: 1: 92006-4: VALVE: BALL 3/4″ NPT
9: 1: 92101: VALVE: SSOV 3/4″ NPT
12: 1: 5018 1-1/2″: NPT MALE/FEMALE UNION
14: 1: 92006-7: VALVE: BALL BRASS 1-1/2″ NPT
15: 1: 64048 ❶: ACTUATOR: SSOV w/ REGULATOR 34 1 97087-12 FLEXIBLE TUBE, 12″
19: 2: 12951-2: BUSHING: CONTROL BOX
22: 2: 92077 1/4″: NPT MXF BRASS BALL VALVE
23: 2: 9-22: PIPE PLUG: 1/4″ NPT: STEEL
25: 1: 61002-21: LOW PRESSURE SWITCH: 7.5”
29: 1: 99017: SNUBBER: PRESSURE: 1/4″
30 1: 60032-1: PRESSURE SWITCH ASSY 1-20″ W.C.

Innovation 600N, 800N, 1060N, 1350N, 1400NK
Air Fuel Delivery System – P/N 24648 rev D, 2/4/2020

Item: Qty: Part #: Description

1: 1: 43101: BLOWER INTAKE MANIFOLD
2: 1: 81160: GASKET, 8.9” BLOWER
3: 1: 58193❶: FASCO BLOWER GPM 7.0
5: 1: 88004: O-RING #2-244 BUNA-N
9: 1: 60011-4: SWITCH ASSY, BLOWER PROOF
10: 1: 9-21: PLUG, HEX HD 1/8 NPT
11: 1: 61002-5: VACUUM PRESSURE SWITCH 4.5”
15: 1: 61024-1: AIR INLET TEMPERATURE SENSOR, 1/8” NPT
16: 1: 124149-1: WIRE ASSY, JUMPER O.T. SWITCHES
17: 1: 59138: FILTER, AIR 6”, INN 1060N, 1350N, 1400NK (Natural Gas and Propane)
18: 1: 59139: FILTER, AIR 6” X 4.5 LG, INN 600N, 800N (Natural Gas and Propane)
19: 1:
24298:-5: A/F VALVE ASSY INN 800N
24298-6: A/F VALVE ASSY INN 1060N
24298-7: A/F VALVE ASSY INN 1350N/1400NK
24298-8: A/F VALVE ASSY INN 600N PROPANE ONLY

Intake Manifold Assembly P/N 24234 rev E

Item: Qty: Part #: Description
1: 1: 44106: INTAKE MANIFOLD
2: 1: 59104: OBSERVATION PORT
3: 1: 66026: IGNITER-INJECTOR
4: 1: 81048: FLAME DETECTOR GASKET
5: 1: 66037: FLAME DETECTOR
6: 2: 93358: PLUG 1/4 NPT HEX HD PIPE
7: 1: GP-18899: BURNER FLANGE GASKET
8: 2: 52037: STUD #10-32
9: 2: 59027: STANDOFF, THREADED #10-32
10: 3: 53033: WASHER: CLOCKING
11: 1: 24247: STAGED IGNITION ASSY
12: 1: 44179: BURNER PLATE
13: 1: 46062: BURNER ASSEMBLY
14: 1: 122977: TWO-WAY CONNECTOR

1. 81048 & 66037 are supplied as kit # 24356-2
2. 66026 & 53033 are supplied as kit #58023
3. GP-18899 is supplied as kit #24335-1

NOTE 1:
Use 0 to 4 “Clocking Washers” to establish correct orientation.

APPENDIX G – Edge [i] Controller Views

Figure G-1 – Edge Controller (P/N 64134) – Exploded View

Figure G-2: Edge [i] Controller Rear View

DIP Switch Function & Default 

SW2:  SW1
1 Bias + – OFF: 1 CO Sensor – mA
2 Termination – OFF: 2 Flow Sensor – V
3 Bias – – OFF: 3 O2 Sensor – V
4 Not Used: 4 Analog In – mA
5 Not Used:
6 Not Used:

Figure G-3: Edge [i] Controller Interface Board (Behind Front Face)

APPENDIX I – Recommended Spares

For the locations of the recommended and optional spare parts listed below, refer to the Parts List illustrations in Appendix E.

TABLE I-1. Recommended Emergency Spare Parts

DESCRIPTION: PARTNO.: QUANTITY

120 VAC/Single-Phase Blower: 58039: One per three units.

SSOV Actuator/Regulator Combo – Used on:
• ALL FM gas train models
• Downstream SSOV on DBB (IRI) gas train models: 64134: One per three units

SSOV Actuator Without Proof of Closure switch:
• Used ONLY on Upstream SSOV on models with a DBB (IRI) gas train: 27086-1: One per three units

Temperature Sensor (Water & Exhaust): 123449: Three per unit

Flame Detector Kit: 24356-2: One kit per unit

Igniter-Injector Kit: 58023: One kit per unit

Low Gas Pressure Switch:
• Natural Gas: INN600N to INN1350N: 61002-1: One per three units
• Propane: INN600N, 800N: 61002-21

High Gas Pressure Switch:
• INN600N to INN1350N (Natural Gas and Propane): 60032-1: One per three units

TABLE I-2. 12 and 24 Month Maintenance Kits

DESCRIPTION: PART NO.: QUANTITY

12-Month Maintenance Kit: 58196-12: One kit per unit
24-month Waterside/Fireside Inspection Kits: 58196-12: One kit per unit

TABLE I-3. Additional Kits Available

DESCRIPTION: PART NO.

Innovation Shell Replacement Kit: 58189
Innovation Heat Exchanger Replacement Kit: 24684-TAB
Innovation Hydro Replacement Kit: 58191-TAB
FASCO GPM 7.0H Blower Replacement Kit: 58193
Innovation Burner Replacement Kit: 58192
Innovation A/F Valve Replacement Kit: 58194
Edge [i] Controller: 69344-4

Change Log:

Date:
Description:
Changed By.

11/19/2019:
Rev B:
Added note regarding removal of temperature sensors, Section
2.7: Internal Recirculation Loop and Appendix E: Part List.
Updated Wiring Diagram: Appendix H:
Chris Blair

4/30/2020:
Rev C:
DIR 20-15: Added support for Propane models INN 600N, 800N, 1060N, 1350N; updated Combustion Calibration instructions in Section 4.3, added Propane gas trains to Appendix E: Part List, updated Appendix I: Recommended Spares.
Corrected part number, Item 11, 61002-5 was 61002-4, pressure 4.5 was 4.0.
Changed orientation of gas ignitor-injector in Section 6.3; now inside 60̊arc.
Changed DIP switch setting in Figure 8.10.1-2
Redesigned rear sheet metal and insulation, Appendix E: Part List:
Chris Blair

11/16/2020:
Rev E:
Added BACnet IP feature in Comm & Network Section (3.3.4.3) **Linley:**
Thobourne

RERCO Innovation Water Heaters User Manual [INN 600N, INN 800N, INN 1060N, NN 1350N] – Optimized PDF
RERCO Innovation Water Heaters User Manual [INN 600N, INN 800N, INN 1060N, NN 1350N] – Original PDF

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>