AER INNOVATION INN600 User manual

GF-128
OMM-0078_0G
AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
USER MANUAL
Installation, Operation and Maintenance
INNOVATION Series
Gas-Fired Water Heaters
Natural Gas Modulating,
Condensing Water Heater
Models:
•INN600
•INN800
•INN1060
•INN1350
Applicable to Serial Numbers
G-12-0693 and Above
Other documents for this product
include:
•GF-5030 INN Gas Supply Guide
•GF-5050 INN Venting Guide
•GF-5060 INN Elect. Power Guide
•GF-5080 INN Sizing Guide
Revised: 07/16/2012

GF-128
OMM-0078_0G
AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
Disclaimer
The information contained in this manual is subject to change without notice from AERCO International,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness for a particular application. AERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.
Technical Support:
(Mon–Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com

GF-128 Innovation Series Water Heaters
OMM-0078_0GInstallation, Operation & Maintenance Manual Table of Contents
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 3of 190
TABLE OF CONTENTS
TABLE OF CONTENTS ...............................................................................................................................3
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 .........................................................................................................15
2.4.1 Installation Clearances.................................................................................................16
2.4.2 Setting the Unit.............................................................................................................17
2.5 WATER INLET AND OUTLET PIPING................................................................................17
2.5.1 WHM Actuator-Controlled Ball Valve Installation..........................................................18
2.6 TEST HOSE BIB CONNECTION........................................................................................19
2.7 SYSTEM RECIRCULATION LOOP ....................................................................................20
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..........................................................................................24
2.10.2 Manual Gas Shutoff Valve..........................................................................................24
2.10.3 External Gas Supply Regulator ..................................................................................25
2.11 AC ELECTRICAL POWER WIRING .................................................................................25
2.11.1 Electrical Power Requirements...................................................................................26
2.12 FIELD CONTROL WIRING...............................................................................................27
2.12.1 OUTDOOR SENSOR IN ............................................................................................28
2.12.2 AIR TEMP SENSOR ..................................................................................................28
2.12.3 O2 Sensor Terminals..................................................................................................28
2.12.4 Flow +/Flow –.............................................................................................................28
2.12.5 ANALOG IN................................................................................................................28
2.12.6 B.M.S. (PWM) IN........................................................................................................29
2.12.7 SHIELD......................................................................................................................29
2.12.8 mA OUT.....................................................................................................................29
2.12.9 RS485 Comm.............................................................................................................29
2.12.10 RS232 Comm (TxD/RxD).........................................................................................29
2.12.11 VFD/Blower..............................................................................................................29
2.12.12 INTERLOCKS ..........................................................................................................29
2.12.13 FAULT RELAY.........................................................................................................30
2.12.14 AUXILIARY (AUX) RELAY CONTACTS...................................................................30
2.13 FLUE GAS VENT INSTALLATION....................................................................................30

Innovation Series Water Heaters GF-128
Table of Contents Installation, Operation & Maintenance Manual OMM-0078_0G
Page 4of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
2.14 COMBUSTION AIR...........................................................................................................31
2.14.1 Combustion From Outside the Building ......................................................................31
2.14.2 Combustion Air from Inside the Building.....................................................................31
2.15 SEALED COMBUSTION...................................................................................................31
CHAPTER 3 OPERATION.............................................................................................33
3.1 INTRODUCTION ................................................................................................................33
3.2 CONTROL PANEL DESCRIPTION.....................................................................................33
3.3 CONTROL PANEL MENUS................................................................................................37
3.3.1 Menu Processing Procedure ........................................................................................37
3.4 OPERATING MENU ...........................................................................................................40
3.5 SETUP MENU ....................................................................................................................40
3.6 CONFIGURATION MENU...................................................................................................41
3.7 WATER HEATER MANAGEMENT (WHM) MENU..............................................................43
3.8 TUNING MENU...................................................................................................................43
3.9 START SEQUENCE...........................................................................................................44
3.10 START/STOP LEVELS.....................................................................................................46
CHAPTER 4 INITIAL START-UP...................................................................................49
4.1 INITIAL START-UP REQUIREMENTS................................................................................49
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ..........................49
4.2.1 Required Tools & Instrumentation................................................................................49
4.2.2 Installing Gas Supply Manometer.................................................................................50
4.2.3 Accessing the Analyzer Probe Port ..............................................................................50
4.2.4 Connecting Multimeter to Flame Detector ....................................................................51
4.3 NATURAL GAS COMBUSTION CALIBRATION.................................................................52
4.4 REASSEMBLY....................................................................................................................55
4.5 TEMPERATURE CONTROL CALIBRATION......................................................................55
4.5.1 Setting the Outlet Water Temperature Setpoint............................................................56
4.5.2 Minimum Load Adjustment...........................................................................................56
4.5.3 Maximum Load Adjustment..........................................................................................57
4.6 OVER-TEMPERATURE LIMIT SWITCHES........................................................................58
CHAPTER 5 SAFETY DEVICE TESTING......................................................................59
5.1 TESTING OF SAFETY DEVICES.......................................................................................59
5.2 LOW GAS PRESSURE FAULT TEST.................................................................................59
5.3 HIGH GAS PRESSURE FAULT TEST................................................................................60
5.4 LOW WATER LEVEL FAULT TEST....................................................................................61
5.5 WATER TEMPERATURE FAULT TEST.............................................................................61
5.6 INTERLOCK TESTS...........................................................................................................62
5.6.1 Remote Interlock..........................................................................................................62
5.6.2 Delayed Interlock..........................................................................................................63

GF-128 Innovation Series Water Heaters
OMM-0078_0GInstallation, Operation & Maintenance Manual Table of Contents
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 5of 190
5.7 FLAME FAULT TESTS.......................................................................................................63
5.8 AIR FLOW FAULT TESTS..................................................................................................64
5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................66
5.10 PURGE SWITCH OPEN DURING PURGE.......................................................................67
5.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................67
5.12 SAFETY PRESSURE RELIEF VALVE TEST....................................................................68
CHAPTER 6 MAINTENANCE........................................................................................69
6.1 MAINTENANCE SCHEDULE..............................................................................................69
6.2 IGNITER-INJECTOR ..........................................................................................................70
6.2.1 Igniter-Injector Part No. 58023......................................................................................70
6.2.2 Igniter Part No. 66023 ..................................................................................................72
6.3 FLAME DETECTOR ...........................................................................................................74
6.4 COMBUSTION CALIBRATION...........................................................................................74
6.5 SAFETY DEVICE TESTING ...............................................................................................74
6.6 FIRESIDE INSPECTION.....................................................................................................74
6.7 WATERSIDE INSPECTION................................................................................................79
6.8 HEAT EXCHANGER CLEANING........................................................................................81
6.8.1 Pumping System Set-Up Instructions...........................................................................81
6.8.2 Cleaning Procedure......................................................................................................82
6.8.3 Testing HydroSkrub Effectiveness................................................................................83
6.9 CONDENSATE DRAIN TRAP.............................................................................................83
6.10 AIR FILTER REPLACEMENT...........................................................................................84
6.11 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME......85
6.12 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN......86
CHAPTER 7 TROUBLESHOOTING GUIDE..................................................................87
7.1 INTRODUCTION ................................................................................................................87
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ....................................99
CHAPTER 8 RS232 COMMUNICATION .....................................................................103
8.1 INTRODUCTION ..............................................................................................................103
8.2 RS232 COMMUNICATION SETUP ..................................................................................103
8.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION.........................................103
8.4 DATA LOGGING...............................................................................................................104
8.4.1 Fault Log....................................................................................................................104
8.4.2 Operation Time Log....................................................................................................105
8.4.3 Sensor Log.................................................................................................................105

Innovation Series Water Heaters GF-128
Table of Contents Installation, Operation & Maintenance Manual OMM-0078_0G
Page 6of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
CHAPTER 9 WATER HEATER MANAGEMENT.........................................................107
9.1 INTRODUCTION ..............................................................................................................107
9.2 GENERAL DESCRIPTION................................................................................................107
9.3 WHM PRINCIPLES OF OPERATION...............................................................................108
9.4 WHM MENU .....................................................................................................................108
9.5 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS ....................................109
9.5.1 Hardware Installation..................................................................................................109
9.5.2 WHM Modbus Network Wiring....................................................................................110
9.5.3 Control and Power Wiring...........................................................................................110
9.6 WHM MENU SETTINGS...................................................................................................112
9.6.1 WHM Mode................................................................................................................112
9.6.2 Comm Address (Located in Setup Menu)...................................................................112
9.6.3 WHM Setpoint............................................................................................................112
9.6.4 WHM Nxt On VP ........................................................................................................112
9.6.5 WHM Nxt Off VP........................................................................................................112
9.6.6 Lead/Lag Hours..........................................................................................................112
9.6.7 Setback Setpoint........................................................................................................112
9.6.8 Setback Start & Setback End.....................................................................................112
9.6.9 WHM Auto Mstr..........................................................................................................113
9.6.10 WHM Auto Timer......................................................................................................113
9.7 WHM PROGRAMMING & START-UP ..............................................................................113
9.8 TROUBLESHOOTING......................................................................................................115
9.9 SEQUENCING VALVE DESCRIPTION & OPERATION ...................................................116
9.9.1 Sequencing Valve Description....................................................................................116
9.9.2 Sequencing Valve Operating Characteristics..............................................................118
APPENDIX A: INNOVATION MENU ITEM DESCRIPTIONS.................................................................119
APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES ............................................................125
APPENDIX C: TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART.....................................129
TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART..............................................................129
APPENDIX D: INNOVATION DEFAULT SETTINGS .............................................................................131
APPENDIX E: PARTS LIST DRAWINGS...............................................................................................133
APPENDIX F: PIPING DRAWINGS........................................................................................................147
APPENDIX G: C-MORE CONTROL PANEL VIEWS .............................................................................169
APPENDIX H: C-MORE WIRING DIAGRAMS.......................................................................................171
APPENDIX I: RECOMMENDED SPARES..............................................................................................179
APPENDIX J: COMBUSTION CALIBRATION (KOREA ONLY) ...........................................................181
APPENDIX K: WARRANTY....................................................................................................................185

GF-128 Innovation Series Water Heaters
OMM-0078_0GInstallation, Operation & Maintenance Manual Foreword
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 7of 190
FOREWORD
The AERCO Innovation Series Potable Water Heaters are modulating units which represent a
true industry advance that meets the needs of today's energy efficiency and environmental
concerns. Designed for use in any domestic water heating system, each Innovation model
provides precisely-controlled potable water within ±2°F of setpoint, regardless of flow rate.
Innovation’s compact size and varied venting capabilities allow maximum installation flexibility.
The Innovation Series Heaters, with their load tracking controls modulate over a 20:1 turn down
ratio to match the system demand and yield high thermal efficiencies.
Innovation Water Heaters are available in four (4) different sizes ranging from 600,000 BTU/Hr.
Input to 1,350,000 BTU/Hr. Input. In addition, all Innovation Heater sizes now include Water
Heater Management (WHM) software which is built in to the C-More Controllers furnished with
each unit. When the heater is ordered with a Sequencing Valve (SV), up to eight (8) Innovation
Water Heaters can be controlled by the WHM system utilizing RS485 Modbus protocol. All
available Innovation Water Heater models are listed in the table on the following page. As this
table shows, units can be ordered with Factory Mutual (FM) or Double Block and Bleed
(formerly IRI) Gas Trains with or without Sequencing Valves.
When installed and operated on natural gas in accordance with this Instruction Manual, the
Innovation Series Models covered herein comply with the NOx emission standards outlined in:
•South Coast Air Quality Management District (SCAQMD), Rule 1146.2
•Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117,
Rule 117.465
Whether used in singular or modular arrangements, the Innovation Heaters offer the maximum
flexibility in venting with minimum installation space requirements. Innovation’s advanced
electronic controls offer simplified integration with today’s Energy Management Systems.
For service or parts, contact your local sales representative or AERCO International, Inc.
IMPORTANT
Unless otherwise specified, the descriptions and procedures provided in
this Installation, Operation & Maintenance Manual apply to all Innovation
Series Water Heaters.

Innovation Series Water Heaters GF-128
Foreword Installation, Operation & Maintenance Manual OMM-0078_0G
Page 8of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
INNOVATION POTABLE WATER HEATER MODELS
Part Number
Description
Shipping
Weight
INN600
Innovation Potable Water Heater, 600,000 BTU/HR Input,
Natural Gas, FM Gas Train
1,060 lbs.
INN600SV
Innovation Potable Water Heater, 600,000 BTU/HR Input,
Natural Gas, FM Gas Train with WHM Sequencing Valve
1,080 lbs.
INN600DBB
Innovation Potable Water Heater, 600,000 BTU/HR Input,
Natural Gas, Double Block & Bleed (Formerly IRI) Gas
Train
1,085 lbs.
INN600SVDBB
Innovation Potable Water Heater, 600,000 BTU/HR Input,
Natural Gas, Double Block & Bleed (Formerly IRI) Gas
Train with WHM Sequencing Valve
1,105 lbs.
INN800
Innovation Potable Water Heater, 800,000 BTU/HR Input,
Natural Gas, FM Gas Train
1,080 lbs.
INN800SV
Innovation Potable Water Heater, 800,000 BTU/HR Input,
Natural Gas, FM Gas Train with WHM Sequencing Valve
1,100 lbs.
INN800DBB
Innovation Potable Water Heater, 800,000 BTU/HR Input,
Natural Gas, Double Block & Bleed (Formerly IRI) Gas
Train
1,095 lbs.
INN800SVDBB
Innovation Potable Water Heater, 800,000 BTU/HR Input,
Natural Gas, Double Block & Bleed (Formerly IRI) Gas
Train with WHM Sequencing Valve
1,115 lbs.
INN1060
Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas, FM Gas Train
1,100 lbs.
INN1060SV
Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas, FM Gas Train with WHM Sequencing
Valve
1,120 lbs.
INN1060DBB
Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas, Double Block & Bleed (Formerly IRI)
Gas Train
1,115 lbs.
INN1060SVDBB
Innovation Potable Water Heater, 1,060,000 BTU/HR
Input, Natural Gas, Double Block & Bleed (Formerly IRI)
Gas Train with WHM Sequencing Valve
1,135 lbs.
INN1350
Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas, FM Gas Train
1,150 lbs.
INN1350SV
Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas, FM Gas Train with WHM Sequencing
Valve
1,170 lbs.
INN1350DBB
Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas, Double Block & Bleed (Formerly IRI)
Gas Train
1,165 lbs.
INN1350SVDBB
Innovation Potable Water Heater, 1,350,000 BTU/HR
Input, Natural Gas, Double Block & Bleed (Formerly IRI)
Gas Train with WHM Sequencing Valve
1,205 lbs.

GF-128 Innovation Series Water Heaters
OMM-0078_0GInstallation, Operation & Maintenance Manual Foreword
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 9of 190
Phrases, abbreviations and acronyms used in this manual are listed in the following Table:
PHRASES, ABBREVIATIONS AND ACRONYMS
Phrase, Abbreviation or
Acronym
Meaning
A (Amp)
Ampere
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
BAS
Building Automation System, often used interchangeably with EMS (see
below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes (signaling
events) transmitted per second. It is not equal to bits per second, unless
each symbol is 1 bit long.
BLDG (Bldg)
Building
CCP
Combustion Control Panel
C-More Controller
(or Control Box)
A control system developed by AERCO and currently used in all Benchmark,
Innovation and KC1000 Series product lines.
CO
Carbon Monoxide
COMM (Comm)
Communication
DBB
Double Block & Bleed. Used to define gas trains containing two SSOVs and
a solenoid operated vent valve. Used interchangeably with IRI.
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pounfd of water 1°F.
Cal.
Calibration
CNTL
Control
DBB
Double block and Bleed (formerly IRI)
DIP
Dual In-Line Package
EMS
Energy Management System; often used interchangeably with BAS
FM
Factory Mutual. Used to define boiler gas trains.
GND
Ground
HDR
Header
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN
Ignition
IGST Board
Ignition/Stepper Board contained in C-More Contro Box
INN
Innovation Water Heater
INTLK (INTL’K)
Interlock
I/O
Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and KC1000
Series products
IP
Internet Protocol
IRI
Industrial Risk Insurers. Used to define gas trains containing two SSOVs and
a solenoid operated vent valve.
ISO
Isolated
LED
Light Emitting Diode
LN
Low NOx
MA (mA)
Milliampere
MAX (Max)
Maximum

Innovation Series Water Heaters GF-128
Foreword Installation, Operation & Maintenance Manual OMM-0078_0G
Page 10 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
PHRASES, ABBREVIATIONS AND ACRONYMS - Continued
Phrase, Abbreviation or
Acronym
Meaning
MIN (Min)
Modbus®
A serial, half-duplex data transmission protocol developed by AEG Modicon
NC (N.C.)
Normally Closed
NO (N.O.)
Normally Open
NOx
Nitrogen Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
PMC Board
A Primary Micro-Controller (PMC) board is contained in the C-More Control
Box used on all Benchmark units.
PPM
Parts Per Million
PTP
Point-to-Point (usually over RS232 networks)
REF (Ref)
Reference
RES.
Resistive
RS232
(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
RTN (Rtn)
Return
SETPT (Setpt)
Setpoint Temperature
SHLD (Shld)
Shield
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
VAC
Volts, Alternating Current
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, or Variable Frequency Drive
W
Watt
W.C.
Water Column
WHM
Water Heater Management

GF-128 Innovation Series Water Heaters Chapter 1
OMM-0078_0GInstallation, Operation & Maintenance Manual Safety Precautions
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 11 of 190
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 11 and 12 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.
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
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.
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.
WARNING
WARNING
WARNING
WARNING

Chapter 1 Innovation Series Water Heaters GF-128
Safety Precautions Installation, Operation & Maintenance Manual OMM-0078_0G
Page 12 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
CAUTION
Must be observed to prevent equipment damage or loss of operating
effectiveness.
CAUTION
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
CAUTION
DO NOT use this heater if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1)
located external to the unit.
IMPORTANT
The Installer must identify and indicate the location of the emergency shutdown
manual gas valve to operating personnel.
MANUAL GAS SHUTOFF VALVE
VALVE OPEN VALVE CLOSED
Figure 1-1. Manual Gas Shutoff Valve
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 the unit. The installer must identify the emergency shut-
off device.

GF-128 Innovation Series Water Heaters Chapter 1
OMM-0078_0GInstallation, Operation & Maintenance Manual Safety Precautions
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 13 of 190
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Water heater Installations within the Commonwealth of Massachusetts
must conform to the following requirements:
•Heater must be installed by a plumber or a gas fitter who is licensed within
the Commonwealth of Massachusetts.
•Prior to unit operation, the complete gas train and all connections must be
leak tested using a non-corrosive soap.
•The vent termination must be located a minimum of 4 feet above grade
level. If side-wall venting is used, the installation must conform to the
following requirements extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or
structure used in whole or in part for residential purposes, including those owned or operated by the
Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above
finished grade in the area of the venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall
horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the
dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be
the responsibility of the property owner to secure the services of qualified licensed professionals for the
installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in 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 can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector
with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in
accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade directly in line with 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.

Chapter 1 Innovation Series Water Heaters GF-128
Safety Precautions Installation, Operation & Maintenance Manual OMM-0078_0G
Page 14 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
(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)]

GF-128 Innovation Series Water Heaters Chapter 2
OMM-0078_0GInstallation, Operation & Maintenance Manual Installation
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 15 of 190
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 and INN1060 and INN1350.
2.2 RECEIVING THE UNIT
Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight is
approximately 1200 pounds. The unit must be moved with the proper rigging equipment for safety and
to avoid equipment damage. The unit should be completely inspected for evidence of shipping damage
and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed.
NOTE:
AERCO is not responsible for lost or damaged freight. Each unit has a Tip-
N-Tell indicator on the outside of the crate. This indicates if the unit has
been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging
materials
After unpacking, a close inspection of the unit should be made to ensure that there is no evidence of
damage not indicated by the Tip-N-Tell indicator. The freight carrier should be notified 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
•Spare Spark Igniter-Injector
•Spare Flame Detector
•ASME Pressure Relief Valve
•Condensate Drain Trap
•1” Gas Supply Shutoff Valve
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.
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.

Chapter 2 Innovation Series Water Heaters GF-128
Installation Installation, Operation & Maintenance Manual OMM-0078_0G
Page 16 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
2.4.1 Installation Clearances
All Innovation Models are packaged in enclosures having identical exterior dimensions. The unit must
be installed with the prescribed clearances for service as shown in Figure 2-1 (shown with optional
Sequencing Valve). The minimum clearance dimensions, required by AERCO, are listed below.
However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s
requirements. Minimum acceptable clearances required are as follows:
•Sides: 24 inches
•Front : 24 inches
•Rear:30 inches
•Top: 18 inches
All gas piping, water piping and electrical conduit or cable must be arranged so that they do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
50.9" 18"
97.25"
75.25"
18.6"
SEQUENCING
VALVE 30"
24"
24"
24"
4" HIGH PAD
Figure 2-1 Innovation Water Heater Clearances
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
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 11 and 12.
WARNING
CAUTION

GF-128 Innovation Series Water Heaters Chapter 2
OMM-0078_0GInstallation, Operation & Maintenance Manual Installation
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 17 of 190
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate
drainage. If anchoring the unit, refer to the dimensional drawings in Appendix F for anchor locations.
Two lifting lugs are provided with the unit and are wire-tied to the top of the heat exchanger. The top
sheet metal cover of the unit must first be removed and the lifting lugs must be installed as shown in
Figure 2-2. USE THESE TWO LUGS TO LIFT AND MOVE THE UNIT. Remove the top panel from the
unit to provide access to the lifting lugs. Remove the four (4) lag screws securing the unit to the
shipping skid. Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping
concrete pad (required) in the desired location.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space
for piping connections and future service/maintenance requirements must also be taken into
consideration. All piping must include ample provisions for expansion.
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 an actuator-controlled ball valve will
be included with the shipment. If the valve is not already installed on the
water inlet of the unit, refer to paragraph 2.5.1 for installation instructions
prior to connecting inlet piping.
2.5 WATER INLET AND OUTLET PIPING
The locations of the 2" NPT cold water inlet and hot water outlet piping connections are shown in
Figure 2-3. Flow rates through the unit are limited to 30 gpm continuous and 40 gpm intermittent.
Shut-off valves and union connections must be installed in the inlet and outlet lines for maintenance.
The use of dielectric unions is recommended.

Chapter 2 Innovation Series Water Heaters GF-128
Installation Installation, Operation & Maintenance Manual OMM-0078_0G
Page 18 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
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 2-3. 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 2-3A), 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 2-3A.
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 3-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.

GF-128 Innovation Series Water Heaters Chapter 2
OMM-0078_0GInstallation, Operation & Maintenance Manual Installation
PR1 7/16/12 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526-0288 Page 19 of 190
Figure 2-3A. Innovation Water Heater Equipped With Sequencing Valve
2.6 TEST HOSE BIB CONNECTION
A Test Hose Bib connection, upstream of the shut off valve on the hot water outlet, is required for
startup and testing (Figure 2-4). The pipe diameter should be a minimum of 3/4". The Test Hose Bib
cannot be omitted.

Chapter 2 Innovation Series Water Heaters GF-128
Installation Installation, Operation & Maintenance Manual OMM-0078_0G
Page 20 of 190 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph.: 800-526-0288 PR1 7/16/12
Figure 2-4. Test Hose Bib Location
2.7 SYSTEM RECIRCULATION LOOP
The System Recirculation Loop Assembly is located inside the unit enclosure at the rear of the unit. In
order to access this assembly, the right rear middle panel must be removed. Refer to Figure 2-5. This
assembly contains a recirculator pump which connects between the upper hot water outlet and lower
cold water inlet of the unit’s heat exchanger. The purpose of this loop is to provide feed-forward
(FFWD) temperature control by mixing a portion of the hot water outlet with the cold water inlet of the
unit. Temperature sensors located in the hot water outlet and cold water inlet provide temperature data
to the C-More Control System. The Control System utilizes this data to modulate the fire rate (Air/Fuel
Valve position) to precisely maintain the hot water outlet temperature at the selected setpoint
temperature.