Document Outline

• FOREWORD
• CHAPTER 1. SAFETY PRECAUTIONS
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2. INSTALLATION
  • 2.1 INTRODUCTION
  • 2.2 RECEIVING THE UNIT
  • 2.3 UNPACKING
  • 2.4 SITE PREPARATION
    • 2.4.1 Installation Clearances
    • 2.4.2 Setting the Unit
  • 2.5 WATER INLET AND OUTLET PIPING
    • 2.5.1 WHM Actuator-Controlled Ball Valve Installation
  • 2.6 TEST HOSE BIB CONNECTION
  • 2.7 SYSTEM RECIRCULATION LOOP
  • 2.8 PRESSURE & TEMPERATURE RELIEF VALVE INSTALLATION
  • 2.9 CONDENSATE DRAIN & PIPING
  • 2.10 GAS SUPPLY PIPING
    • 2.10.1 Gas Supply Specifications.
    • 2.10.2 Manual Gas Shutoff Valve
    • 2.10.3 External Gas Supply Regulator
      • 2.10.3.1 Massachusetts Installations Only
      • 2.10.3.2 All Installations (Except Massachusetts)
  • 2.11 AC ELECTRICAL POWER WIRING
    • 2.11.1 Electrical Power Requirements
  • 2.12 FIELD CONTROL WIRING
    • 2.12.1 OUTDOOR AIR IN Terminal
    • 2.12.2 COMBUSTION AIR Terminals
    • 2.12.3 O2 SENSOR Terminals
    • 2.12.4 SPARK SIGNAL Terminals
    • 2.12.5 ANALOG IN Terminals
    • 2.12.6 VALVE FEEDBACK Terminals
    • 2.12.7 SHIELD Terminals
    • 2.12.8 ANALOG OUT Terminals
    • 2.12.9 RS485 Comm Terminals
    • 2.12.10 RS232 Comm Terminals
    • 2.12.11 VFD/BLOWER Terminals
    • 2.12.12 Interlock Terminals
      • 2.12.12.1 REMOTE INTL’K Terminals
      • 2.12.12.2 DELAYED INTL’K Terminals
    • 2.12.13 FAULT RELAY Terminals
    • 2.12.14 AUX RELAY Terminals
  • 2.13 FLUE GAS VENT INSTALLATION
  • 2.14 COMBUSTION AIR
    • 2.14.1 Combustion From Outside the Building
    • 2.14.2 Combustion Air from Inside the Building
  • 2.15 DUCTED COMBUSTION
• CHAPTER 3. OPERATION
  • 3.1 INTRODUCTION
  • 3.2 CONTROL PANEL DESCRIPTION
  • 3.3 CONTROL PANEL MENUS
    • 3.3.1 Menu Processing Procedure
  • 3.4 OPERATING MENU
  • 3.5 SETUP MENU
  • 3.6 CONFIGURATION MENU
  • 3.7 TUNING MENU
  • 3.8 CALIBRATION MENU
  • 3.9 START SEQUENCE
  • 3.10 START/STOP LEVELS
• CHAPTER 4. INITIAL START-UP
  • 4.1 INITIAL START-UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
    • 4.2.1 Required Tools & Instrumentation
    • 4.2.2 Installing Gas Supply Manometer
    • 4.2.3 Accessing the Analyzer Probe Port
    • 4.2.4 Connecting Multimeter to Flame Detector
    • 4.2.5 Recommendations for Temperature Calibration
    • 4.2.6 Recommendations for WHM (Water Heater Management) Operation
  • 4.3 NATURAL GAS COMBUSTION CALIBRATION
  • 4.4 PROPANE COMBUSTION CALIBRATION
  • 4.5 REASSEMBLY
  • 4.6 TEMPERATURE CONTROL CALIBRATION
    • 4.6.1 Setting the Outlet Water Temperature Setpoint
    • 4.6.2 Minimum Load Adjustment
    • 4.6.3 Maximum Load Adjustment
  • 4.7 OVER-TEMPERATURE LIMIT SWITCHes
• CHAPTER 5. SAFETY DEVICE TESTING
  • 5.1 INTRODUCTION
  • 5.2 LOW GAS PRESSURE FAULT TEST
  • 5.3 HIGH GAS PRESSURE FAULT TEST
  • 5.4 LOW WATER LEVEL FAULT TEST
  • 5.5 WATER TEMPERATURE FAULT TEST
  • 5.6 INTERLOCK TESTS
    • 5.6.1 Remote Interlock
    • 5.6.2 Delayed Interlock
  • 5.7 FLAME FAULT TESTs
  • 5.8 AIR FLOW FAULT TESTS
  • 5.9 SSOV PROOF OF CLOSURE SWITCH
  • 5.10 PURGE SWITCH OPEN DURING PURGE
  • 5.11 IGNITION SWITCH OPEN DURING IGNITION
  • 5.12 SAFETY PRESSURE RELIEF VALVE TEST
• CHAPTER 6. MAINTENANCE
  • 6.1 MAINTENANCE SCHEDULE
  • 6.2 IGNITER-INJECTOR
  • 6.3 FLAME DETECTOR
  • 6.4 COMBUSTION CALIBRATION
  • 6.5 SAFETY DEVICE TESTING
  • 6.6 FIRESIDE INSPECTION
  • 6.7 WATERSIDE INSPECTION
    • 6.7.1 Anode Replacement
  • 6.8 HEAT EXCHANGER CLEANING
    • 6.8.1 Pumping System Set-Up Instructions
    • 6.8.2 Cleaning Procedure
    • 6.8.3 Testing HydroSkrub Effectiveness
  • 6.9 CONDENSATE DRAIN TRAP
  • 6.10 AIR FILTER REPLACEMENT
  • 6.11 LOW WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST
    • 6.11.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
    • 6.11.2 Low Water Cutoff (LWCO) - Standard C-More Test
  • 6.12 SHUTTING THE WATER HEATER DOWN FOR AN EXTENDED PERIOD OF TIME
  • 6.13 PLACING THE HEATER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
• CHAPTER 7. TROUBLESHOOTING GUIDE
  • 7.1 INTRODUCTION
  • 7.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
• CHAPTER 8. WATER HEATER MANAGEMENT
  • 8.1 GENERAL DESCRIPTION
  • 8.2 WHM PRINCIPLES OF OPERATION
  • 8.3 NEW AERCO WHM FEATURES
    • 8.3.1 Valve Feedback
    • 8.3.2 Valve Supervisor
    • 8.3.3 Valve Control
    • 8.3.4 Modbus Header Sensor
    • 8.3.5 Automatic Temperature Sensor Calibration
    • 8.3.6 Manual Mode Password Required
    • 8.3.7 Quick Re-Flash Feature
    • 8.3.8 WHM Auto Mstr
    • 8.3.9 Run Hours and Run Cycles
    • 8.3.10 High Temperature Governor
  • 8.4 WHM STATUS DISPLAYS
  • 8.5 BST ALTERNATING STATUS DISPLAYS
  • 8.6 WHM MENU
  • 8.7 WHM MENU ITEM DESCRIPTIONS
  • 8.8 WHM HARDWARE INSTALLATION & SET-UP INSTRUCTIONS
    • 8.8.1 Hardware Installation
    • 8.8.2 WHM Modbus Network Wiring
    • 8.8.3 Control and Power Wiring
  • 8.9 WHM PROGRAMMING & START-UP
  • 8.10 TROUBLESHOOTING
  • 8.11 SEQUENCING VALVE DESCRIPTION & OPERATION
    • 8.11.1 Sequencing Valve Description
    • 8.11.2 Sequencing Valve Operating Characteristics
  • APPENDIX A – INNOVATION MENU ITEM DESCRIPTIONS
  • Table A-1: Operating Menu Item Descriptions
  • Table A-2: Setup Menu Item Descriptions
  • Table A-3: Configuration Menu Item Descriptions
  • Table A-4: Tuning Menu Item Descriptions
  • Table A-5: Calibration Menu Item Descriptions
  • APPENDIX B – STARTUP, STATUS AND FAULT MESSAGES
  • APPENDIX C – TEMPERATURE SENSOR RESISTANCE/VOLTAGE CHART
  • APPENDIX D – DIMENSIONAL DRAWINGS
  • APPENDIX E – PARTS LIST DRAWINGS
  • APPENDIX F – PIPING DRAWINGS
  • APPENDIX G – C-MORE CONTROL PANEL VIEWS
  • APPENDIX H – C-MORE WIRING DIAGRAMS
  • APPENDIX I – RECOMMENDED SPARES
  • APPENDIX J – COMBUSTION CALIBRATION (KOREA ONLY)
  • APPENDIX K – WARRANTY