Watts Aerco Innovation 800 User manual

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
Installation, Operation & Maintenance
OMM-0120_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 174
GF-128-I Phone: [phone]/2016
USER MANUAL
Installation, Operation and Maintenance
INNOVATION Series
Gas-Fired Hot Water Boilers
Natural Gas
Modulating, Condensing
Hot Water Boiler Models
Applicable to Serial Number
G-16-2000and above
This guide applies to the
following Innovation models
•Innovation 800
•Innovation 1060
•Innovation 1350
Other documents for this
product include:
•GF-5035 INN Gas Supply Guide
•GF-5055 INN Venting Guide
•GF-5065 INN Electrical Power Guide
Latest Update: 11/15/2016
U.S. Patent No. 9,243,848
SELO

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
Installation, Operation & Maintenance
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11/15/2016 Phone: [phone] GF-128-I
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
DISCLAIMER
The information contained in this manual is subject to change without notice from AERCO
International, Inc. AERCO makes no warranty of any kind with respect to this material, including,
but not limited to, implied warranties of merchantability and fitness for a particular application.
AERCO International is not liable for errors appearing in this manual, nor for incidental or
consequential damages occurring in connection with the furnishing, performance, or use of
these materials.

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
Installation, Operation & Maintenance
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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...............................................................................................13
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 ......................................................................... 18
2.6 TEST HOSE BIB CONNECTION........................................................................................20
2.7 SYSTEM RECIRCULATION LOOP.....................................................................................20
2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION .....................................21
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..................................................................................26
2.11.1 Electrical Power Requirements ....................................................................................................26
2.12 FIELD CONTROL WIRING ...............................................................................................27
2.12.1 OUTDOOR AIR IN Terminal........................................................................................................... 28
2.12.2 COMBUSTION AIR Terminals........................................................................................................ 28
2.12.3 O2 SENSOR Terminals ..................................................................................................................28
2.12.4 SPARK SIGNAL Terminals.............................................................................................................. 28
2.12.5 ANALOG IN Terminals .................................................................................................................. 29
2.12.6 VALVE FEEDBACK Terminals.........................................................................................................29
2.12.7 SHIELD Terminals.......................................................................................................................... 29
2.12.8 ANALOG OUT Terminals............................................................................................................... 29
2.12.9 RS485 Comm Terminals ...............................................................................................................30
2.12.10 RS232 Comm Terminals ............................................................................................................. 30
2.12.11 VFD/BLOWER Terminals............................................................................................................. 30
2.12.12 Interlock Terminals.....................................................................................................................30
2.12.13 FAULT RELAY Terminals.............................................................................................................. 31
2.12.14 AUX RELAY Terminals .................................................................................................................31
2.13 FLUE GAS VENT INSTALLATION....................................................................................31
2.14 COMBUSTION AIR...........................................................................................................32
2.14.1 Combustion From Outside the Building .......................................................................................32
2.14.2 Combustion Air from Inside the Building ..................................................................................... 32

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2.15 DUCTED COMBUSTION..................................................................................................32
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 ...........................................................................................................39
3.5 SETUP MENU ....................................................................................................................40
3.6 CONFIGURATION MENU...................................................................................................40
3.7 TUNING MENU...................................................................................................................42
3.8 CALIBRATION MENU.........................................................................................................43
3.9 START SEQUENCE ...........................................................................................................45
3.10 START/STOP LEVELS.....................................................................................................48
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.................................................................................................50
4.2.2 Installing Gas Supply Manometer .................................................................................................. 50
4.2.3 Accessing the Analyzer Probe Port................................................................................................. 51
4.2.4 Connecting Multimeter to Flame Detector....................................................................................51
4.2.5 Recommendations for Temperature Calibration ...........................................................................52
4.2.6 Recommendations for WHM (Water Heater Management) Operation........................................ 52
4.3 NATURAL GAS COMBUSTION CALIBRATION .................................................................53
4.4 REASSEMBLY....................................................................................................................56
4.5 TEMPERATURE CONTROL CALIBRATION......................................................................56
4.5.1 Setting the Outlet Water Temperature Setpoint ...........................................................................57
4.5.2 Minimum Load Adjustment............................................................................................................57
4.5.3 Maximum Load Adjustment...........................................................................................................58
4.6 OVER-TEMPERATURE LIMIT SWITCHes.........................................................................59
CHAPTER 5. SAFETY DEVICE TESTING .....................................................................................61
5.1 INTRODUCTION.................................................................................................................61
5.2 LOW GAS PRESSURE FAULT TEST.................................................................................61
5.3 HIGH GAS PRESSURE FAULT TEST................................................................................62
5.4 LOW WATER LEVEL FAULT TEST....................................................................................63
5.5 WATER TEMPERATURE FAULT TEST.............................................................................63
5.6 INTERLOCK TESTS...........................................................................................................64
5.6.1 Remote Interlock............................................................................................................................64
5.6.2 Delayed Interlock ...........................................................................................................................65
5.7 FLAME FAULT TESTs........................................................................................................65
5.8 AIR FLOW FAULT TESTS..................................................................................................66
5.9 SSOV PROOF OF CLOSURE SWITCH .............................................................................68
5.10 PURGE SWITCH OPEN DURING PURGE.......................................................................69
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................69

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5.12 SAFETY PRESSURE RELIEF VALVE TEST....................................................................70
CHAPTER 6. MAINTENANCE......................................................................................................... 71
6.1 MAINTENANCE SCHEDULE..............................................................................................71
6.2 IGNITER-INJECTOR ..........................................................................................................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........................................................................................80
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.............................................................................................84
6.10 AIR FILTER REPLACEMENT...........................................................................................85
6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ...................................86
6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................ 86
6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test ..................................................................... 88
6.12 SHUTTING THE HOT WATER BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
88
6.13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN......89
6.14 SPARK MONITOR (AC CURRENT TRANSDUCER)........................................................89
CHAPTER 7. TROUBLESHOOTING GUIDE ................................................................................91
7.1 INTRODUCTION.................................................................................................................91
7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ..................................103
CHAPTER 8. WATER HEATER MANAGEMENT .................................................................... 107
8.1 GENERAL DESCRIPTION................................................................................................107
8.2 WHM PRINCIPLES OF OPERATION...............................................................................108
8.3 NEW AERCO WHM FEATURES ......................................................................................108
8.3.1 Valve Feedback............................................................................................................................. 108
8.3.2 Valve Supervisor...........................................................................................................................108
8.3.3 Valve Control................................................................................................................................108
8.3.4 Modbus Header Sensor................................................................................................................ 109
8.3.5 Automatic Temperature Sensor Calibration ................................................................................ 109
8.3.6 Manual Mode Password Required............................................................................................... 109
8.3.7 Quick Re-Flash Feature.................................................................................................................109
8.3.8 WHM Auto Mstr ........................................................................................................................... 110
8.3.9 Run Hours and Run Cycles............................................................................................................110
8.3.10 High Temperature Governor...................................................................................................... 110
8.4 WHM STATUS DISPLAYS................................................................................................110
8.5 WATER HEATER MANAGEMENT ALTERNATING STATUS DISPLAYS.........................111
8.6 WHM MENU .....................................................................................................................111
8.7 WHM MENU ITEM DESCRIPTIONS.................................................................................113

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8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS ....................................117
8.8.1 Installation Notes .........................................................................................................................117
8.8.2 Hardware Installation...................................................................................................................118
8.8.3 WHM Modbus Network Wiring....................................................................................................119
8.8.4 Control and Power Wiring............................................................................................................120
8.9 WHM PROGRAMMING & START-UP ..............................................................................121
8.10 TROUBLESHOOTING....................................................................................................123
8.11 SEQUENCING VALVE DESCRIPTION & OPERATION .................................................123
8.11.1 Sequencing Valve Description.................................................................................................... 123
8.11.2 Sequencing Valve Operating Characteristics.............................................................................. 126
APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS................................................127
Table A-1: Operating Menu Item Descriptions.........................................................................127
Table A-2: Setup Menu Item Descriptions...............................................................................128
Table A-3: Configuration Menu Item Descriptions...................................................................129
Table A-4: Tuning Menu Item Descriptions .............................................................................131
Table A-5: Calibration Menu Item Descriptions .......................................................................133
APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES.............................................137
APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART .....................141
APPENDIX D – DIMENSIONAL DRAWINGS .........................................................................143
APPENDIX E – PARTS LIST DRAWINGS..............................................................................145
APPENDIX F – PIPING DRAWINGS......................................................................................155
APPENDIX G – C-MORE CONTROL PANEL VIEWS.............................................................165
APPENDIX H –C-MORE WIRING DIAGRAMS.....................................................................167
APPENDIX I – RECOMMENDED SPARES............................................................................171
APPENDIX K – WARRANTY..................................................................................................173

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FOREWORD
The AERCO Innovation Series Potable Hot Water Boilers are modulating units which represent
a true industry advance that meets the needs of today's energy efficiency and environmental
concerns. Designed for use in any domestic water heating system, each Innovation model
provides precisely-controlled potable water within ± 2°F (1.1°C) of setpoint, regardless of flow
rate. Innovation’s compact size and varied venting capabilities allow maximum installation
flexibility. The Innovation Series Heaters, with their load tracking controls modulate over a 20:1
turn down ratio to match the system demand and yield high thermal efficiencies.
Innovation Hot Water Boilers are available in three 3) different sizes ranging from 1,060,000
BTU/Hr. (311 kW) input to 1,350,000 BTU/Hr. (396 kW) input. In addition, all Innovation Heater
sizes now include Water Heater Management (WHM) software which is built in to the C-More
Controllers furnished with each unit. When the heater is ordered with a Sequencing Valve (SV),
up to eight (8) Innovation Hot Water Boilers can be controlled by the WHM system utilizing
RS485 Modbus protocol. All available Innovation Hot Water Boiler 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 Gas Trains with or without Sequencing Valves.
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 Hot Water Boilers.
INNOVATION POTABLE HOT WATER BOILER MODELS
Part Number Description
Shipping
Weight
INN800
Innovation Potable Hot Water Boiler, 800,000 BTU/Hr. (234.5
kW) Input
1,080 lbs.
(489.9 kg.)
INN1060
Innovation Potable Hot Water Boiler, 1,060,000 BTU/HR
(310.7 kW) Input
1,100 lbs.
(499.0 kg.)
INN1350
Innovation Potable Hot Water Boiler, 1,350,000 BTU/HR
(395.6 kW) Input
1,150 lbs.
(521.6 kg.)

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Phrases, abbreviations and acronyms used in this manual are listed in the following table:
PHRASES, ABBREVIATIONS AND ACRONYMS
Phrase, Abbreviation
& Acronym
Meaning
A (Amp) Ampere
ADDR Address
AGND Analog Ground
ALRM Alarm
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
AUX
Auxiliary
BAS
Building Automation System, often used interchangeably with EMS
(see below)
Baud Rate
Symbol rate, or simply the number of distinct symbol changes
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BLDG (Bldg) Building
BTU British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound (0.45 kg) of water 1° F (0.55 ° C).
BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)
C-More Controller
(or Control Box)
A control system developed by AERCO and currently used in all
Benchmark, Innovation and KC1000 Series product lines.
CO Carbon Monoxide
COMM (Comm) Communication
Cal. Calibration
CNTL Control
CPU Central Processing Unit
DIP
Dual In-Line Package, a type of switch
EMS Energy Management System; often used interchangeably with BAS
FM Factory Mutual. Used to define gas trains.
FRU Field Replacement Unit
GF-xxxx Gas Fired (an AERCO document numbering system)
GND Ground
GPH Gallons per Hour
HX Heat Exchanger
Hz Hertz (Cycles Per Second)
I.D. Inside Diameter
IGN Ignition

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Phrase, Abbreviation
& Acronym
Meaning
IGST Board Ignition/Stepper Board, contained in C-More Control Box
INN Innovation Hot Water Boiler
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 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
O2
Oxygen
O.D. Outside Diameter
OMM Operation and Maintenance Manual
OnAER AERCO’s on-line remote system monitoring system
PCB Printed Circuit Board
PMC Board Primary Micro-Controller (PMC) board, contained in the C-More
P/N Part Number
PPM Parts per Million
PSI Pounds per Square Inch (1 PSI = 6.89 kPa)
PTP Point-to-Point (usually over RS232 networks)
P&T Pressure and Temperature
ProtoNode Hardware interface between BAS and a boiler or hot water boiler
PVC Poly Vinyl Chloride, a common synthetic plastic
PWM Pulse Width Modulation
RES. Resistive

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Phrase, Abbreviation
& Acronym Meaning
RS232
(or EIA-232) A standard for serial, full-duplex (FDX) transmission of data based on the RS232 Standard
RS422
(or EIA-422) A standard for serial, full-duplex (FDX) transmission of data based on the RS422 Standard
RS485
(or EIA-485) A standard for serial, half-duplex (HDX) transmission of data based on the RS485 Standard
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
SPDT Single Pole Double Throw, a type of switch
SSD Slave to Slave programming
SSOV Safety Shut Off Valve
SV Sequencing Valve
(Used with Water Heater Management (WHM)
system)
TEMP (Temp) Temperature
Terminating Resistor A resistor placed at each end of a daisy-chain or multi-drop network in
order to prevent reflections that may cause invalid data in the
communication
Tip-N-Tell A device that indicates if a package was tipped during shipping
UL A business that tests and validates products
VAC
Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluorescent Display, also Variable Frequency Drive
W Watt
WHM Water Heater Management
W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa)
µA Micro amp (1 million
th
of an ampere)

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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.
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.
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 hot water boiler:
1. The hot water boiler can only be used for applications where the chlorine
concentrations Do Not Exceed 4 mg/L which is the Environmental
Protection Agency limit for chlorine concentrations in drinking water.
2. Do Not use this heater for a pool heating application.
--WARNING! -
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
--WARNING! -
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
--WARNING! -
ELECTRICAL VOLTAGES UP TO 220 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE COVER ON THE UNIT’S POWER BOX
(LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.

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

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1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed to verify all system-
operating parameters. If there is an emergency, turn off the electrical power supply to the
AERCO heater and close the manual gas valve located upstream of the unit. The installer must
identify the emergency shut-off device.

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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 Hot Water Boiler models INN800, INN1060 and INN1350.
2.2 RECEIVING THE UNIT
Each Innovation Water Heating System is shipped as a single crated unit. The shipping weight
is approximately 1200 pounds (544 kg). The unit must be moved with the proper rigging
equipment for safety and to avoid equipment damage. The unit should be completely inspected
for evidence of shipping damage and shipment completeness at the time of receipt from the
carrier and before the bill of lading is signed.
NOTE
AERCO is not responsible for lost or damaged freight. Each unit has a Tip-
N-Tell indicator on the outside of the crate. This indicates if the unit has
been turned on its side during shipment. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either packed separately within
the unit’s shipping container or are factory installed on the unit:
•ASME Pressure and Temperature Relief Valve
•Condensate Drain Trap
If the Innovation Hot Water Boiler 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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CHAPTER 2 – INSTALLATION
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2.4 SITE PREPARATION
Ensure that the site selected for installation of the Innovation Hot Water Boiler includes:
•Access to AC Input Power at 220 VAC, Single-Phase, 50 Hz @ 15 Amps.
•Access to Natural Gas line at a minimum pressure of 4 inches W.C. (1.0 kPa) with the
unit operating at maximum capacity.
2.4.1 Installation Clearances
All Innovation models are packaged in enclosures having identical exterior dimensions. The unit
must be installed with the prescribed clearances for service as shown in Figure 2-1 (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.
Figure 2-1. Innovation Hot Water Boiler Clearances
--WARNING! -
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS.
--CAUTION -
While packaged in the shipping container, the unit must be moved by pallet
jack or forklift from the FRONT ONLY.
30”
(76cm)
24” (61cm)
24” (61cm)
24”
(61cm)
50.9” (1.29 m)
18” (46 cm)
97.25”
(2.47 m)
75.25”
(1.91 m)
4” to 6” (10.2 to 15.2 cm) high housekeeping concrete pad.
Ensure that the housekeeping pad does NOT extend under the condensate assembly.
18.6”
(46 cm)

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
CHAPTER 2 – INSTALLATION
OMM-0120_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 17 of174
GF-128-I Phone: [phone]/2016
2.4.2 Setting the Unit
The unit must be installed on a 4 to 6 inch (10.2 to 15.2 cm) housekeeping pad to ensure
proper condensate drainage. Two lifting lugs are provided with the unit and are wire-tied to the
top of the heat exchanger. The top sheet metal cover of the unit must first be removed and the
lifting lugs must be installed as shown in Figure 2-2. USE THESE TWO LUGS TO LIFT AND
MOVE THE UNIT. Remove the top panel from the unit to provide access to the lifting lugs.
Remove the four (4) lag screws securing the unit to the shipping skid. Lift the unit off the
shipping skid and position it on the 4 to 6 inch (10.2 to 15.2 cm) housekeeping concrete pad
(required) in the desired location.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
Figure 2-2. Partial Top View Showing Installed Lifting Lugs
IMPORTANT
If the Innovation Hot Water Boiler is equipped for use with the C-More
Water Heater Management (WHM) system, then an actuator-controlled ball
valve will be included with the shipment. Refer to section 2.5.1 for
installation instructions prior to connecting inlet piping.
LIFTING LUGS

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
CHAPTER 2 – INSTALLATION
Page 18 of 174 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0120_0A
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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 Loctite ® 7649 to prime the threads
and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
IMPORTANT
If the Innovation Hot Water Boiler is equipped for use with the C-More
Water Heater Management (WHM) system, then an actuator-controlled ball
valve will be included with the shipment. Refer to section 2.5.1 for
installation instructions prior to connecting inlet piping.
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
2.5.1 WHM Actuator-Controlled Ball Valve Installation
If the Innovation Hot Water Boiler was ordered for use with the C-More Water Heater
Management (WHM) system and the actuator-controlled ball valve is not already installed on
the unit (Figure 2-3b), it will be packed separately within the shipping container.
P&T RELIEF
VALVE
COLD WATER INLET
2” (5.08 cm) NPT
DRAIN VALVE
EXHAUST MANIFOLD
AIR INLET
NATURAL GAS INLET
1” (2.54 cm) NPT
HOT WATER OUTLET
2” (5.08 cm) NPT

Innovation Hot Water Hot Water Boiler User Manual - INTERNATIONAL
CHAPTER 2 – INSTALLATION
OMM-0120_0A AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 19 of174
GF-128-I Phone: [phone]/2016
NOTE
AERCO requires use of WHM sequencing valves in a multi-unit tankless
configuration.
If installation is required, proceed as follows:
WHM Ball Valve Installation
1. Remove the ball valve from its stowed location within the shipping container.
2. Attached the valve to the cold water inlet of the unit using the pipe union and nipple
provided.
3. Ensure that the valve is positioned with the actuator enclosure position as shown in Figure
2-3b.
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 Hot Water Boiler 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 pipe 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
2.7 SYSTEM RECIRCULATION LOOP
The System Recirculation Loop Assembly is located inside the unit enclosure at the rear of the
unit. In order to access this assembly, the right rear middle panel must be removed. Refer to
Figure 2-5. This assembly contains a recirculation pump that connects the upper hot water
outlet to the lower cold water inlet of the unit’s heat exchanger. The purpose of this loop is to
provide feed-forward (FFWD) temperature control by mixing a portion of the hot water outlet
with the cold water inlet of the unit. Temperature sensors located in the hot water outlet and cold
water inlet provide temperature data to the C-More Control System. The Control System utilizes
this data to modulate the fire rate (Air/Fuel Valve position) to precisely maintain the hot water
outlet temperature at the selected setpoint temperature.
TO DRAIN
TEST
HOSE BIB
HOT
WATER
OUT
TEST HOSE