AER Innovation 600 User manual

Innovation Water Heaters Installation, Operation & Maintenance Manual
OMM-0078_0M AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1 of 216
GF-128 Phone: [phone]/2015
USER MANUAL
Installation, Operation and Maintenance
INNOVATION Series
Gas-Fired Water Heaters
Natural Gas or Propane
Modulating, Condensing
Water Heater Models
Applicable to Serial Number
G-15-2265 and above
This guide applies to the
following Innovation models
• Innovation 600
• Innovation 800
• Innovation 1060
• Innovation 1350
Other documents for this
product include:
• GF-5030 INN-Recon Gas Supply Guide
• GF-5050 INN-Recon Venting Guide
• GF-5060 INN-Recon Elect. Power Guide
• GF-5080 INN Sizing Guide
Latest Update: 09/11/2015

Innovation Water Heaters Installation, Operation & Maintenance Manual
Page 2 of 216 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0078_0M
09/11/2015 Phone: [phone] GF-128
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
DISCLAIMER
The information contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to this material, including,
but not limited to, implied warranties of merchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual, nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of
these materials.

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TABLE OF CONTENTS
FOREWORD ............................................................................................................................................. 7
CHAPTER 1. SAFETY PRECAUTIONS ......................................................................................... 13
1.1 WARNINGS & CAUTIONS ..................................................................................................13
1.2 EMERGENCY SHUTDOWN ...............................................................................................14
1.3 PROLONGED SHUTDOWN ...............................................................................................15
CHAPTER 2. INSTALLATION ........................................................................................................17
2.1 INTRODUCTION.................................................................................................................17
2.2 RECEIVING THE UNIT .......................................................................................................17
2.3 UNPACKING .......................................................................................................................17
2.4 SITE PREPARATION .........................................................................................................18
2.4.1 Installation Clearances ...................................................................................................................18
2.4.2 Setting the Unit ..............................................................................................................................19
2.5 WATER INLET AND OUTLET PIPING ................................................................................20
2.5.1 WHM Actuator-Controlled Ball Valve Installation .........................................................................20
2.6 TEST HOSE BIB CONNECTION ........................................................................................21
2.7 SYSTEM RECIRCULATION LOOP.....................................................................................22
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION .....................................23
2.9 CONDENSATE DRAIN & PIPING .......................................................................................24
2.10 GAS SUPPLY PIPING ......................................................................................................26
2.10.1 Gas Supply Specifications. ............................................................................................................ 26
2.10.2 Manual Gas Shutoff Valve ............................................................................................................26
2.10.3 External Gas Supply Regulator ..................................................................................................... 27
2.11 AC ELECTRICAL POWER WIRING ..................................................................................28
2.11.1 Electrical Power Requirements ....................................................................................................28
2.12 FIELD CONTROL WIRING ...............................................................................................29
2.12.1 OUTDOOR AIR IN Terminal...........................................................................................................30
2.12.2 COMBUSTION AIR Terminals........................................................................................................30
2.12.3 O2 SENSOR Terminals .................................................................................................................. 30
2.12.4 SPARK SIGNAL Terminals..............................................................................................................30
2.12.5 ANALOG IN Terminals .................................................................................................................. 31
2.12.6 VALVE FEEDBACK Terminals......................................................................................................... 31
2.12.7 SHIELD Terminals..........................................................................................................................31
2.12.8 ANALOG OUT Terminals............................................................................................................... 31
2.12.9 RS485 Comm Terminals ...............................................................................................................32
2.12.10 RS232 Comm Terminals ............................................................................................................. 32
2.12.11 VFD/BLOWER Terminals.............................................................................................................32
2.12.12 Interlock Terminals..................................................................................................................... 32
2.12.13 FAULT RELAY Terminals..............................................................................................................33
2.12.14 AUX RELAY Terminals ................................................................................................................. 33
2.13 FLUE GAS VENT INSTALLATION ....................................................................................33
2.14 COMBUSTION AIR ...........................................................................................................34
2.14.1 Combustion From Outside the Building....................................................................................... 34

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2.14.2 Combustion Air from Inside the Building .....................................................................................34
2.15 DUCTED COMBUSTION ..................................................................................................35
CHAPTER 3. OPERATION ..............................................................................................................37
3.1 INTRODUCTION.................................................................................................................37
3.2 CONTROL PANEL DESCRIPTION .....................................................................................37
3.3 CONTROL PANEL MENUS ................................................................................................41
3.3.1 Menu Processing Procedure ..........................................................................................................41
3.4 OPERATING MENU ...........................................................................................................43
3.5 SETUP MENU ....................................................................................................................44
3.6 CONFIGURATION MENU ...................................................................................................44
3.7 TUNING MENU ...................................................................................................................46
3.8 CALIBRATION MENU .........................................................................................................47
3.9 START SEQUENCE ...........................................................................................................49
3.10 START/STOP LEVELS .....................................................................................................52
CHAPTER 4. INITIAL START-UP..................................................................................................53
4.1 INITIAL START-UP REQUIREMENTS ................................................................................53
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION...........................53
4.2.1 Required Tools & Instrumentation................................................................................................. 53
4.2.2 Installing Gas Supply Manometer .................................................................................................. 54
4.2.3 Accessing the Analyzer Probe Port................................................................................................. 55
4.2.4 Connecting Multimeter to Flame Detector.................................................................................... 55
4.2.5 Recommendations for Temperature Calibration ........................................................................... 56
4.2.6 Recommendations for WHM (Water Heater Management) Operation........................................56
4.3 NATURAL GAS COMBUSTION CALIBRATION .................................................................57
4.4 PROPANE COMBUSTION CALIBRATION .........................................................................60
4.5 REASSEMBLY ....................................................................................................................62
4.6 TEMPERATURE CONTROL CALIBRATION ......................................................................63
4.6.1 Setting the Outlet Water Temperature Setpoint ........................................................................... 63
4.6.2 Minimum Load Adjustment............................................................................................................64
4.6.3 Maximum Load Adjustment...........................................................................................................65
4.7 OVER-TEMPERATURE LIMIT SWITCHes .........................................................................66
CHAPTER 5. SAFETY DEVICE TESTING .....................................................................................67
5.1 INTRODUCTION.................................................................................................................67
5.2 LOW GAS PRESSURE FAULT TEST .................................................................................67
5.3 HIGH GAS PRESSURE FAULT TEST ................................................................................68
5.4 LOW WATER LEVEL FAULT TEST ....................................................................................69
5.5 WATER TEMPERATURE FAULT TEST .............................................................................69
5.6 INTERLOCK TESTS ...........................................................................................................70
5.6.1 Remote Interlock............................................................................................................................70
5.6.2 Delayed Interlock ...........................................................................................................................71
5.7 FLAME FAULT TESTs ........................................................................................................71
5.8 AIR FLOW FAULT TESTS ..................................................................................................72

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5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................74
5.10 PURGE SWITCH OPEN DURING PURGE .......................................................................75
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................75
5.12 SAFETY PRESSURE RELIEF VALVE TEST ....................................................................76
CHAPTER 6. MAINTENANCE......................................................................................................... 77
6.1 MAINTENANCE SCHEDULE ..............................................................................................77
6.2 IGNITER-INJECTOR ..........................................................................................................78
6.3 FLAME DETECTOR ...........................................................................................................80
6.4 COMBUSTION CALIBRATION ...........................................................................................80
6.5 SAFETY DEVICE TESTING ...............................................................................................80
6.6 FIRESIDE INSPECTION .....................................................................................................80
6.7 WATERSIDE INSPECTION ................................................................................................85
6.7.1 Anode Replacement ....................................................................................................................... 86
6.8 HEAT EXCHANGER CLEANING ........................................................................................87
6.8.1 Pumping System Set-Up Instructions.............................................................................................88
6.8.2 Cleaning Procedure ........................................................................................................................89
6.8.3 Testing HydroSkrub Effectiveness..................................................................................................89
6.9 CONDENSATE DRAIN TRAP .............................................................................................91
6.10 AIR FILTER REPLACEMENT ...........................................................................................92
6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ...................................93
6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................93
6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test .....................................................................95
6.12 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME ......95
6.13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ......96
6.14 SPARK MONITOR (AC CURRENT TRANSDUCER) ........................................................96
CHAPTER 7. TROUBLESHOOTING GUIDE ................................................................................97
7.1 INTRODUCTION.................................................................................................................97
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................. 109
CHAPTER 8. WATER HEATER MANAGEMENT .................................................................... 113
8.1 GENERAL DESCRIPTION ................................................................................................ 113
8.2 WHM PRINCIPLES OF OPERATION ............................................................................... 114
8.3 NEW AERCO WHM FEATURES ...................................................................................... 114
8.3.1 Valve Feedback............................................................................................................................. 114
8.3.2 Valve Supervisor...........................................................................................................................114
8.3.3 Valve Control................................................................................................................................114
8.3.4 Modbus Header Sensor................................................................................................................ 115
8.3.5 Automatic Temperature Sensor Calibration ................................................................................115
8.3.6 Manual Mode Password Required ............................................................................................... 115
8.3.7 Quick Re-Flash Feature................................................................................................................. 115
8.3.8 WHM Auto Mstr ...........................................................................................................................116
8.3.9 Run Hours and Run Cycles............................................................................................................116
8.3.10 High Temperature Governor...................................................................................................... 116
8.4 WHM STATUS DISPLAYS ................................................................................................ 116

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8.5 WATER HEATER MANAGEMENT ALTERNATING STATUS DISPLAYS......................... 117
8.6 WHM MENU ..................................................................................................................... 117
8.7 WHM MENU ITEM DESCRIPTIONS ................................................................................. 119
8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS .................................... 123
8.8.1 Installation Notes ......................................................................................................................... 123
8.8.2 Hardware Installation...................................................................................................................123
8.8.3 WHM Modbus Network Wiring.................................................................................................... 124
8.8.4 Control and Power Wiring............................................................................................................126
8.9 WHM PROGRAMMING & START-UP .............................................................................. 127
8.10 TROUBLESHOOTING .................................................................................................... 129
8.11 SEQUENCING VALVE DESCRIPTION & OPERATION ................................................. 129
8.11.1 Sequencing Valve Description.................................................................................................... 129
8.11.2 Sequencing Valve Operating Characteristics..............................................................................132
APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS ................................................ 133
Table A-1: Operating Menu Item Descriptions ......................................................................... 133
Table A-2: Setup Menu Item Descriptions ............................................................................... 134
Table A-3: Configuration Menu Item Descriptions ................................................................... 135
Table A-4: Tuning Menu Item Descriptions ............................................................................. 137
Table A-5: Calibration Menu Item Descriptions ....................................................................... 139
APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES ............................................. 143
APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART ..................... 147
APPENDIX D – DIMENSIONAL DRAWINGS ......................................................................... 149
APPENDIX E – PARTS LIST DRAWINGS .............................................................................. 151
APPENDIX F – PIPING DRAWINGS ...................................................................................... 173
APPENDIX G – C-MORE CONTROL PANEL VIEWS ............................................................. 187
APPENDIX H – C-MORE WIRING DIAGRAMS ..................................................................... 189
APPENDIX I – RECOMMENDED SPARES ............................................................................ 205
APPENDIX J – KOREAN COMBUSTION CALIBRATION ....................................................... 207
J1 – NATURAL GAS COMBUSTION CALIBRATION.............................................................. 207
J2 – PROPANE COMBUSTION CALIBRATION ..................................................................... 210
J3 – REASSEMBLY ................................................................................................................ 212
APPENDIX K – WARRANTY ................................................................................................. 213

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FOREWORD
The AERCO Innovation Series Potable Water Heaters are modulating units which represent a
true industry advance that meets the needs of today's energy efficiency and environmental
concerns. Designed for use in any domestic water heating system, each Innovation model
provides precisely-controlled potable water within ±2°F (1.1°C) of setpoint, regardless of flow
rate. Innovation’s compact size and varied venting capabilities allow maximum installation
flexibility. The Innovation Series Heaters, with their load tracking controls modulate over a 20:1
turn down ratio to match the system demand and yield high thermal efficiencies.
Innovation Water Heaters are available in four (4) different sizes ranging from 600,000 BTU/Hr.
(175.8 kW) input to 1,350,000 BTU/Hr. (395.6 kW) input. In addition, all Innovation Heater sizes
now include Water Heater Management (WHM) software which is built in to the C-More
Controllers furnished with each unit. When the heater is ordered with a Sequencing Valve (SV),
up to eight (8) Innovation Water Heaters can be controlled by the WHM system utilizing RS485
Modbus protocol. All available Innovation Water Heater models are listed in the table on the
following page. As this table shows, units can be ordered with Factory Mutual (FM) or Double
Block and Bleed (formerly IRI) Gas Trains with or without Sequencing Valves.
When installed and operated on natural gas in accordance with this Instruction Manual, the
Innovation Series models covered herein comply with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
• Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117,
Rule 117.465
Whether used in singular or modular arrangements, the Innovation Heaters offer the maximum
flexibility in venting with minimum installation space requirements. Innovation’s advanced
electronic controls offer simplified integration with today’s Energy Management Systems.
For service or parts, contact your local sales representative or AERCO International, Inc.
IMPORTANT
Unless otherwise specified, the descriptions and procedures provided in
this Installation, Operation & Maintenance Manual apply to all Innovation
Series Water Heaters.

Innovation Water Heaters Installation, Operation & Maintenance Manual
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INNOVATION POTABLE WATER HEATER MODELS
Part Number Description
Shipping
Weight
INN600
INN600P
Innovation Potable Water Heater, 600,000 BTU/HR (175.8
kW) Input, Natural Gas or Propane, FM Gas Train
1,060 lbs.
(480.8 kg.)
INN600SV
INN600SVP
Innovation Potable Water Heater, 600,000 BTU/HR (175.8
kW) Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve
1,080 lbs.
(489.9 kg.)
INN600DBB
INN600PDBB
Innovation Potable Water Heater, 600,000 BTU/HR (175.8
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train
1,085 lbs.
(492.1 kg.)
INN600SVDBB
INN600SVPDBB
Innovation Potable Water Heater, 600,000 BTU/HR (175.8
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,105 lbs.
(501.2 kg.)
INN800
INN800P
Innovation Potable Water Heater, 800,000 BTU/HR (234.5
kW) Input, Natural Gas or Propane, FM Gas Train
1,080 lbs.
(489.9 kg.)
INN800SV
INN800SVP
Innovation Potable Water Heater, 800,000 BTU/HR (234.5
kW) Input, Natural Gas, or Propane FM Gas Train with WHM
Sequencing Valve
1,100 lbs.
(499.0 kg.)
INN800DBB
INN800PDBB
Innovation Potable Water Heater, 800,000 BTU/HR (234.5
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train
1,095 lbs.
(496.7 kg.)
INN800SVDBB
INN800SVPDBB
Innovation Potable Water Heater, 800,000 BTU/HR (234.5
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,115 lbs.
(505.8 kg.)
INN1060
INN1060P
Innovation Potable Water Heater, 1,060,000 BTU/HR (310.7
kW) Input, Natural Gas or Propane, FM Gas Train
1,100 lbs.
(499.0 kg.)
INN1060SV
INN1060SVP
Innovation Potable Water Heater, 1,060,000 BTU/HR (310.7
kW) Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve
1,120 lbs.
(508.0 kg.)
INN1060DBB
INN1060PDBB
Innovation Potable Water Heater, 1,060,000 BTU/HR (310.7
kW) Input, Natural Gas, or Propane Double Block & Bleed
(Formerly IRI) Gas Train
1,115 lbs.
(505.8 kg.)
INN1060SVDBB
INN1060SVPDBB
Innovation Potable Water Heater, 1,060,000 BTU/HR (310.7
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,135 lbs.
(514.8 kg.)
INN1350
INN1350P
Innovation Potable Water Heater, 1,350,000 BTU/HR (395.6
kW) Input, Natural Gas or Propane, FM Gas Train
1,150 lbs.
(521.6 kg.)
INN1350SV
INN1350SVP
Innovation Potable Water Heater, 1,350,000 BTU/HR (395.6
kW) Input, Natural Gas or Propane, FM Gas Train with WHM
Sequencing Valve
1,170 lbs.
(530.7 kg.)
INN1350DBB
INN1350PDBB
Innovation Potable Water Heater, 1,350,000 BTU/HR (395.6
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train
1,165 lbs.
(528.4 kg.)
INN1350SVDBB
INN1350SVPDBB
Innovation Potable Water Heater, 1,350,000 BTU/HR (395.6
kW) Input, Natural Gas or Propane, Double Block & Bleed
(Formerly IRI) Gas Train with WHM Sequencing Valve
1,205 lbs.
(546.6 kg.)

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Phrases, abbreviations and acronyms used in this manual are listed in the following table:
PHRASES, ABBREVIATIONS AND ACRONYMS
Phrase, Abbreviation
& Acronym 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)
C-More Controller
(or Control Box)
A control system developed by AERCO and curre
ntly 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. Formerly IRI.
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.
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

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Phrase, Abbreviation
& Acronym Meaning
IGN Ignition
IGST Board Ignition/Stepper Board, contained in C-More Control Box
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 thousand
th
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
O
2
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 C-More
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

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Phrase, Abbreviation
& Acronym
Meaning
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 Slave to Slave programming
SSOV Safety Shut Off Valve
SV
Sequencing Valve (Used with Water Heater Management (WHM)
system)
TEMP (Temp) Temperature
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network in
order to prevent reflections that may cause invalid data in the
communication
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 W.C. = 249 Pa)
µA Micro amp (1 million
th
of an ampere)

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Innovation Water Heaters Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
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CHAPTER 1. SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired heaters and ANSI/NFPASB for LP gas-fired heaters. Where applicable, the
equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class;
which should be carefully followed in all cases. Authorities having jurisdiction should be
consulted before installations are made.
See pages 15 and 16 for information on installations within the Commonwealth of
Massachusetts.
IMPORTANT
This Instruction Manual is an integral part of the product and must be
maintained in legible condition. It must be given to the user by the installer
and kept in a safe place for future reference.
IMPORTANT
Read the following restrictions prior to installing the water heater:
1. The water heater can only be used for applications where the chlorine
concentrations Do Not Exceed 4 mg/L which is the Environmental
Protection Agency limit for chlorine concentrations in drinking water.
2. Do Not use this heater for a pool heating application.
WARNING!
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
WARNING!
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
WARNING!
ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE COVER ON THE UNIT’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.

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CHAPTER 1 – SAFETY PRECAUTIONS
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WARNING!
A DOUBLE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNIT. THE SWITCH MUST BE INSTALLED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO
UNIT SHEET METAL ENCLOSURES.
CAUTION
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
CAUTION
DO NOT use this heater if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
IMPORTANT
The Installer must identify and indicate the location of the emergency
shutdown manual gas valve to operating personnel.
Figure 1-1. Manual Gas Shutoff Valve
MANUAL GAS SHUT-OFF VALVE
VALVE OPEN VALVE CLOSED

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1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed to verify all system-
operating parameters. If there is an emergency, turn off the electrical power supply to the
AERCO heater and close the manual gas valve located upstream of the unit. The installer must
identify the emergency shut-off device.
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Water heater Installations within the Commonwealth of Massachusetts
must conform to the following requirements:
• Heater must be installed by a plumber or a gas fitter who is licensed within
the Commonwealth of Massachusetts.
• Prior to unit operation, the complete gas train and all connections must be
leak tested using a non-corrosive soap.
• The vent termination must be located a minimum of 4 feet (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

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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)]

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CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
AERCO Innovation Water Heater models INN600, INN800, INN1060 and INN1350.
2.2 RECEIVING THE UNIT
Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight
is approximately 1200 pounds (544 kg). The unit must be moved with the proper rigging
equipment for safety and to avoid equipment damage. The unit should be completely inspected
for evidence of shipping damage and shipment completeness at the time of receipt from the
carrier and before the bill of lading is signed.
NOTE
AERCO is not responsible for lost or damaged freight. Each unit has a Tip-
N-Tell indicator on the outside of the crate. This indicates if the unit has
been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap
If the Innovation Water Heater is equipped for use with the AERCO Water Heater Management
(WHM) system, an actuator-controlled ball valve will also be included with the unit.
When optional accessories are ordered, they may be packed within the unit’s shipping
container, factory installed on the unit, or packed and shipped in a separate container. Any
standard or optional accessories shipped loose should be identified and stored in a safe place
until ready for installation or use.

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2.4 SITE PREPARATION
Ensure that the site selected for installation of the Innovation Water Heater includes:
• Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps.
• Access to Natural Gas line at a minimum pressure of 4 inches W.C. (1.0 kPa) or to
Propane at a minimum pressure of 7 inches W.C. (1.7 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 2-1 (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.
50.9" 18"
97.25"
75.25"
18.6"
SEQUENCING
VALVE 30"
24"
24"
24"
4" HIGH PAD
Figure 2-1. Innovation Water Heater Clearances
WARNING!
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.
CAUTION
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
30”
(1.76m)
24” (0.61m)
24” (0.61m)
24”
(0.61m)
50.9” (1.29m)
18” (0.45m)
97.25”
(2.47m)
75.25”
(1.91m)
4” TO 6” (10.2 to 15.2 cm) HIGH HOUSEKEEPING CONCRETE PAD
Ensure that the housekeeping pad does NOT extend under the condensate assembly.
18.6”
(0.47mm
)

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FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 (Safety Precautions), pages 13 and 14.
2.4.2 Setting the Unit
The unit must be installed on a 4 to 6 inch (10.2 to 15.2 cm) housekeeping pad to ensure
proper condensate drainage. Two lifting lugs are provided with the unit and are wire-tied to the
top of the heat exchanger. The top sheet metal cover of the unit must first be removed and the
lifting lugs must be installed as shown in Figure 2-2. USE THESE TWO LUGS TO LIFT AND
MOVE THE UNIT. Remove the top panel from the unit to provide access to the lifting lugs.
Remove the four (4) lag screws securing the unit to the shipping skid. Lift the unit off the
shipping skid and position it on the 4 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.
Figure 2-2. Partial Top View Showing Installed Lifting Lugs
IMPORTANT
If the Innovation Water Heater is equipped for use with the C-More Water
Heater Management (WHM) system, then an actuator-controlled ball valve
will be included with the shipment. Refer to section 2.5.1 for installation
instructions prior to connecting inlet piping.
LIFTING LUGS

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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 2-3a. 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.
NOTE
All piping must be arranged so that it does not interfere with
removal of any covers, inhibit service or maintenance, or prevent
access between the unit and walls, or another unit.
Figure 2-3a. Water Inlet & Outlet Locations
2.5.1 WHM Actuator-Controlled Ball Valve Installation
If the Innovation Water Heater was ordered for use with the C-More Water Heater Management
(WHM) system and the actuator-controlled ball valve is not already installed on the unit (Figure
2-3b), it will be packed separately within the shipping container. If installation is required,
proceed as follows:
WHM Ball Valve Installation
1. Remove the ball valve from its stowed location within the shipping container.
2. Attached the valve to the cold water inlet of the unit using the pipe union and nipple
provided.
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure
2-3b.
P&T RELIEF
VALVE
COLD WATER INLET
2” (5.08 cm) NPT
DRAIN VALVE
EXHAUST MANIFOLD
AIR INLET
NATURAL GAS INLET
1” (2.54 cm) NPT
HOT WATER OUTLET
2” (5.08 cm) NPT