AER Innovation 600 User manual

Innovation Installation, Operation & Maintenance Manual GF-128
OMM-0078_0O AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1 of 194
GF-128 Phone: [phone]/2017
OPERATION & MAINTENANCE MANUAL
Natural Gas and Propane Gas Modulating, Condensing Water heaters
Latest Release: 08/10/2017
This Guide Applies to the Following Models:
Natural Gas:
•Innovation 600
•Innovation 800
•Innovation 1060
•Innovation 1350
Propane:
•Innovation 600P
•Innovation 800P
•Innovation 1060P
•Innovation 1350P
Other documents for this product include:
•GF-5030 INN Gas Supply Guide
•GF-5050 INN Venting Guide
•GF-5060 INN Electric Power Guide
•GF-5080 INN Sizing Guide
600, 800, 1060, 1350 MBH Water Heaters
USER MANUAL
Applies to Serial Numbers:
G-17-1700 and above
U.S. Patent No. 9,243,848

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TABLE OF CONTENTS
FOREWORD ............................................................................................................................................. 7
CHAPTER 1. SAFETY PRECAUTIONS ......................................................................................... 11
1.1 WARNINGS & CAUTIONS..................................................................................................11
1.2 EMERGENCY SHUTDOWN...............................................................................................12
1.3 PROLONGED SHUTDOWN ...............................................................................................12
CHAPTER 2. INSTALLATION ........................................................................................................15
2.1 INTRODUCTION.................................................................................................................15
2.2 RECEIVING THE UNIT.......................................................................................................15
2.3 UNPACKING.......................................................................................................................15
2.4 SITE PREPARATION .........................................................................................................16
2.4.1 Installation Clearances ...................................................................................................................16
2.4.2 Setting the Unit ..............................................................................................................................17
2.5 WATER INLET AND OUTLET PIPING................................................................................18
2.5.1 WHM Actuator-Controlled Ball Valve Installation ......................................................................... 19
2.6 TEST HOSE BIB CONNECTION........................................................................................20
2.7 INTERNAL RECIRCULATION LOOP..................................................................................21
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION .....................................22
2.9 CONDENSATE DRAIN & PIPING.......................................................................................22
2.10 GAS SUPPLY PIPING ......................................................................................................24
2.10.1 Gas Supply Specifications.............................................................................................................25
2.10.2 Manual Gas Shutoff Valve ............................................................................................................ 25
2.10.3 External Gas Supply Regulator ..................................................................................................... 26
2.11 AC ELECTRICAL POWER WIRING..................................................................................27
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 ..................................................................................................................30
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..............................................................................................................32
2.12.14 AUX RELAY Terminals .................................................................................................................33
2.13 FLUE GAS VENT INSTALLATION....................................................................................33
2.14 COMBUSTION AIR...........................................................................................................34
2.14.1 Combustion From Outside the Building....................................................................................... 34
2.14.2 Combustion Air from Inside the Building .....................................................................................34

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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...................................................................................................................47
3.8 CALIBRATION MENU.........................................................................................................48
3.9 START SEQUENCE ...........................................................................................................50
3.10 START/STOP LEVELS.....................................................................................................53
CHAPTER 4. INITIAL START-UP..................................................................................................55
4.1 INITIAL START-UP REQUIREMENTS................................................................................55
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION...........................55
4.2.1 Required Tools & Instrumentation................................................................................................. 56
4.2.2 Installing Gas Supply Manometer .................................................................................................. 56
4.2.3 Accessing the Analyzer Probe Port.................................................................................................57
4.2.4 Connecting Multimeter to Flame Detector.................................................................................... 57
4.2.5 Recommendations for Temperature Calibration ........................................................................... 58
4.2.6 Recommendations for WHM Operation ........................................................................................58
4.3 NATURAL GAS COMBUSTION CALIBRATION .................................................................59
4.4 PROPANE COMBUSTION CALIBRATION.........................................................................62
4.5 REASSEMBLY....................................................................................................................64
4.6 TEMPERATURE CONTROL CALIBRATION......................................................................65
4.6.1 Setting the Outlet Water Temperature Setpoint ...........................................................................65
4.6.2 Minimum Load Adjustment............................................................................................................66
4.6.3 Maximum Load Adjustment...........................................................................................................66
4.7 OVER-TEMPERATURE LIMIT SWITCHes.........................................................................68
CHAPTER 5. SAFETY DEVICE TESTING .....................................................................................69
5.1 INTRODUCTION.................................................................................................................69
5.2 LOW GAS PRESSURE FAULT TEST.................................................................................69
5.3 HIGH GAS PRESSURE FAULT TEST................................................................................70
5.4 LOW WATER LEVEL FAULT TEST....................................................................................71
5.5 WATER TEMPERATURE FAULT TEST.............................................................................71
5.6 INTERLOCK TESTS...........................................................................................................72
5.6.1 Remote Interlock............................................................................................................................72
5.6.2 Delayed Interlock ...........................................................................................................................73
5.7 FLAME FAULT TESTs........................................................................................................73
5.8 AIR FLOW FAULT TESTS..................................................................................................74
5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................76
5.10 PURGE SWITCH OPEN DURING PURGE.......................................................................77

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5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................77
5.12 SAFETY PRESSURE RELIEF VALVE TEST....................................................................78
CHAPTER 6. MAINTENANCE......................................................................................................... 79
6.1 MAINTENANCE SCHEDULE..............................................................................................79
6.2 IGNITER-INJECTOR ..........................................................................................................80
6.3 FLAME DETECTOR ...........................................................................................................82
6.4 COMBUSTION CALIBRATION...........................................................................................82
6.5 SAFETY DEVICE TESTING ...............................................................................................82
6.6 FIRESIDE INSPECTION.....................................................................................................83
6.7 WATERSIDE PORT INSPECTION .....................................................................................87
6.8 WATERSIDE HEAT EXCHANGER INSPECTION AND CLEANING...................................88
6.8.1 HEAT EXCHANGER CLEANING ........................................................................................................ 89
6.9 CONDENSATE DRAIN TRAP.............................................................................................93
6.10 AIR FILTER REPLACEMENT...........................................................................................95
6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ...................................96
6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................96
6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test .....................................................................98
6.12 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME......98
6.13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN......99
6.14 SPARK MONITOR (AC CURRENT TRANSDUCER)........................................................99
CHAPTER 7. TROUBLESHOOTING GUIDE ............................................................................. 101
7.1 INTRODUCTION...............................................................................................................101
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ..................................113
CHAPTER 8. WATER HEATER MANAGEMENT .................................................................... 117
8.1 GENERAL DESCRIPTION................................................................................................117
8.2 WHM PRINCIPLES OF OPERATION...............................................................................118
8.3 NEW AERCO WHM FEATURES ......................................................................................118
8.3.1 Valve Feedback............................................................................................................................. 118
8.3.2 Valve Supervisor...........................................................................................................................118
8.3.3 Valve Control................................................................................................................................ 118
8.3.4 Modbus Header Sensor................................................................................................................ 119
8.3.5 Automatic Temperature Sensor Calibration ................................................................................ 119
8.3.6 Manual Mode Password Required ............................................................................................... 119
8.3.7 WHM Auto Mstr ...........................................................................................................................119
8.3.8 Run Hours and Run Cycles............................................................................................................119
8.3.9 High Temperature Governor........................................................................................................120
8.4 WHM STATUS DISPLAYS................................................................................................120
8.5 WATER HEATER MANAGEMENT ALTERNATING STATUS DISPLAYS.........................121
8.6 WHM MENU .....................................................................................................................122
8.7 WHM MENU ITEM DESCRIPTIONS.................................................................................124
8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS ....................................128
8.8.1 Installation Notes .........................................................................................................................128
8.8.2 Hardware Installation...................................................................................................................129
8.8.3 WHM Modbus Network Wiring....................................................................................................130

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8.8.4 Control and Power Wiring............................................................................................................131
8.9 WHM PROGRAMMING & START-UP ..............................................................................132
8.10 TROUBLESHOOTING....................................................................................................134
8.11 SEQUENCING VALVE DESCRIPTION & OPERATION .................................................135
8.11.1 Sequencing Valve Description.................................................................................................... 135
8.11.2 Sequencing Valve Operating Characteristics.............................................................................. 137
APPENDIX A – Innovation Menu Item Descriptions................................................................139
Table A-1: Operating Menu Item Descriptions.........................................................................139
Table A-2: Setup Menu Item Descriptions...............................................................................140
Table A-3: Configuration Menu Item Descriptions...................................................................141
Table A-4: Tuning Menu Item Descriptions .............................................................................144
Table A-5: Calibration Menu Item Descriptions .......................................................................146
APPENDIX B – Startup, Status And Fault Messages..............................................................149
APPENDIX C – Temperature Sensor Resistance/Voltage Chart.............................................153
APPENDIX D – Dimensional Drawings...................................................................................155
APPENDIX E – Parts List Drawings........................................................................................157
APPENDIX F – Piping Drawings.............................................................................................169
APPENDIX G – C-More Control Panel Views..........................................................................179
APPENDIX H – C-More Wiring Diagrams ...............................................................................181
APPENDIX I – Recommended Spares....................................................................................189
APPENDIX J –Warranty........................................................................................................191

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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 600,000 BTU/Hr.
(175.8 kW) input to 1,350,000 BTU/Hr. (395.6 kW) input; available models are listed below.
All Innovation Heater sizes include Water Heater Management (WHM) software, which is built
into each unit’s C-More Controller. 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. Units can be ordered 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:
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
TABLE F1: INNOVATION POTABLE WATER HEATER MODELS
Innovation
Models
Description Shipping
Weight
INN600
INN600P Innovation Potable Water Heater, 600,000 BTU/Hr. (175.8 kW)
Input, with Natural Gas or Propane Gas Train 1,060 lbs.
(480.8 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.)
INN800
INN800P Innovation Potable Water Heater, 800,000 BTU/Hr. (234.5 kW) Input, with Natural Gas or Propane Gas Train 1,080 lbs. (489.9 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.)
INN1060
INN1060P Innovation Potable Water Heater, 1,060,000 BTU/Hr. (310.7 kW) Input, with Natural Gas or Propane Gas Train 1,100 lbs. (499.0 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.)
INN1350
INN1350P Innovation Potable Water Heater, 1,400,000 BTU/Hr. (410.3 kW) Input, with Natural Gas or Propane Gas Train 1,150 lbs. (521.6 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.)

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FORWARD
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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:
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)
C-More 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.

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AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
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 C-More 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 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
O2Oxygen
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
Controller
P/N Part Number

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AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
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 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 inch W.C. = 249 Pa)
µA Micro amp (1 millionth of an ampere)

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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 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.
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 AND CAREFULLY DECREASE ALL TRAPPED
PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE.
WARNING!
ELECTRICAL CURRENT OF 220 or 110 AND 24 VOLTS AC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE THE UNIT’S POWER BOX COVER (LOCATED
BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED AT ALL TIMES, EXCEPT
DURING MAINTENANCE AND SERVICING.

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WARNING!
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.
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
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
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.
VALVE OPEN VALVE CLOSED

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CHAPTER 1 – SAFETY PRECAUTIONS
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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:

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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
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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 Heaters.
2.2 RECEIVING THE UNIT
Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight
is 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.
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:
•ASME Pressure and Temperature 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 either:
o110 VAC, Single-Phase, 60 Hz @ 20 Amps
o220 VAC, Single-Phase, 50/60 Hz @ 20 Amps
•Access to a Natural Gas line with a minimum pressure of 4 inches W.C. (1.0 kPa) or to
a Propane gas line with 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.
24” (0.61m)
24” (0.61m)
24”
(0.61
m)
30”
(0.76 m)
97.25”
(2.47m)
75.25”
(1.91m)
18.6”
(47cm)
50.9” (1.29m)
18” (0.46m)
4” to 6” (10.2 to 15.2 cm) high concrete housekeeping pad. Ensure that
this pad does NOT extend under the condensate assembly.

Innovation Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
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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) housekeeping pad to avoid base
corrosion. 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
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.
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 C-More 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 2-3a. Water Inlet & Outlet Locations
P&T RELIEF
VALVE
COLD WATER INLET
2” NPT
DRAIN VALVE
EXHAUST MANIFOLD
AIR INLET
HOT WATER OUTLET
2” NPT

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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 2-3b, 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
2-3b.
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 2-3b. Innovation Water Heater Equipped With Sequencing Valve
HEATER DRAIN VALVE
2” NPT UNION
BALL VALVE
WITH ACTUATOR
2” NPT

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2.6 TEST HOSE BIB CONNECTION
A Test Hose Bib connection, upstream of the shut off valve on the hot water outlet, is required
for startup and testing (Figure 2-4). The test hose diameter should be a minimum of 3/4" (1.9
cm). The Test Hose Bib cannot be omitted.
Figure 2-4. Test Hose Bib Location
TO DRAIN
TEST
HOSE BIB
HOT
WATER
OUT
TEST HOSE