SmartPlate Installation, Operation & Maintenance Manual
USER MANUAL
Installation, Operation & Maintenance Manual
Single Wall and Double Wall Water Heater Models
Single Wall Heater Models:
SP23, SP33, SP45, SP69, SP150
Double Wall Heater Models:
SPDW23, SPDW32, SPDW42, SPDW61,
SPDW113
Initial Release: 07/14/2017
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Phone: 800-526-0288
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TABLE OF CONTENTS
CHAPTER 1. GENERAL INFORMATION ................................................................................ 5
1.1 INTRODUCTION ................................................................................................................................... 5
1.2 ELECTRONIC CONTROL SYSTEM/SMARTPLATE (ECS/SP) .................................................................... 6
1.2.1 Control Box Assembly ................................................................................................................... 7
1.2.2 Feed-Forward Temperature Sensors ............................................................................................ 8
1.2.3 Outlet Temperature Sensors ........................................................................................................ 8
1.2.4 Boiler Water Inlet/Outlet Temperature Sensors .......................................................................... 8
1.3 SMARTPLATE PIPING ASSEMBLIES ...................................................................................................... 9
1.4 ELECTRONIC CONTROL VALVE, MXG-461............................................................................................ 9
CHAPTER 2. INSTALLATION ................................................................................................11
2.1 INTRODUCTION ................................................................................................................................. 11
2.2 RECEIVING AND UNPACKING SMARTPLATE ...................................................................................... 11
2.3 SITE SELECTION AND PREPARATION ................................................................................................. 12
2.3.1 Installation Clearances ................................................................................................................ 12
2.3.2 Setting the Unit ........................................................................................................................... 13
2.3.3 Repositioning ECS/SP Control Box .............................................................................................. 14
2.4 HEATING FLUID AND DOMESTIC HOT WATER (DHW) PIPING........................................................... 15
2.5 SMARTPLATE ELECTRICAL WIRING CONNECTIONS ........................................................................... 16
2.6 ADDITIONAL COMPONENT INSTALLATION ....................................................................................... 21
CHAPTER 3. FUNCTIONAL DESCRIPTION ..........................................................................23
3.1 INTRODUCTION ................................................................................................................................. 23
3.2 MECHANICAL OVERVIEW .................................................................................................................. 23
3.3 ELECTRONIC CONTROL OVERVIEW ................................................................................................... 24
3.4 OVER-TEMPERATURE CONTROL AND SAFETY FEATURES ................................................................. 24
CHAPTER 4. ADJUSTMENT ..................................................................................................27
4.1 INTRODUCTION ................................................................................................................................. 27
4.2 SMARTPLATE 3-WAY CONTROL VALVE, MXG-461 ADJUSTMENT ..................................................... 27
4.2.1 Control Valve Calibration and Status Indications ....................................................................... 27
4.2.2 Manual Control of 3-Way Valve – Removable Handwheel to Hamper Tampering .................... 30
4.2.3 Setpoint Temperature Adjustment ............................................................................................ 31
4.2.4 Over-Temperature Alarm Limit Adjustment .............................................................................. 34
CHAPTER 5. OPERATION .....................................................................................................37
5.1 INTRODUCTION ................................................................................................................................. 37
5.2 PRE-OPERATIONAL CHECKS & PROCEDURES .................................................................................... 37
5.3 INITIAL START-UP .............................................................................................................................. 38
5.4 CHECKING MIXED INLET TEMPERATURE ........................................................................................... 39
5.5 SHUTTING DOWN THE SYSTEM ......................................................................................................... 39
CHAPTER 6. SCHEDULED MAINTENANCE .........................................................................41
6.1 INTRODUCTION ................................................................................................................................. 41
6.2 BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK ................................................................. 42
6.3 PLATE PACK LEAKAGE CHECKS (DOUBLE-WALL MODELS ONLY)....................................................... 43
6.4 OVER-TEMP SWITCH CHECK .............................................................................................................. 43
6.5 STRAINER INSPECTION AND CLEANING ............................................................................................ 44
6.6 CONTROL VALVE OPERATIONAL CHECK ............................................................................................ 44
6.7 TEMPERATURE SENSOR CHECKS ....................................................................................................... 44
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6.8 RECIRCULATION PUMP CHECK .......................................................................................................... 45
6.9 PERIODIC CLEANING OF HEAT EXCHANGER ...................................................................................... 46
CHAPTER 7. TROUBLESHOOTING ......................................................................................47
7.1 INTRODUCTION ................................................................................................................................. 47
7.2 TROUBLESHOOTING PROCEDURES ................................................................................................... 47
CHAPTER 8. CORRECTIVE MAINTENANCE ........................................................................57
8.1 INTRODUCTION ................................................................................................................................. 57
8.2 SINGLE WALL HEAT EXCHANGER MAINTENANCE ............................................................................. 57
8.3 HEAT EXCHANGER CLEANING & DE-SCALING ................................................................................... 57
8.4 SINGLE-WALL HEAT EXCHANGER REPLACEMENT ............................................................................. 60
8.5 DOUBLE-WALL HEAT EXCHANGER MAINTENANCE ........................................................................... 63
8.6 DOUBLE-WALL HEAT EXCHANGER CLEANING ................................................................................... 64
8.6.1 Heat Exchanger Cleaning and De-Scaling (In-Place Method) ..................................................... 64
8.6.2 Heat Exchanger Cleaning By Disassembly .................................................................................. 64
8.7 DOUBLE-WALL HEAT EXCHANGER OPENING AND CLOSING ............................................................. 66
8.7.1 OPENING HEAT EXCHANGER ...................................................................................................... 67
8.7.2 REMOVAL AND INSERTION OF PLATES ....................................................................................... 69
8.7.3 CLOSING HEAT EXCHANGER ....................................................................................................... 70
8.8 DOUBLE-WALL HEAT EXCHANGER GASKET REPLACEMENT .............................................................. 73
8.8.1 Replacing Gaskets on Channel Plates ......................................................................................... 73
8.8.2 Replacing Gaskets on End Plate (First Plate Against Frame Plate) ............................................. 74
8.9 DOUBLE-WALL HEAT EXCHANGER REPLACEMENT ........................................................................... 76
8.10 CONTROL VALVE ELECTRONIC MODULE REPLACEMENT AND VALVE REMOVAL ........................... 80
8.10.1 Electronics Module Replacement ............................................................................................. 80
8.10.2 Control Valve Replacement ...................................................................................................... 82
8.11 RECIRCULATION PUMP REPLACEMENT........................................................................................... 83
8.12 STRAINERS ....................................................................................................................................... 85
8.13 ECS/SP CONTROL BOX ASSEMBLY AND COMPONENTS .................................................................. 87
8.14 CONTROL BOX ASSEMBLY REPLACEMENT ...................................................................................... 87
8.15 TEMPERATURE CONTROLLER REPLACEMENT ................................................................................. 88
8.16 OVER-TEMPERATURE SWITCH AND TEMPERATURE INDICATORS .................................................. 89
8.17 24 VAC STEP-DOWN TRANSFORMER REPLACEMENT ..................................................................... 90
APPENDIX A .................................................................................................................................. 95
APPENDIX B – ECS/SP WIRING DIAGRAM & TERMINAL BLOCK CONNECTIONS ........................ 105
APPENDIX C – SMART PLATE PIPING DRAWINGS....................................................................... 107
APPENDIX D – DIMENSIONAL DRAWINGS.................................................................................. 119
APPENDIX E – PART LISTS ........................................................................................................... 121
APPENDIX F – RECOMMENDED SPARE PARTS ........................................................................... 131
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SmartPlate Installation, Operation & Maintenance Manual
CHAPTER 1 – GENERAL INFORMATION
CHAPTER 1. GENERAL INFORMATION
1.1 INTRODUCTION
This manual provides detailed coverage for the AERCO SmartPlate line of Water-to-Water
Heaters. Each SmartPlate Water Heater model is equipped with AERCO’s Electronic Control
System (ECS), specifically designed for SmartPlate (ECS/SP), and an Electronic Control Valve,
MXG-461. This Control System and Valve combination is used with all SmartPlate models and
sizes.
The following SmartPlate Single-Wall and Double-Wall Heat Exchanger Water Heater models
are available:
Type
Single Wall
Double Wall
SmartPlate Models
SP23, SP33 SP45, SP69, SP150
SPDW23, SPDW32, SPDW42, SPDW61, SPDW113
Pressure
Options *
Power
Options**
150 PSI
200 PSI
150 PSI
120V 60 Hz
220V 50 Hz
220V 60 Hz
200 PSI
* Appropriate add-on kits differentiates overall product for given DHW side operating pressure.
** Internal power wiring and recirculation pump differentiates the power option.
Figure 1-1 shows a typical SmartPlate Water Heater with a single-wall heat exchanger. Piping
assembly components are similar for double-wall models. The remaining sections in this chapter
provide descriptions of the units, assemblies and sub-assemblies included with the SmartPlate
models.
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CHAPTER 1 – GENERAL INFORMATION
ECS
CONTROL
BOX
RELIEF VALVE
CONTROL
VALVE
MXG-461
INTAKE
MIXING BOX
BOILER WATER COLD WATER
OUTLET
INLET
BOILER WATER
DIFFERENTIAL
PRESSURE GAUGE
BOILER
WATER INLET
DHW OUTLET
BOILER
WATER INLET
STRAINER
DOMESTIC
WATER INLET
STRAINER
DRAIN
VALVE
RECIRCULATION
PUMP
HEAT EXCHANGER
(BEHIND SUPPORT ASSY)
Figure 1-1. Typical SmartPlate Packaged Water Heater – Single Wall Shown
1.2 ELECTRONIC CONTROL SYSTEM/SMARTPLATE (ECS/SP)
Identical Electronic Control Systems are used on all SmartPlate models. This system,
commonly referred to as the ECS/SP, contains a Control Box Assembly which includes all of the
electronic circuitry for the ECS/SP. In addition, the ECS/SP includes several sensors and safety
devices which provide temperature and flow control information to the Control Box circuitry. The
Control Box and the additional devices included in the ECS are shown in Figure 1-2. The
additional devices included in the ECS/SP include:
• Feed-Forward (Mixed Water) Temperature Sensor (Type J Thermocouple)
• DHW Outlet Dual Temperature Sensors (Type J Thermocouples)
• Boiler Water Inlet/Outlet Temperature Sensors (Type J Thermocouples)
• Over-Temperature Alarm (With Safety Shutdown)
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CHAPTER 1 – GENERAL INFORMATION
If desired, the ECS/SP can be ordered with a Modbus communication option. This option
permits the ECS/SP to be externally controlled by an Energy Management System (EMS),
Building Automation System (BAS), or a computer supplied by other manufacturers.
The ECS/SP assemblies and components are described in the following subordinate sections.
DHW
OUTLET DUAL
TEMP. SENSOR
RECIRCULATION
PUMP
FEED-FWD
(MIXED WATER)
TEMP. SENSOR
CONTROL
BOX
BOILER WATER
IN/OUT
TEMP SENSORS
CONTROL
VALVE,
MXG-461
Figure 1-2. Electronic Control System/SmartPlate (ECS/SP)
1.2.1 CONTROL BOX ASSEMBLY
The front panel on the Control Box assembly contains all of the display devices for the ECS/SP.
These include the Temperature Controller, an Over-Temperature Indicator/Switch and Boiler
Water In/Out Temperature Indicators.
The Temperature Controller is the “brain” of the ECS/SP, which processes data received from
the temperature sensors. Using feed forward and PID (Proportional Integral Derivative)
algorithms, the Temperature Controller provides a 0 to 10 VDC control signal to the Control
Valve Actuator, which precisely modulates the Control Valve for optimum DHW outlet
temperature control. The upper display on the front panel of the Temperature Controller displays
the current DHW outlet temperature. The lower display continuously displays the DHW setpoint
temperature currently stored in the Temperature Controller.
The Over-Temperature indicator/switch included in the Control Box constantly monitors and
displays the unit’s outlet temperature to ensure it does not exceed the preset high temperature
limit. The over-temperature limit is factory-set 20°F above the unit’s setpoint temperature
specified on the sales order. If an over-temperature condition occurs, this device sounds an
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CHAPTER 1 – GENERAL INFORMATION
audible alarm and cuts off power to the Control Valve Actuator thereby closing the Control Valve
and shutting off the boiler water flow to the unit.
The Boiler Water inlet and outlet temperatures are sensed on the surface of the inlet/outlet
pipes and are provided for informational and troubleshooting purposes only. They are not used
for temperature control but they do have alarm limits available for customer settings, if desired.
The Control Box components are housed in a steel enclosure with a hinged front door. This
door contains a clear polycarbonate window which permits maintenance personnel to view the
controls and displays of the Temperature Controller, and other display devices mounted on a
recessed panel behind the door. All sensor and control signal connections are made via cable
connections at the bottom of the Control Box. External AC power (120 VAC, 60 Hz, 220 VAC 50
Hz or 220V, 60 Hz) is supplied via the cutout on the bottom of the Control Box. If desired, the
Control Box can be easily repositioned in 90° increments from its default position shown in
Figure 1-1. Refer to Chapter 2, section 2.3.3 for details.
1.2.2 FEED-FORWARD TEMPERATURE SENSORS
The Feed-Forward Temperature Sensor (Type J thermocouple) is installed in the cold water
inlet mixing box on the unit. The Temperature Sensor monitors a portion of the inlet flow to the
unit and provides a feed-forward signal to the Temperature Controller which is proportional to
the change in flow through the unit.
1.2.3 OUTLET TEMPERATURE SENSORS
The Control System includes a Dual Temperature Sensor which is installed in the hot water
outlet of the unit. This sensor contains two identical Type J thermocouples. The first
thermocouple connects directly to the Temperature Controller to provide feedback PID control
for the outlet water temperature. The second thermocouple connects to the Over-Temperature
Indicator/Switch in the Control Box.
1.2.4 BOILER WATER INLET/OUTLET TEMPERATURE SENSORS
Two additional Temperature Sensors (Type J thermocouples) are provided with the Control
System. One Temperature Sensor is attached to the boiler water inlet and the other is attached
to the boiler water outlet of the unit. These two Sensors are connected to two identical
Temperature Display Indicators in the Control Box to provide real-time indications of the inlet
and outlet boiler water temperatures. These Temperature Indicators are physically identical to
the Over-Temperature Indicator/Switch, but are used as “Indicator-Only” devices and do not
provide any switching functions. However, the Boiler Water Inlet Indicator will signal an alarm
condition if the boiler water temperature exceeds 250°F.
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CHAPTER 1 – GENERAL INFORMATION
1.3 SMARTPLATE PIPING ASSEMBLIES
The diameter of the piping assemblies furnished with the water heater will depend on the size of
the heat exchanger installed in the SmartPlate model ordered. Smaller sized models utilize 1.5”
piping assemblies, while the larger sizes utilize 2” piping assemblies. Refer to Table 1-1 below
for the size of the piping assemblies used in each Single-Wall and Double-Wall SmartPlate
model.
TABLE 1-1. SmartPlate Model Piping Assemblies
Type
SmartPlate Model
Piping Assembly
Diameter
SP23, SP33
1.5”
Single-Wall
Double-Wall
SP45, SP69, SP150
2”
SPDW23, SPDW32
1.5”
SPDW42, SPDW61, SPDW113
2”
In addition to the heat exchanger and piping components, each SmartPlate Piping Assembly
contains a number of other important components and assemblies. The items include:
•
•
•
•
•
•
•
Mixing box
Recirculation Pump, (Continuously ON)
Isolation & Drain Valves
Strainers (Boiler Water & DHW Sides)
Blow-down Valves
Relief Valve
Air Vent Valve
Figure 1-3 illustrates the locations of the above-mentioned items for a single-wall heat
exchanger. Piping components are similar for double-wall models.
1.4 ELECTRONIC CONTROL VALVE, MXG-461
The 3-Way Electronic Control Valve (Siemens MXG-461) is powered by 24 VAC which is
received from the ECS/SP Control Box. The Temperature Controller in the Control Box supplies
a 0 – 10 VDC control signal to precisely modulate the 3-Way Valve to accurately control the
temperature of the DHW output to the desired setpoint. The Control Valve is shown in Figure 14. The connection unions have flat face gaskets that provide the fluid seal.
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CHAPTER 1 – GENERAL INFORMATION
RELIEF VALVE
3-WAY CONTROL
VALVE
AIR VENT
VALVE
ISOLATION
BALL VALVE
(4 PLCS)
BOILER WATER
OUTLET
INTAKE
MIXING BOX
COLD WATER
INLET
HEAT
EXCHANGER
BOILER WATER
DIFFERENTIAL
PRESSURE GAUGE
RECIRCULATION PUMP
BOILER WATER INLET
DRAIN VALVE
DHW OUTLET
STRAINERS WITH BLOWDOWN VALVES
Figure 1-3. Typical SmartPlate Piping Assembly – 2” Piping Shown
ELECTRONICS
MODULE
HANDWHEEL
PORT A
VALVE
BODY
PORT AB
PORT B
Figure 1-4. Electronic Control Valve
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CHAPTER 2 – INSTALLATION
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
All of the SmartPlate Water Heater models are shipped fully assembled and ready for
installation. Therefore, installation will consist of the following tasks:
• Unpack the SmartPlate Water Heater from its shipping container.
• Position and secure the unit at the site.
• Install the Relief Valve and Air Vent Valve on the mixing box.
• On units installed in New York City, install a second Relief Valve on the boiler water intake
piping.
• Connect the hot boiler water piping to the unit.
• Connect the domestic hot water (DHW) piping to the unit.
• Connect external AC power to the ECS/SP Control Box.
• If required, connect Modbus control wiring to the Temperature Controller in the ECS/SP
Control Box.
2.2 RECEIVING AND UNPACKING SMARTPLATE
Each SmartPlate Water Heater is shipped as a single crated unit. The packaged shipping
weight will vary from 380 to approximately 1100 pounds depending on the model ordered. The
unit must be moved with the proper equipment (forklift, pallet jack, etc.) to avoid possible injury
to personnel or damage to the shipping container or unit. The shipping carton should be
inspected for damage incurred during transit prior to signing the bill of lading.
NOTE:
AERCO is not responsible for lost or damaged freight. The freight carrier must be notified
immediately of any damage detected.
Unpack the SmartPlate Water Heater from its shipping container taking care not to damage the
unit when cutting away the packaging material.
Remove the package containing the Relief Valve and Air Vent Valves. This package may also
contain an additional Relief Valve. See section 2.6 for a complete list of parts and installation
instructions.
Remove the bolts securing the unit to its shipping skid. Perform a complete visual inspection of
the unit to ensure there is no evidence of damage.
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CHAPTER 2 – INSTALLATION
2.3 SITE SELECTION AND PREPARATION
Ensure that the site selected for installation of the SmartPlate Water Heater includes the
following:
• Access to AC input power at 120 VAC/60 Hz, 220 VAC/50 Hz or 220 VAC 60 Hz, single
phase.
• Close proximity to the boiler to be used as the heating fluid (hot water) source
• If applicable; access to Modbus Network wiring within the prescribed wire lengths (see
section 2.5.
2.3.1 INSTALLATION CLEARANCES
The heater must be installed with the prescribed clearances for service as shown in Figure 2-1.
the minimum clearance dimensions recommended by AERCO are listed below. However, if
local building codes require additional clearances, these codes shall supersede AERCO’s
recommendations.
•
•
•
•
Sides:
Front:
Rear:
Top:
24 in. (61 cm)
24 in. (61 cm)
24 in. (61 cm)
12 in. (30.5 cm)
All water piping and electrical conduit must be arranged so that it does not interfere with the
removal of any Water Heater assemblies/parts or inhibit service or maintenance of the unit.
Figure 2-1. SmartPlate Water Heater Clearances
CAUTION!
While packaged in the shipping container, the heater must be move using a forklift or pallet
jack. After unpacking, the heater should be lifted and moved using the lifting tabs (single-wall
model), or frame cutouts (double-wall model) provided on the heater. Alternately, a forklift or
pallet jack may be used to move the unit by inserting the tines through the cutouts in the
heater base (Figure 2-1). Refer to the information in the following section.
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2.3.2 SETTING THE UNIT
SmartPlate Single-Wall models contain two lifting tabs at the top of the frame assembly (Figure
2-2 a). Use these tabs to lift and move the unit. Double-Wall models contain two round cutouts
on the frame plate and two on the pressure plate of the heat exchanger (Figure 2-2 b). To lift
and move the unit, use these cutouts, or wrap the lifting strap around the threaded bolts
protruding from the heat exchanger (Figure 2-2 b).
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.
LIFTING TABS
ECS/SP
CONTROL BOX
CONTROL
VALVE
Figure 2-2 a. SmartPlate Lifting Provisions – Single-Wall Models
CAUTION!
For Single-Wall models, DO NOT attempt to reposition the ECS/SP Control Box with the
panel displays facing the unit’s Piping Assembly, as the location of the lifting tabs will prevent
the Control Box door from opening fully (Figure 2-2 a).
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FRAME
CUTOUTS
PRESSURE
PLATE
CUTOUTS
Figure 2-2 b. SmartPlate Lifting Provisions – Double-Wall Models
2.3.3 REPOSITIONING ECS/SP CONTROL BOX
If required, the front panel displays of the ECS/SP Control Box can be repositioned from the
default left-side of the unit (Figure 2-2) to either the right side or rear of the unit to optimize
viewing of the panel displays. Repositioning of the Control Box is accomplished as follows:
REPOSITIONING ECS/SP CONTROL BOX Instructions
1. Power the unit off.
2. Disconnect external cables at their respective connections (Molex).
3. From the rear of the unit (Figure 2-3, below), remove the four Phillips head screws
securing the base of the Control Box to the unit’s frame assembly.
4. Position the Control Box to the desired orientation to provide easy viewing of the control
panel displays.
5. Ensure that all power and control wiring are of sufficient length to prevent undue stress on
the wiring connections. Reposition wiring harnesses as necessary.
6. Replace the four Phillips head screws removed in step 1.
7. Apply power if previously connected.
8. This completes the repositioning of the ECS/SP Control Box.
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REPOSITIONING ECS/SP CONTROL BOX Instructions
ECS/SP
CONTROL
BOX
SUPPORT
FRAME
PHILLIPS HD.
SCREWS
(4 PLCS)
HEAT
EXCHANGER
(SINGLE-WALL)
SMARTPLATE – PARTIAL REAR VIEW
Figure 2-3. Repositioning ECS/SP Control Box
2.4 HEATING FLUID AND DOMESTIC HOT WATER (DHW) PIPING
The diameter of the heating fluid (hot boiler water) and DHW piping will depend on the model
number and size of the unit being installed. Refer to Table 2-1 for applicable piping sizes.
TABLE 2-1. Pipe Sizing Chart
Type
SmartPlate Water Heater Model
Pipe Diameter
SP23, SP33
1.5 inches
SP45, SP69, SP150
2.0 inches
SPDW23, SPDW32
1.5 inches
SPDW42, SPDW61, SPDW113
2.0 inches
Single-Wall
Double-Wall
CAUTION!
Two pipe wrenches MUST be used when installing boiler water and DHW piping unions to
prevent pipe rotation and avoid leaks.
The locations and spacing for the heating fluid (hot boiler water) and DHW piping are provided
in Dimensional Drawings AP-A-846 (Single-Wall) and AP-A-847 (Double-Wall), included in
Appendix D of this document. In addition, sample piping diagrams are provided in Appendix C
for single and multiple unit installations.
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CHAPTER 2 – INSTALLATION
IMPORTANT!
When SmartPlate Water Heaters are shipped from the factory, all four isolation ball valves
and the drain valve (Figure 1-3) are opened. Close all valves during installation. Do not open
the valves until instructed to do so in Chapter 5 of this manual.
2.5 SMARTPLATE ELECTRICAL WIRING CONNECTIONS
The SmartPlate ECS/SP Control Box and all other ECS/SP components are installed on the unit
prior to shipment from the factory. Therefore, electrical connections to the ECS/SP basically
consist of connecting external AC power to the ECS/SP Control Box. The system can be
powered by a single-phase AC voltage of 120 VAC, 60 Hz, 220 VAC, 50 Hz or 220 VAC 60 Hz.
However, if the ECS/SP was ordered with the Modbus Communication option, several additional
signal lead connections will need to be made inside the Control Box. These signal leads will
permit the ECS/SP to be controlled by an external Energy Management System (EMS), Building
Automation System (BAS), or Computer. Proceed as follows:
NOTE:
Following installation, a lock (Not Supplied) can be installed on the front door of the Control
Box, if desired, to prevent unauthorized access to ECS settings.
ELECTRICAL WIRING CONNECTIONS Instructions
1. Loosen the captive screw on the right-front portion of the Control Box (Figure 2-4) to open
the hinged panel door.
PANEL DOOR
CAPTIVE
SCREW
HOLE FOR
LOCK
Figure 2-4. ECS/SP Control Box Front View
2. Next, open the door and loosen the captive screw at the top of the recessed panel (Figure
2-5).
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ELECTRICAL WIRING CONNECTIONS Instructions
PANEL CAPTIVE
SCREW
Figure 2-5. Recessed Panel Behind ECS/SP Control Box Door
3. Swing down the recessed panel to access Terminal Block TB-2 on the bottom interior
surface of the Control Box, shown in Figure 2-6.
NOTE:
Use 14 to 18 AWG wire for AC power wiring connections to the SmartPlate ECS/SP Control
Box.
4. Feed the external 120/220 VAC power leads through the cutout labeled “POWER IN” on
the bottom of the Control Box.
5. Connect the LINE, NEUTRAL and GROUND leads to the TB-2 terminals shown in Figure
2-6.
6. Check the connection of wire #100 on the right side of TB-2 to ensure the power is routed
to the proper connection for the 24 VAC transformer. If the incoming power is 120 VAC,
wire #100 should be connected to the terminal with a black wire and the orange wire
should have nothing connected to its terminal. Conversely, if the incoming power is 220
VAC, wire #100 should be connected to the terminal with the orange wire and the black
wire left unconnected.
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CHAPTER 2 – INSTALLATION
ELECTRICAL WIRING CONNECTIONS Instructions
INSTALL EXTERNAL POWER
WIRING THROUGH THIS
CUT-OUT
REAR
TO
TRANSFORMER
120/24 VAC
GND
NEUTRAL
ORANGE
WHITE
LINE
BLACK
220/24 VAC
POWER
SWITCH
100
102
100F
GND
GND
102
101
TB-2
FROM
FUSE
INTERIOR BOTTOM SURFACE
FOR 220 VAC, WIRE #100
MUST BE CONNECTED
TO THIS TERMINAL
Figure 2-6. ECS/SP Control Box AC Power Connections
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CHAPTER 2 – INSTALLATION
ELECTRICAL WIRING CONNECTIONS Instructions
Figure 2-7: Remote Relay Option Kit (P/N 69018) Schematic
7. If the ECS was ordered with the Modbus Communication Option, proceed to step 8.
However, if this option is not included, no further steps are required. In that case, re-secure
the hinged swing-down panel of the Control Box and close the front panel door.
NOTE:
Step 8 applies ONLY to SmartPlate Control Systems that include a Temperature Controller
(Eurotherm, model 2408) equipped with a Communications Board that allows connection to
Modbus Networks. The required signal connections will depend on the ports available on
the Energy Management System (EMS), Building Automation System (BAS), or Computer
being used with the ECS/SP.
CAUTION!
DO NOT route Modbus communication wiring in the same conduit as power wiring.
Attempting to do so may result in excessive noise on the signal lines. Also, ensure that the
RS232 or RS485 signal cable connections do not exceed the following lengths:
• RS232 Cable: 50 feet maximum
• RS485 Cable: 4,000 feet maximum
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CHAPTER 2 – INSTALLATION
ELECTRICAL WIRING CONNECTIONS Instructions
8. To permit Modbus control of the ECS/SP, refer to Table 2-2, below, and connect the
appropriate wire leads to the Temperature Controller terminals listed. Refer to the
Temperature Controller (Eurotherm 2408) pinouts shown in Figure 2-8 to locate the
required terminals. Also, refer to Appendix A for instructions on how to change the
Temperature Controller Modbus address and for a listing of active Modbus data addresses
for the 2408 Controller. In addition, the Eurotherm documents referenced in this Appendix
provide additional communication information related to Modbus.
NOTE:
The complete wiring diagram for the SmartPlate Electronic Control System is provided in
Appendix B of this Instruction Manual. In addition, the wiring connections for Control Box
Terminal Blocks TB-1 and TB-2 are also provided for reference purposes.
NOTE:
AERCO recommends that shielded, twisted-pair cable be used for communication wiring.
Examples of suitable wiring are: Belden 9841, 8761, 3105A, or equivalent.
TABLE 2-2. Modbus Communication Signal Connections
COMPUTER CONTROL CABLE
2408 TEMP. CONTROLLER
RS232/9-PIN
SIGNAL NAME
PIN NO.
SIGNAL NAME
RS232/25-PIN
RS485
PIN NO.
PIN NO.
PIN NO.
GROUND
HD
GROUND
5
7
GROUND
RECEIVE
HE
TRANSMIT
3
2
A(-)
TRANSMIT
HF
RECEIVE
2
3
B(+)
2408 CONTROLLER
1A
HA L
1B
HB N
1C
HC
1D
HD LA
2A
HE LB
2B
HF LC
2C
JA AA
2D
JB AB
3A
JC AC
3B
JD VI
3C
JE V+
JF V-
3D
In1
In2
C
SEE TABLE 2-2 FOR COMM CONNECTIONS
Figure 2-8. Temperature Controller (Eurotherm 2408) Terminal Connection Diagram
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CHAPTER 2 – INSTALLATION
2.6 ADDITIONAL COMPONENT INSTALLATION
A number of SmartPlate Water Heater components are included in an installation kit. These
parts must be installed after the unit is setup at the site.
There are six installation kits. The parts in each kit depend on the SmartPlate model, the
pressure option, and whether it is being installed in New York City.
Kit #
58128-1
58128-2
58128-3
58128-4
58128-5
58128-6
Applies to SmartPlate Models
SP23, SP33, SP45, SP69, SP150
SPDW23, SPDW32, SPDW42, SPDW61, SPDW113
SP23, SP33, SP45, SP69, SP150
SPDW23, SPDW32, SPDW42, SPDW61, SPDW113
SP23, SP33, SPDW23, SPDW32
SP45, SP69, SP150, SPDW42, SPDW61, SPDW113
SP23, SP33, SPDW23, SPDW32
SP45, SP69, SP150, SPDW42, SPDW61, SPDW113
Pressure
NYC Option
150 PSI
No
200 PSI
150 PSI
Yes
200 PSI
The contents of the kits are shown below (see Appendix E for a full list and quantity per kit)
Part #
92070
92130
92065-1
92134-1
92111
93521
93505
93451
Description
Air Vent Valve 1" 150 PSI
Air Vent Valve ¾", 200 PSI
Relief Valve, ¾M X ¾F, 150 PSI
Relief Valve, 200 PSI
Relief Valve
Reducing Bushing, 1 ½” to ¾“
Reducing Bushing 1" to ¾"
Nipple, ¾", 2" Lg.
Complete the instructions below to install Relief Valve and Air Vent valves.
ADDITIONAL COMPONENT INSTALLATION Instructions
1. If you have a 150 PSI unit, install the parts as shown in Figure 2-9.
Relief Valve
P/N 92065-1
1 ½” to ¾” Bushing
P/N 93521
Air Vent Valve
P/N 92070
Intake Mixing
Box
Figure 2-9. Relief Valve and Air Vent Valve Installation – 150 PSI – Exploded
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CHAPTER 2 – INSTALLATION
ADDITIONAL COMPONENT INSTALLATION Instructions
2. If you have a 200 PSI unit, install the parts as shown in Figure 2-10.
Air Vent Valve
P/N 92130
Relief Valve
P/N 92134-1
Nipple, ¾”
P/N 93451
Bushing, 1 ½” to ¾”
P/N 93521
Bushing, 1” to ¾”
P/N 93505
Intake Mixing
Box
Figure 2-10. Relief Valve and Air Vent Valve Installation – 200 PSI – Exploded
3. If the unit is being installed in New York City only (kits 58128-3 – 58128-6), in addition to
the steps above you must install a second Relief Valve (P/N 92111) in the Boiler Water
Intake Ball Valve/Strain combo, as shown in Figure 2-11. If the unit has 2 inch piping
(models SP-42, SP-61 or SP-113), you must include the 1” to ¾” bushing (P/N 93505).
Units with 1 ½” piping do not need this bushing.
Relief Valve Outlet
Relief Valve
P/N 92111
BOILER WATER
INLET
NOTE:
Rotate the Relief Valve so that the
outlet connection to the drain hose does
not interfere with other components
Bushing, 1” to ¾”
(2” Piping Only)
P/N 93505
Figure 2-11. Relief Valve Installation – New York City Option
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CHAPTER 3 – FUNCTIONAL DESCRIPTION
CHAPTER 3. FUNCTIONAL DESCRIPTION
3.1 INTRODUCTION
SmartPlate Water Heaters are equipped with a stainless steel plate heat exchanger, an ECS/SP
Electronic Control System, and an MXG-461 Control Valve. This design results in a highly
responsive system which provides virtually constant hot water flow at the selected setpoint
temperature.
Accessories included with SmartPlate Water Heaters include:
• Boiler water and domestic water Y-strainers with blow-down valves
• Relief Valve
• Air Vent Valve
• Isolation valves and domestic water drain valve
• Boiler water differential pressure gauge
• Domestic water air vent
• Integral domestic water circulator pump
A simplified functional block diagram for the SmartPlate Water Heater is shown in Figure 3-1.
The following sections provide a top-level functional overview of system operation.
3.2 MECHANICAL OVERVIEW
The cold water enters heat exchanger through the inlet connection, strainer, and mixing box.
Cold water flows through the plate heat exchanger, where it is heated by hot boiler water, and
then discharged through the Domestic Hot Water (DHW) outlet connection. A portion of hot
water is pumped into the mixing box where it is mixed with the cold water entering the heater,
thereby providing a load sensing feed forward function.
Boiler water supplied to the heat exchanger passes through the inlet connection and strainer.
The boiler water heats the colder domestic water, and is then discharged through the boiler
water outlet connection. The boiler water flow is controlled by the 3-way MXG-461 Control
Valve which is located in the outlet path of the boiler water piping connection. If desired, the
Control Valve configuration can be changed to a 2-Way Valve by closing the Ball Valve located
between the boiler water inlet connection and port B of the Valve (see Figure 3-1). However if
this 2-Way configuration is used, ensure that a by-pass line is installed in the boiler water piping
(outside the unit) to avoid dead-heading the boiler water pump.
For SmartPlate models with Double-Wall heat exchangers, heat transfer plates are positioned
together to form one assembly with an air space between them. This protects against leakage of
boiler water into the domestic water. If one of the plates should develop a leak (boiler water or
domestic water, whichever is leaking), the water will enter the air space and exit to the
atmosphere. It will flow out through leak detection channels alerting an operator that a leak has
occurred.
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CHAPTER 3 – FUNCTIONAL DESCRIPTION
3.3 ELECTRONIC CONTROL OVERVIEW
The primary control mechanism for the ECS/SP is an Electronic Process Controller which is
installed in the Control Box. The Controller utilizes feed forward and PID (Proportional Integral
Derivative) algorithms to provide precise control of the unit’s outlet temperature. Outlet
temperature control is accomplished by modulating the open/closed position of the MXG-461
Control Valve Actuator.
The Controller continuously monitors the unit’s outlet temperature via a thermocouple located in
the outlet port. The Controller also receives a feed-forward signal from the temperature sensor
mounted in the mixed water mixing box as shown in Figure 3-1. The mixed water sensor
monitors flow changes through the unit and provides a feed-forward signal to the Controller
proportional to the change in flow. The mixed water temperature provides an instantaneous
feed-forward response for loads ranging from 0.5 GPM to the maximum Water Heater flow. The
Water Heater uses a cartridge circulator to create reliable mixed flow conditions in the mixing
box.
The Controller provides a 0-to-10 VDC output signal to the MXG-461 Control Valve Actuator.
This 0 to 10 VDC signal proportionally modulates the Control Valve position from fully closed (0
VDC) to fully open (10 VDC). The control signal varies as necessary to maintain the setpoint
temperature programmed into the Controller. Under normal conditions, the unit’s outlet
temperature is maintained within ±4°F of the desired setpoint based on a load change of 50% or
less. Surface-mount sensors and digital displays are also provided in the ECS/SP Control
System to monitor the supply and return water temperatures of the boiler water.
3.4 OVER-TEMPERATURE CONTROL AND SAFETY FEATURES
The Control Box contains an Over-Temperature Switch which continuously monitors and
displays the unit’s outlet water temperature from input received from the thermocouple installed
in the hot water outlet port. Normally, the Over-Temperature Switch is set 20°F above the unit’s
setpoint temperature. If the programmed over-temperature limit is exceeded, the OverTemperature Switch is activated. This in turn sounds an audible alarm, disconnects power from
the Control Valve Actuator moving the Control Valve to the full-bypass position (B – AB). It
should be noted that the Over-Temperature Switch has a slightly slower response to
temperature changes than the Temperature Controller. Therefore, slightly different temperature
readings may appear momentarily in their respective displays, particularly during system startup.
The Control Valve Actuator also incorporates a “Fail-Safe” feature which automatically closes
the valve if there is a loss of the 0 to 10 VDC control signal or loss of input power. The 24 VAC
power supply transformer has an integral 3 amp circuit breaker to protect the Control Valve
electronics.
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CHAPTER 3 – FUNCTIONAL DESCRIPTION
DHW OUTLET TEMP
CONTROL BOX
POWER INPUT
120VAC,
VAC,60
60Hz
Hz
120
OR
OR 50 Hz
220 Hz,
220 VAC, 50 Hz
or
220 VAC, 60 Hz
24 VAC XFMR
WITH 3A, 24 VAC
CKT BRKR
POWER
SWITCH
OVER-TEMP
SWITCH
DHW DUAL OUTLET TEMP
TEMPERATURE
CONTROLLER
F
FUSE
0 – 10 V
FEED FORWARD TEMP
TO CIRC
PUMP
24 VAC
TC MIX
3-WAY
AB
BOILER
WATER (BW)
OUT
A
MIXED IN
STRAINER
DOMESTIC
COLD
WATER IN
MIXED
TEMP
BW OUT
B
TCOUT
(SEE NOTE 1)
( SEE NOTE 2)
HEAT
EXCHANGER
CIRC
PUMP
TC IN
STRAINER
TC DUAL
DHW
OUT
BW IN
BOILER
WATER (BW)
IN
DHW OUT
DOMESTIC WATER
NOTES:
1. THE BW TC IN & BW TC OUT THERMOCOUPLES ARE CONNECTED TO DISPLAY DEVICES IN THE
CONTROL BOX. THESE ARE “INDICATION ONLY” DISPLAYS WHICH MAY BE USER-CONFIGURED FOR
ALARM SETTINGS.
2. THE BOILER WATER BYPASS LINE IS NORMALLY OPEN (3-WAY VALVE CONFIGURATION). FOR A
2-WAY CONFIGURATION, CLOSE THE VALVE ON THE BYPASS LINE. ENSURE THAT A BYPASS LINE IS
INSTALLED EXTERNAL TO THE SMART PLATE.
Figure 3-1. SmartPlate Water Heater Functional Block Diagram
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CHAPTER 3 – FUNCTIONAL DESCRIPTION
(This Page Is Intentionally Blank)
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CHAPTER 4 – ADJUSTMENT
CHAPTER 4. ADJUSTMENT
4.1 INTRODUCTION
This chapter provides the adjustment procedures for the 3-Way Control Valve, MXG-461 and
the SmartPlate Electronic Control System (ECS/SP).
Prior to shipment from AERCO, all MXG-461 Control Valve Actuators are adjusted (autostroked) to ensure that they properly position the Control Valve from the fully-open to the fullyclosed positions. In addition, the ECS/SP is adjusted to the Setpoint Temperature specified on
the Sales Order.
It is recommended that the following procedures be performed to the extent necessary prior to
placing the SmartPlate Water Heater into operation. Also, the applicable procedures MUST be
performed following replacement of the MXG-461 Control Valve or ECS/SP components to
ensure that all parameters are properly set.
CAUTION!
As a precaution, ensure that all heating fluid hot boiler water shutoff valves are fully closed
prior to performing any of the following adjustment procedures.
4.2 SMARTPLATE 3-WAY CONTROL VALVE, MXG-461 ADJUSTMENT
The 3-Way Control Valves, (Siemens, MXG-461) used on all SmartPlate models are powered
by 24 VAC. For SmartPlate Water Heater applications, each 3-Way Valve is controlled by a 0 to
10 VDC signal received from the Temperature Controller (Eurotherm 2408) contained in the
ECS/SP. A 0 VDC signal places the Control Valve in the full bypass position from port B to port
AB (valve shaft up). A 10 VDC signal places the Control Valve in the full flow position from port
A to port AB (valve shaft down).
4.2.1 CONTROL VALVE CALIBRATION AND STATUS INDICATIONS
The control Valve Actuators are self-calibrating for all Valve sizes. Therefore, simply proceed as
follows to automatically adjust the Valve Actuator:
CONTROL VALVE CALIBRATION Instructions
1. Refer to Figure 4-1 and loosen the two (2) captive screws securing the cover on the
Electronics Module of the MXG-461 Control Valve.
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CHAPTER 4 – ADJUSTMENT
CONTROL VALVE CALIBRATION Instructions
COVER
SCREWS (2)
HAND-WHEEL
Figure 4-1. Control Valve Electronics Module – Top View
2. Remove the Electronics Module cover from the Valve to access the internal components
shown in Figure 4-2
HAND-WHEEL
ON
1
2
3
AUTOSTROKE
BUTTON
DIP SWITCHES
LED
Figure 4-2. Control Valve with Electronics Module Cover Removed
NOTE:
When external 120/240 VAC power is properly connected to the ECS/SP Control Box, 24
VAC power is supplied to the MXG-461 Control Valve when the Control Box POWER switch
is set to the ON position. The POWER switch is located on the right side of the Control Box.
3. Ensure that all three (3) DIP switches shown in Figure 4-2 are in the OFF (Down) position
as shown.
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CHAPTER 4 – ADJUSTMENT
CONTROL VALVE CALIBRATION Instructions
4. Set the ECS/SP Control Box POWER switch to the ON position to apply 24 VAC power to
the Control Valve Actuator (pins 1 (G0) and 2 (G). Ensure the Valve is in the AUTO
position, the LED indicator will light green continuously indicating that Valve operation is
normal (no faults).
5. Using a pin or paper clip, depress the auto-stroke button in the opening of the terminal
housing (Figure 4-2). This will initiate calibration of the Control Valve.
6. During actuator calibration, the LED indicator (Figure 4-2) will flash green for approximately
10 seconds. The Control Valve will be briefly closed and fully opened.
7. Upon successful completion of the Valve calibration process, the LED indicator will stop
flashing and remain ON continuously green.
8. The two-color (Red/Green) indicator is useful in determining the operating status of the
Control Valve. Refer to Table 4-1 for descriptions of the possible LED status displays which
may be encountered.
TABLE 4-1. Control Valve MXG-461 LED Status Indicators
LED Display
Status
On continuously
Description
Automatic Mode (normal, no faults)
- Mechanically set to MANUAL
LED green
Flashing
- Mechanically set to OFF
- Currently in Auto-Calibrate Mode
- General fault
On continuously
LED red
- Microprocessor fault
Flashing
LED
- General calibration fault
Off
- Faulty 24 VAC supply (Too low)
- No 24 VAC supply
- Electronics Module fault
9. Turn off power to the Control Valve by setting the ECS/SP Control Box POWER switch to
the OFF position.
10. Replace and secure the Electronics Module cover by tightening the two captive screws.
WARNING!
MANUAL CONTROL OPERATION OF THE 3-WAY VALVE DISABLES THE OVERTEMPERATURE & POWER LOSS SAFETY SHUTDOWN FEATURES OF THE SYSTEM.
MANUAL OPERATION IS ONLY USED FOR PROBLEM DIAGNOSIS.
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CHAPTER 4 – ADJUSTMENT
4.2.2 MANUAL CONTROL OF 3-WAY VALVE – REMOVABLE HANDWHEEL TO
HAMPER TAMPERING
If desired, the control path (A-to-AB) of the Control Valve, (Siemens, MXG-461) can be opened
manually up to 95% of full-stroke. Refer to Figure 4-3 and proceed as follows:
MANUAL CONTROL OF 3-WAY VALVE Instructions
1. .Remove the water heater from service prior to using the manual operating mode.
2. Press the handwheel inward and rotate it clockwise to the MANUAL position. This will
disable the 0 to 10 VDC control signal from the ECS/SP Temperature Controller. The Valve
can now be mechanically rotated. The temperature control system is now disabled. Be
sure to return to the AUTO mode prior to returning the system to heating service use (see
step 4).
3. To disable automatic control of the Valve, press the handwheel inward and rotate it
counterclockwise to the OFF position. This will close the Valve.
4. To set the Valve for automatic (AUTO) operation, rotate the handwheel to the AUTO
position. The handwheel will pop up when in the AUTO position, thereby allowing it to be
controlled by the ECS/SP Temperature Controller.
Push down
to rotate
CCW
OFF
AUTO
MANUAL
Push down
to rotate
CW
Figure 4-3. Control Valve Auto, Manual and Off Positions
The SmartPlate Electronic Control System (ECS/SP) is preset at the setpoint temperature
specified on the Sales Order. The over-temperature alarm limit is normally set 20°F above the
specified setpoint. If no setpoint or over-temperature alarm limit is specified, the ECS/SP will be
set to the Factory Default values of 140°F (setpoint) and 160°F (over-temperature alarm limit). If
changes are required, the setpoint and over-temperature alarm limits can be easily changed.
This is accomplished using the controls provided on the Temperature Controller and the OverTemperature Switch contained in the Control Box shown in Figure 4-4. These items can be
viewed through the window on the front door of the Control Box. To access these controls and
adjust the setpoint or over-temperature alarm limit, open the hinged Control Box door. Proceed
as indicated in sections 4.2.3 or 4.2.4 to adjust the required parameters:
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CHAPTER 4 – ADJUSTMENT
OVER TEMPERATURE
SWITCH
TEMPERATURE
CONTROLLER
BOILER WATER
TEMPERATURE
INDICATORS
Figure 4-4. Control Box – Front View
NOTE:
When the Power Switch on the Control Box is set to the ON position, it also energizes the
internal 24 VAC Transformer in the Control Box. This in turn provides 24 VAC power to the
Control Valve Actuator, provided that the water temperature at the heater outlet is below the
high temperature limit setting.
4.2.3 SETPOINT TEMPERATURE ADJUSTMENT
The setpoint temperature is adjusted using the controls and displays provided on the
Temperature Controller (Eurotherm 2408). These controls and displays are illustrated and
described in Figure 4-5 and Table 4-2. If necessary, setpoint temperature adjustment is
accomplished as follows:
SETPOINT TEMPERATURE ADJUSTMENT Instructions
1. With the Control Box door open, set the ON/OFF POWER switch on the right side to the ON
position. The Temperature Controller will initiate a self-test for approximately 3 seconds.
Following the self-test, the top display will show the current outlet water temperature of the
unit and the lower display will show the current setpoint temperature stored in memory
(default = 140°F).
2. Ensure that the Temperature Controller is set to the AUTO (automatic) mode and the AUTO
indicator is lit. If the MAN indicator is lit, press the AUTO/MAN button to toggle the mode
setting. Indicator OP1 should also be lit.
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CHAPTER 4 – ADJUSTMENT
SETPOINT TEMPERATURE ADJUSTMENT Instructions
3. If the lower display does not show the desired setpoint temperature, press the ▲ or ▼ arrow
button to change the display to the desired value.
4. Two seconds after the ▲ or ▼ arrow button is released, the display will blink to indicate that
the Temperature Controller has accepted and stored the displayed value.
2408
OP 1
OP 2
SP2
REM
AUTO
RUN
HOLD
MAN
Figure 4-5. Temperature Controller
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CHAPTER 4 – ADJUSTMENT
SETPOINT TEMPERATURE ADJUSTMENT Instructions
TABLE 4-2. Temperature Controller Operating Controls, Indicators & Displays
CONTROL or
INDICATOR
MEANING
FUNCTION
OP1
Output 1 Indicator
OP1 lights when a 0 to 10 VDC signal is being
supplied to the ECSSP Valve Actuator
OP2
Output 2 Indicator
Not used for the ECS/SP application
SP2
Setpoint 2
Indicator
Not used for the ECS/SP application
REM
AUTO
MAN
RUN
HOLD
(a)
(b)
(c)
(d)
OMM-0069_0G
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Remote Setpoint
Indicator
REM lights when the ECS/SP is set up to be
controlled by a Remote (Modbus) signal.
REM will also flash when Modbus communication
is active.
Auto/Manual Button
and Indicators
When button is pressed, the Controller is toggled
between the automatic (AUTO) and manual (MAN)
modes. When first set to manual the valve will
close and show zero percentage (0 %) on the
display.
• AUTO lights when in the automatic mode.
(Setpoint temperature setting appears in lower
display)
• MAN lights when in the manual mode.
(Valve percent open appears in lower display)
Run/Hold Button
and Indicators
Not used for ECS/SP application
Page Button
Press Page button to select a new list of
parameters
Scroll Button
Press Scroll button to select a new parameter in a
list
Down Button
Press to decrease the value shown in the lower
display
Up Button
Press to increase the value shown in the lower
display
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CHAPTER 4 – ADJUSTMENT
4.2.4 OVER-TEMPERATURE ALARM LIMIT ADJUSTMENT
The over-temperature alarm limit setting is adjusted using the controls and display on the OverTemperature Switch. The alarm limit is normally set 20°F above the specified setpoint. The
controls and display are illustrated and described in Figure 4-6 and Table 4-3. If necessary,
over-temperature alarm limit adjustment is accomplished as follows:
REPOSITIONING ECS/SP CONTROL BOX Instructions
1. With the Control Box door open, set the ON/OFF POWER switch on the right side to the
ON position.
2. Press the SET button on the Over-Temperature Switch. SP will appear in the display.
3. Press the SET button again. The current over-temperature limit value stored in memory will
be displayed. (default = 20°F above setpoint specified on Sales Order, or 160°F if no
setpoint is specified).
4. If the display does not show the desired over-temperature alarm setting, press the ▲ or ▼
arrow button to change the display to the desired temperature setting.
5. Once the desired over-temperature alarm setting is displayed, press the SET button to
store the setting in memory.
6. To calibrate the offset (P1), press and hold the SET button for 8 seconds on the OverTemperature Switch. Access code value 0 is shown in the display. The switch comes from
the factory with the code set at 0. AERCO recommends that you do not change this code.
7. Press the SET button again to enter the code. The first parameter label (SP) will appear in
the display.
8. Using the ▲ and ▼ arrow keys, select parameter P1.
9. Press SET to view the value stored in memory.
10. If the desired value is not displayed, modify the setting using the ▲ and ▼ arrow keys. The
value can be changed from -10° to +10° offset. Press SET to enter the value and exit to the
text parameter.
11. To exit the programming mode, press the SET and ▼ buttons simultaneously, or simply
wait one minute and the display will automatically exit the programming mode.
12. Once the programming mode has been exited, the display will show the unit’s current
outlet water temperature.
Figure 4-6. Over-Temperature Switch
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CHAPTER 4 – ADJUSTMENT
REPOSITIONING ECS/SP CONTROL BOX Instructions
TABLE 4-3. Over-Temperature Switch Controls and Indicators
CONTROL or
INDICATOR
LED Display
RST
SET
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MEANING
FUNCTION
TEMP status
Displays current water temperature or
setpoint.
RESET Button
Resets the unit after an alarm condition.
UP Button
Increases the displayed temperature.
DOWN Button
Decreases the displayed temperature.
SET Button
Used to access and store parameters in the
unit.
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CHAPTER 4 – ADJUSTMENT
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CHAPTER 5 – OPERATION
CHAPTER 5. OPERATION
5.1 INTRODUCTION
This chapter provides the pre-operational checks, initial start-up and operating procedures for
SmartPlate Water Heaters.
WARNING!
FLUIDS MUST BE GRADUALLY INTRODUCED TO THE UNIT. FAILURE TO DO SO CAN
CAUSE DAMAGE TO HEAT EXCHANGER PLATES. WHEN UNIT IS EMPTY OR COLD,
DO NOT ADMIT HOT FLUID TO THE UNIT SUDDENLY. WHEN UNIT IS HOT, DO NOT
SHOCK WITH COLD FLUID.
CAUTION!
Do NOT operate equipment exceeding design conditions as specified on the nameplate.
SmartPlate Water Heaters must never be subjected to pressure greater than the maximum
differential pressure specified on the nameplate.
Sudden rises in pressure may cause leakage or damage to plates or gaskets of double-wall
models and damage single-wall heat exchangers.
5.2 PRE-OPERATIONAL CHECKS & PROCEDURES
All SmartPlate Water Heater installation procedures provided in Chapter 2 must be fully
completed prior to performing Pre-Operational checks. In addition, the following items should be
checked:
PRE-OPERATIONAL CHECKS & PROCEDURES Instructions
1. Ensure that external single-phase AC power at 120 VAC/60 Hz or 240 VAC/50 Hz is
properly connected to the ECS/SP Control Box.
2. Verify that the ECS/SP Temperature Controller setpoint and Over-Temperature Switch
alarm limit have been properly set using the procedures in Chapter 4 - Adjustment.
3. Open the isolation valve in the unit’ cold water inlet line (see Figure 1-1).
4. The air vent, located in the top of the mixing box, allows air to escape during the fill
process (a hissing sound may be heard). If a hissing sound is not heard through the air
vent, close the air vent cap and then open it 2 full turns counterclockwise. Do Not remove
the air vent cap.
5. On 150 PSI units, when the hissing sound from the air vent stops, carefully open the Relief
Valve to vent any remaining air, and then close the Relief Valve when the heater is full.
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CHAPTER 5 – OPERATION
5.3 INITIAL START-UP
In order to prevent a possible over-temperature condition during initial start-up, AERCO
recommends that the following steps be performed in the order specified:
INITIAL START-UP Instructions
1. With the ECS/SP Control Box door open, set the POWER switch on the right side of the
box to the ON position. This will provide power to the complete ECS and MXG-461 Control
Valve. When power is initially applied, the ECS/SP Temperature Controller automatically
performs a self-test sequence for approximately three seconds. Proceed immediately to
the next step.
2. Upon completion of the self-test, the Temperature Controller will show the present water
heater outlet temperature in the upper display and the setpoint temperature in the lower
display.
3. Press the AUTO/MAN button on the front panel of the Temperature Controller (Figure 4-5)
and toggle the display to the MAN (Manual) mode. The MAN indicator will light when the
Manual mode is selected.
4. When in the Manual mode, the upper display will continue to show the current outlet water
temperature of the heater. The lower display will show the position of the MXG-461 Control
Valve Actuator in %. When the Manual mode is initially selected, the lower display will
show 0%, indicating that the Control Valve is fully closed.
5. Open the stop valve in the building recirculation system, if employed.
6. Open the isolation valve in the hot water outlet line. Connect a hose to the field-piped
“Hose Connection” (see Piping Diagrams in Appendix C) or open several hot water fixtures
in the building to ensure water flow through the heater.
7. Slowly open the isolation valves in the boiler water inlet and boiler water outlet connections
of the heater.
8. Using the ▲ arrow button, set the MXG-461 Control Valve to the 10% position and monitor
the outlet water temperature of the heater.
9. Next, continue to increase the valve “open” position in 5% increments until the water
temperature starts to increase at a moderate rate.
10. When the outlet water temperature has increased to within 20°F of the desired setpoint,
press the AUTO/MAN button and toggle the Temperature Controller to the AUTO mode.
The AUTO indicator will light and the MAN indicator will go off. When in the AUTO mode
the upper display will continue to show the outlet water temperature of the heater. The
lower display will show the selected setpoint temperature.
11. When in the AUTO mode, the ECS will stabilize at the selected setpoint temperature (see
Chapter 3). Once stabilized, the ECS/SP is set for unattended operation with no further
operator intervention.
12. Check the boiler water differential pressure gauge (Figure 1-1) to ensure that the indicator
dial is in the green area. If the dial moves to the red or yellow area, refer to Chapter 8
Corrective Maintenance.
13. Close the hose connection or hot water fixtures opened in step 6.
14. During start-up of Double-Wall models, there may be some evidence of leakage prior to the
plates and gaskets reaching their working temperature. If leakage continues, check to
ensure that dimension "A" in Figure 5-1 is correct within ±1% of the value shown on the
channel plate assembly instructions. (Refer to Chapter 8, section 8.7.1 for details).
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CHAPTER 5 – OPERATION
5.4 CHECKING MIXED INLET TEMPERATURE
If desired, the water heater mixed inlet temperature can be monitored using the controls and
displays on the Temperature Controller. This is accomplished as follows:
CHECKING MIXED INLET TEMPERATURE Instructions
1. Press the Page (
) button and select iP.
2. Next, press the Scroll (
) button and scroll to Li.2.
3. When Li.2 is shown in the upper display, the lower display will show the water heater
mixed inlet temperature. The temperature will be displayed for several seconds and then
the Controller will revert to the default displays (outlet water temperature and setpoint).
Figure 5-1. Double-Wall Heat Exchanger Only
5.5 SHUTTING DOWN THE SYSTEM
To shut down the Water Heater for a short period of time, simply turn OFF power and close the
isolation valves as described in steps 1 and 2 below. However, if the unit will be shut down for
an extended period of time, it will be necessary to drain the unit using the appropriate steps
listed below for the type of heat exchanger used (single-wall or double-wall). Proceed as
follows:
SHUTTING DOWN THE SYSTEM Instructions
1. Turn the POWER switch on the side of the ECS/SP Control Box to OFF.
2. Close all four of the Isolation Ball Valves (Figure 8-1).
3. Connect a drain hose to the Strainer on the Boiler Water side of the piping assembly
(Figure 5-2). Open the valve on the Strainer and drain the boiler water from the unit. It will
be necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe
during draining.
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CHAPTER 5 – OPERATION
SHUTTING DOWN THE SYSTEM Instructions
4. Next, connect a hose to the Drain Valve on the DHW Side of the piping assembly. Open
the Relief Valve to allow air into the pipe during draining.
5. Open the Drain Valve to drain the domestic water from the unit.
6. After the boiler water and domestic water have been drained from the unit, close the Relief
Valve opened in step 4 and tighten the Victaulic coupling loosened in step 3.
CAUTION!
Step 7 applies ONLY to SmartPlate Double-Wall models. Skip this step for all Single-Wall
models.
7. For SmartPlate Double-Wall Water Heater models, it is also advisable to separate and
clean the plates using the procedures in Chapter 8, section 8.6.2. Leave the double-wall
heat exchanger in an un-tightened or slightly tightened condition. Cover the heat
exchanger with dark plastic to protect it from welding light and dirt (rubber gaskets are
sensitive to welding light). Do not store organic solvents or acids in the room. Avoid heat
or ultraviolet light.
RELIEF VALVE
ISOLATION VALVE
AIR VENT
DOMESTIC WATER
STRAINER
BOILER WATER
STRAINER
DRAIN VALVE
Figure 5-2. Typical SmartPlate Piping
8. To place the Water Heater back in service, fill the unit and perform the pre-operational
checks and start-up procedures described in sections 5.2 and 5.3.
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CHAPTER 6 – SCHEDULED MAINTENANCE
CHAPTER 6. SCHEDULED MAINTENANCE
6.1 INTRODUCTION
SmartPlate Water Heaters require regular routine maintenance to keep the unit operating at
optimum efficiency. AERCO recommends that the tasks listed in Table 6-1 – Scheduled
Maintenance Action, be performed at the periodic intervals specified. Table 6-1 consists of three
columns arranged as follows:
• Interval Column. The Interval column contains alphabetical symbols which list all of the
recommended scheduled maintenance tasks contained in this chapter. The following
interval symbols shall be used in the order of increasing intervals: W (Weekly), Q
(Quarterly), S (Semi-Annually), A (annually) and P (periodic).
• Maintenance Action Column. This column lists the required maintenance action which
corresponds to the interval symbol in the previous column.
• Reference Column. This column lists the section number containing the required
procedure.
TABLE 6-1. Scheduled Maintenance Actions
Interval
Maintenance Task
Reference
W
Check Boiler Water Differential Pressure Gauge.
6.2
W
Double-Wall Only: Check plate packs for
leakage
6.3
Q
Every 3 months, check the operation of the
Over-Temp Switch in the ECS/SP Control Box
6.4
Q, S
After the first 3 months, check the operation of
the Control Valve in the Boiler Water piping.
Then, check operation every 6 months.
6.6
S
Every 6 months, check the Strainers on both the
Boiler Water and Domestic Water Piping.
6.5
A
Once each year, check the Temperature
Sensors
6.7
A
Once each year, check the operation of the
Recirculation Pump
6.8
P
Periodic cleaning of the heat exchanger may be
necessary, depending on conditions and
settings.
6.9
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CHAPTER 6 – SCHEDULED MAINTENANCE
6.2 BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK
Once each week check the Differential Pressure Gauge on the unit’s Boiler Water Inlet as
follows:
BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK Instructions
1. Refer to Figure 6-1 and locate the Differential Pressure Gauge.
2. Check to ensure that the Gauge reading is in the Green area on the dial.
3. If the Gauge is reading in the Red area of the dial, attach a hose to the blow-down valve at
the base of the Strainer. Cycle the blow-down valve open and closed 6 times.
4. If the Gauge still reads in the Red area on the dial, you may have too much boiler water
flow through the unit, or the strainer may be clogged. If the strainer has just been cleaned,
try reducing the flow rate. Refer to Chapter 8 – Corrective Maintenance to repair or replace
the Differential Pressure Gauge.
5. If the Gauge reading is in the Green area for 3 consecutive weeks, this maintenance task
can be performed monthly, instead of weekly.
ECS
CONTROL
BOX
FEED FWD
TEMP SENSOR
CONTROL
VALVE
MXG-461
INTAKE
MIXING BOX
DOMESTIC WATER
INLET STRAINER
BOILER WATER
DIFFERENTIAL
PRESSURE GAUGE
BOILER
WATER INLET
STRAINER
DHW DUAL OUTLET
TEMP SENSOR
DRAIN VALVE
RECIRCULATION PUMP
Figure 6-1. Location of Components for Scheduled Maintenance
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CHAPTER 6 – SCHEDULED MAINTENANCE
6.3 PLATE PACK LEAKAGE CHECKS (DOUBLE-WALL MODELS
ONLY)
For SmartPlate Double-Wall Water Heater models, check the Plate Pack for leaks as follows:
PLATE PACK LEAKAGE CHECKS Instructions
1. Remove the splash guard to access the Plate Pack (see Figure 5-1).
2. Check for leakage between the Plate Pack and Frame [see Figure 6-2 (A)].
a) If there is evidence of leakage, use a felt-tip marker to mark the area where the
leakage appears to be coming from.
b) Refer to Chapter 8, sections 8.7 and 8.8 to correct the cause of the leakage.
3. Check for leakage between plates to the outside [see Figure 6-2 (B)]
a) If there is evidence of leakage, mark the area with a felt tip marker on the two plates
next to the leakage.
b) Refer to Chapter 8, section 8.7 and 8.8 to correct the cause of the leakage.
4. If there is no evidence of leakage, replace the splash guard on the Plate Pack and return
the unit to service use.
(A) LEAKAGE BETWEEN
PLATE PACK & FRAME
(B) LEAKAGE BETWEEN
PLATES TO OUTSIDE
Figure 6-2. Double-Wall Heat Exchanger Leakage Checks - Splash Guard
Removed
6.4 OVER-TEMP SWITCH CHECK
Once every 3 months, check the Over-Temp Switch located in the ECS/SP Control Box as
follows:
OVER-TEMP SWITCH CHECK Instructions
1. Refer to Chapter 4, section 4.2.4 and lower the Over-Temp setting to approximately 5°F
below the present setpoint temperature shown in the lower display of the Temperature
Controller.
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CHAPTER 6 – SCHEDULED MAINTENANCE
OVER-TEMP SWITCH CHECK Instructions
2. Verify that an Over-Temp Alarm is generated and the following events occur:
a) The Control Valve (Siemens MXG-461) closes.
b) The Over-Temp Switch generates an audible alarm.
3. Following successful completion of the Over-Temp alarm check, return the Over Temp
Switch setting to its original setting (20°F above the unit’s setpoint).
6.5 STRAINER INSPECTION AND CLEANING
Every 6 months, check and clean the Strainers in both the Boiler Water and Domestic Water
piping of the unit. Perform the following steps for each Strainer:
STRAINER INSPECTION AND CLEANING Instructions
1. Attach a hose to the blow-down valve at the base of the Strainer. Cycle the blow-down
valve open and closed 6 times.
2. If the Strainer cannot be cleared using the procedure described above, refer to Chapter 8 –
Corrective Maintenance, section 8.12.
6.6 CONTROL VALVE OPERATIONAL CHECK
Refer to Chapter 4, section 4.2 and recalibrate the Control Valve. Also, check the LED indicator
to ensure the Valve is functioning correctly.
NOTE:
To avoid repeated draining of the Water Heater, perform the annual scheduled maintenance
checks specified in section 6.9 at the same time.
6.7 TEMPERATURE SENSOR CHECKS
SmartPlate Water Heaters contain a Feed-Forward Temperature Sensor in the Mixing Box and
a Dual Temperature Sensor in the DHW Outlet Port. Once each year, these Sensors should be
checked to ensure there is no scale build-up.
TEMPERATURE SENSOR CHECKS Instructions
1. Turn the POWER switch on the side of the ECS/SP Control Box to OFF to disconnect AC
power from the unit.
2. Close the Inlet and Outlet Isolation Valves on the Boiler Water and DHW lines of the unit.
3. Connect a hose to the Drain Valve and run it to a convenient floor drain. Open the Drain
Valve near the DHW Outlet to drain the water from the pipes and heat exchanger.
4. Disconnect and remove the Single Feed-Forward Sensor from the Mixing Box and the Dual
Outlet Temperature Sensor from the DHW Outlet Port (Figure 6-1).
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CHAPTER 6 – SCHEDULED MAINTENANCE
TEMPERATURE SENSOR CHECKS Instructions
5. Inspect the Sensors for evidence of scale build-up on the stainless-steel sleeve of the
Sensors. If necessary, clean the Sensors using a wire brush.
6. In addition to the immersion Sensors mentioned above, check the attachment of the
surface-mount Sensors on the Boiler Water Inlet and Outlet piping.
6.8 RECIRCULATION PUMP CHECK
The Recirculation Pump is installed between the DHW inlet and outlet pipes beneath the Mixing
Box.
WARNING!
PRIOR TO PERFORMING THE FOLLOWING STEPS, ENSURE THAT THE POWER
SWITCH ON THE SIDE ECS/SP CONTROL BOX IS OFF AND THE HEATER HAS BEEN
DRAINED AS SPECIFIED IN THE PREVIOUS SECTION.
PLATE PACK LEAKAGE CHECKS Instructions
1. Make sure that the POWER switch on the Control Box is OFF.
2. Ensure that the Drain Valve is open and the water has been drained from the unit.
3. Locate the Recirculation Pump and disconnect the flanges from the piping.
4. Carefully slide the Pump out and rotate to inspect. DO NOT pull on the electrical conduit
when removing Pump.
5. If there is evidence of scale build-up, disconnect the conduit and electrical power
connections from the Pump. Service or replace the Pump as necessary.
6. If there is no evidence of scale build-up on the Recirculation Pump, reinstall the Pump and
reconnect the flanges.
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CHAPTER 6 – SCHEDULED MAINTENANCE
6.9 PERIODIC CLEANING OF HEAT EXCHANGER
It may be necessary to de-scale the heat exchanger periodically, depending on water conditions
and temperature settings. Section 8.2 describes the descaling process for the Water Heater’s
heat exchanger.
The frequency of cleaning can be determined locally based on the performance of the heater
and/or prior experience with similar equipment. Generally, the cleaning requirements will follow
the trends shown in Table 6-2:
TABLE 6-2. Heat Exchanger Cleaning Guidelines
Projected Cleaning Frequency
Operating Conditions
Rarely
Annually
Semi-Annually
Monthly
Boiler Water Inlet Temp
<150ºF
~170ºF
~200ºF
~220ºF
Domestic Water Setpoint
<130ºF
140 - 160ºF
160 - 180ºF
Calcium Hardness Level
<20 mg/L
20 - 40 mg/L
40 - 60 mg/L
>80 mg/L
If calcium hardness level, boiler water inlet temperature, and domestic water setpoint fall under
different cleaning intervals in Table 6-2, the heat exchanger may be cleaned between those
periods, starting with the most frequent interval. During the next few cleaning intervals observe
how much scale is removed to determine if less frequent intervals can be followed.
Example:
BW inlet temperature = 180ºF
Domestic water setpoint = 140ºF
Calcium Hardness level = 40 mg/L
Heat exchanger Cleaning Frequency: Start out with semi-annually (every six months) schedule
(180ºF BW falls under semi-annually and the DHW setpoint and calcium hardness level fall
under annually). Observe the next few cleanings on how much scale is removed to determine if
an annual (yearly) cleaning frequency is more appropriate.
NOTE:
Refer to section 8.2 and 8.5 for heat exchanger maintenance procedure.
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CHAPTER 7 – TROUBLESHOOTING
CHAPTER 7. TROUBLESHOOTING
7.1 INTRODUCTION
The troubleshooting procedures provided in this chapter are intended to aid service and
maintenance personnel in isolating the most probable cause of a fault in a packaged SmartPlate
Water Heater. Prior to performing the troubleshooting steps and procedures in this chapter,
perform the following preliminary checks:
TROUBLESHOOTING Instructions
1. Ensure that external AC power at 120 VAC or 220 VAC is being supplied to the SmartPlate
ECS/SP Control Box.
2. Check to ensure that all Electronic Control System (ECS/SP) electrical cable connections
are secure.
3. Ensure that the Electronic Control Valve (MXG-461) is securely connected to the cable
plug from the ECS/SP Control Box.
4. Check the fuse in the ECS/SP Control Box that supplies power the Recirculation Pump an
Electronic Control Valve.
5. Ensure that both the upstream and downstream shut-off valves are fully open.
6. Check the circuit breaker on the 24 VAC Transformer inside the ECS/SP Control Box.
NOTE:
In addition to the procedures contained in this chapter, also check the troubleshooting
sections of the Boiler Operation and Maintenance Manual being used with the Water Heater
and any other ancillary equipment manuals associated with the installation.
7.2 TROUBLESHOOTING PROCEDURES
Troubleshooting procedures for SmartPlate Water Heaters are provided in Tables 7-1, 7-2 and
7-3. Table 7-1 provides troubleshooting procedures for the MXG-461 Control Valve and Piping
Assembly components. Table 7-2 provides troubleshooting procedures for the ECS/SP
Electronic Control System. Table 7-3 provides a troubleshooting guide to aid in resolving
temperature control issues which may be encountered during Water Heater operation. Also,
when troubleshooting ECS/SP faults related to the Temperature Controller (Eurotherm, model
2408), refer to Appendix A for additional information concerning process fault and diagnostic
alarms.
When a fault occurs in a SmartPlate Water Heater, proceed as follows to isolate and correct the
fault:
TROUBLESHOOTING PROCEDURES Instructions
1. Refer to the FAULT INDICATION column in the following tables and locate the fault that
best describes the existing conditions.
2. Proceed to the PROBABLE CAUSE column and, if more than one item is listed, start with
the first item shown for the fault condition.
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CHAPTER 7 – TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES Instructions
3. Perform the corresponding checks and procedures listed in the CORRECTIVE ACTION
column for the first PROBABLE CAUSE.
4. Continue checking each additional PROBABLE CAUSE for the existing fault until the fault
has been corrected.
5. Refer to the applicable procedures in Chapter 8 – Corrective Maintenance if component
removal and/or replacement is required.
TABLE 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly
No.
T1
T2
Fault Indication
Probable Cause
System not operating.
Control Valve is closed
and outlet water temp. is
far below setpoint.
System over-heats by
more than 10°F above the
desired setpoint.
Outlet temp is below
Over-Temp limit setting
1. No power supplied to
Control Valve
1. Remove Valve Electronics Module cover
(Figure 4-1) and verify that 24 VAC power
is present at pin 1 of terminal strip.
Restore power if necessary. Proceed to
Table 7-2 and check Over-Temp Switch
and 24 VAC Transformer circuit breaker to
ensure they have not tripped.
2. Control signal not being
supplied from Temp.
Controller.
2. Verify presence of a 0 to 10 VDC control
signal at pin 5 of terminal strip. If control
signal is not present, troubleshoot
ECS/SP per Table 7-2.
1. Control Valve is in the
MANUAL mode.
1. Ensure Control Valve is set to the AUTO
mode.
2. Control Valve not fully
closed.
2. Check the 0 – 10 VDC control signal
being supplied to Actuator. If signal is
greater than 0 VDC when heater outlet
temperature is 10°F (or more) above the
desired setpoint, proceed to next item in
list.
3. Temp. Controller not
set properly or
defective.
3. Refer to Chapter 4 – Adjustments and
check current setting of Temp. Controller.
Readjust if necessary. If adjustment does
not clear fault, proceed to Table 7-2 and
continue.
4. Control Valve not
calibrated correctly
4. Refer to Chapter 4, section 4.2 and autocalibrate the valve by pressing the button
(Figure 4-2). If Valve stem does not fully
stroke up and down, contact AERCO for
assistance.
5. Heat exchanger scaled
on DHW side.
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Corrective Action
5. Clean and de-scale heat exchanger.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly
No.
T3
T3
Fault Indication
Probable Cause
System outlet water
temperature is below
desired setpoint
(Continued)
1. Boiler water inlet
strainer is clogged
1. Check the strainer differential pressure
gauge. If gauge is in the “RED” area,
blow down the strainer and re-check until
gauge is in the “GREEN” area.
2. Boiler water temp is too
low.
2. Check the Boiler Water IN temperature
on the Control Box display indicator.
Verify that the temperature is equal to the
boiler water temperature to which the unit
was sized.
3. Boiler water flow rate
too low.
3. Check system pump and measure flow
rate to the Water Heater with an ultrasonic meter.
4. Temp controller is not
properly set.
4. Refer to Chapter 4, section 4.2.3 and
check the current setpoint temperature
setting on the Temp Controller. If the
setting is below the desired setpoint,
readjust as necessary.
5. Control Valve is not
opening properly.
5. Remove Electronics module cover on
Valve and view the Status LEDs. See
Table 7-1A to check the Valve status.
6. Heat exchanger is
fouled on boiler water
side.
6. Proceed as follows:
a. Close isolation valves
b. Clean strainers
7. Clean or de-scale heat exchanger.
7. Heat exchanger is
scaled on boiler water
side
T4
Wide variation in Water
Heater outlet temperature
during wide variations in
flow
Corrective Action
8. Heat exchanger is too
small for load.
8. Reduce load or resize heat exchanger.
1. ECS/SP mixed water
temperature sensor is
not functioning properly
1. Refer to Table 7-2 and check the
operation of the mixed water temperature
sensor.
2. DHW internal
Recirculation Pump is
not functioning properly
2. Proceed as follows:
a. Check the fuse on the side of the
ECS Control Box and replace if
blown.
b. Check input power to Recirculation
Pump.
c. Check the temperature of the copper
tube above the Pump. It should be the
same as the outlet DHW temperature.
If cold, repair or replace pump as
required.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly
No.
T5
Fault Indication
Probable Cause
Rapid fluctuations in
heater outlet temperature
which do not follow load
changes
1. Temp. Controller is not
functioning properly.
Corrective Action
1. Refer to Table 7-2 and troubleshoot the
Temp. Controller.
TABLE 7-1A. Control Valve MXG-461 LED Status Indicators
LED Display
LED green
LED red
LED
Page 50 of 134
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Status
Description
On continuously
Automatic Mode (normal, no faults)
Flashing
- Mechanically set to MANUAL
- Mechanically set to OFF
- Currently in Auto-Calibrate Mode
On continuously
- General fault
- General calibration fault
- Microprocessor fault
Flashing
- Faulty 24 VAC supply (Too low)
Off
- No 24 VAC supply
- Electronics Module fault
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP)
No.
T1
Fault Indication
System not operating.
All displays are blank.
Probable Cause
1. External 120 VAC
power disconnected.
2. Defective fuse on side
of Control Box.
3. Defective ON/OFF
switch on Control Box.
T2
T3
T4
T5
Temperature Controller is
ON, but Temperature
Indicators are blank
1. Circuit breaker tripped
2. Defective 24 VAC
transformer in Control
Box
Water Heater outlet temp.
consistently above
Setpoint by 10°F or more.
However, temperature is
below Over-Temp. limit
setting.
1. Temp. Controller is
not properly set.
Over-Temp Alarm occurs
repeatedly.
NOTE
Audible alarms will be
generated if Outlet Temp
Sensor is open. Erroneous
temperature readings will
be displayed if Sensor is
shorted.
1. Over-Temp Switch not
properly set.
Boiler Water Inlet audible
alarm activated
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2. Faulty Temp. Sensor
(thermocouple) is
connected to Temp.
Controller.
2. Open or shorted
Outlet Temp. Sensor
(thermocouple)
connected to OverTemp. Switch.
3. Over-Temp Switch is
defective.
1. Boiler water temp. is
greater than 250°F.
2. Alarm setting is not
correct.
3. Indicator is defective.
Corrective Action
1. Ensure external circuit breaker is ON.
Check for 120 or 240 VAC power across
TB-2 terminal leads 101 (Line) and 102
(Neutral).
2. Check the fuse on the right side of the
Control box. Replace if blown.
3. Set ON/OFF POWER switch to the ON
(Up) position and verify that the switch
indicator lights. Also:
a. Verify that 120 VAC is present across TB2 terminal leads 101 (Line) and 102
(Neutral).
b. If voltage not present, replace ON/OFF
POWER switch.
1. Reset the circuit breaker on the 24 VAC
step-down transformer.
2. Check the 120 VAC or 240 VAC power on
TB-2 (see Appendix B). Verify that 24 VAC
is present across the Blue and Brown
wires terminated on TB-1. If 24 VAC is not
present, replace the 24 VAC transformer
in the Control Box.
1. Refer to Chapter 4 – Adjustment and
check current setting of Temp. Controller.
Readjust if necessary.
2. Verify Outlet Temp Sensor is securely
connected to cable plug. Replace the Dual
Sensor if necessary
1. Refer to Chapter 4 and check the current
setting of the ECS Over-Temp. Switch.
Readjust if necessary.
2. Check thermocouple connections between
Sensor connector plug and TB-1 terminal
leads 111 (+) and 112 (-). If connections
are secure, replace Dual Temp Sensor.
3. Replace Over-Temp Switch.
1. Correct the boiler water temperature
supply to the Water Heater.
2. Refer to section 4.2.4 to reset the alarm
limit to 220°F
3. Refer to Chapter 8, section 8.15 for
replacement instructions.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP)
No.
T6
Fault Indication
Over-Temp. Alarm
condition cannot be
cleared.
Over-Temp Switch
displays erroneous
temperature readings
T7
Outlet water temp. far
below Setpoint
Probable Cause
1. Shorted Outlet Temp.
Sensor.
2. Defective Over-Temp.
Switch.
3. 3-Way Control Valve
not closing fully during
no-load conditions.
4. A “No-Flow” condition
caused a gradual
buildup of heat to the
water in vessel.
5. Water Heater
recirculation pump
shut off or failed.
1. Incorrect Temp
Controller setting
2. Defective Temp.
Controller.
3. Heat exchanger
fouled on Boiler Water
side.
4. Defective Control
Valve Actuator
5. Boiler water supply
temp. is too low.
6. Boiler Failure
T8
Wide fluctuations in outlet
water temperature during
large flow changes.
Page 52 of 134
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1. Water Heater
Recirculation Pump
not operating.
2. Boiler water temperature drops below
DHW setpoint during
heavy demand, then
recovers.
3. Boiler water temperature drops below
DHW setpoint but
does not recover until
load is reduced.
4. Boiler water supply
temperature is too
high.
Corrective Action
1. Replace Outlet Temp, Sensor.
2. Replace Over-Temp Switch.
3. Calibrate 3-Way Control Valve per section
4.2.1.
4. Open hot water valve at sink or tub outlet
to see if fault clears. If there is no flow
through heater, go to Probable Cause 5.
5. Check recirculation pump to ensure it is
turned on and functioning properly. Also,
check pump fuse on side of Control Box.
1. Refer to Chapter 4 and check the current
setting of Over-Temp. Switch. Readjust if
necessary.
2. Remove the cover from the Electronics
Module of the Control Valve and verify that
the Temp. Controller is generating a
control signal greater than 0 VDC. If not
replace Temp. Controller.
3. Clean Boiler Water Inlet Strainer.
Clean heat exchanger.
4. Replace Valve Actuator (SEE TABLE 7.1)
5. Increase boiler water temperature.
6. Check operational status of Boiler.
1. Check Control Box fuse and power to
pump.
2. Install Boiler Water Buffer Tank to provide
hot water reservoir for the Water Heater to
draw from during large load swings.
3. The boiler water supply is under-sized.
Add more boilers or reduce DHW usage.
4. Control Valve is not seating properly. See
Chapter 4 and auto-stroke valve.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-2. Troubleshooting – Electronic Control System (ECS/SP)
No.
T9
Fault Indication
Probable Cause
Corrective Action
Temperature control not
within specifications.
Items T1 – T8 check out
OK.
Wide fluctuations in
outlet water temperature
under low flow
conditions.
1. Unexpected system
1. See Table 7-3 for Temperature Control
dynamics.
2. Outlet Temp Sensor
connected to Temp
Controller gives
inconsistent or
intermittent
readings.
3. Mixed Water Temp
Sensor is open,
shorted or gives
inconsistent
readings.
4. Recirculation Pump
Troubleshooting.
2. Replace Outlet Temp Dual Sensor at
the Water Heater outlet port.
3. Replace Mixed Water Temp Sensor.
4. Replace Recirculation Pump
failure.
T10
Wide fluctuations in
outlet water temperature
under low flow
conditions.
1. Outlet Temp Sensor
connected to Temp
Controller gives
inconsistent or
intermittent
readings.
2. Mixed Water Temp
1. Replace Outlet Temp Dual Sensor at
Water Heater outlet port.
2. Replace Mixed Water Temp Sensor.
Sensor is open,
shorted or gives
inconsistent
readings.
3. Recirculation Pump
3. Replace Recirculation Pump
failure.
NOTE:
Refer to the Dynamic Temperature Control Settings specified in Table 7-3A when performing
the Corrective Actions listed in Table 7-3 which follows. Adjustment of Pb, Pb2 and FFPb can
be accomplished from the first menu level on the Eurotherm 2408 Controller. Refer to
Chapter 4, section 4.2 for procedure.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-3. Troubleshooting Guide for Temperature Control Issues
No.
Observation
Probable Cause
Corrective Action
T9-1
Too much valve
oscillations or too wide
outlet temperature
oscillation at low flow
T9-2
Too wide a deviation in Dynamic loop response
outlet temperature when time variation from the
domestic flow changes
engineering development
system. Many factors
contribute to this type of
dynamic system
variation.
Decrease the Proportional value (Pb
and/or Pb2) and/or decrease
FeedForward (FFpb).
Note 1: This may increase
oscillations at low flow.
Note 2: A change in FFpb will cause
the valve to fully open initially and
over temperature may occur. Be
sure the domestic outlet is shut to
prevent scalding.
T9-3
On decrease in flow,
outlet temperature
initially goes up but
then under-shoots
setpoint too much
before coming to
setpoint
Dynamic loop response
time variation from the
engineering development
system. Many factors
contribute to this type of
dynamic system
variation.
Increase Proportional (Pb or Pb2)
first. If that has little or no effect then
increase FeedForward (FFpb.
Note: A change in FFpb will cause
the valve to fully open initially and
over temperature may occur. Be
sure the domestic outlet is shut to
prevent scalding.
T9-4
On increase in flow,
outlet temperature
initially goes down but
then overshoots setpoint
too much before coming
to setpoint
Dynamic loop response
time variation from the
engineering development
system. Many factors
contribute to this type of
dynamic system
variation.
Increase Proportional (Pb or Pb2)
first. If that has little or no effect then
increase FeedForward (FFpb).
Note: A change in FFpb will cause
the valve to fully open initially and
over temperature may occur. Be
sure the domestic outlet is closed to
prevent scalding.
T9-5
After a change in
domestic flow, outlet
temperature remains too
far from setpoint for too
long
Dynamic loop response
time variation from the
engineering development
system. Many factors
contribute to this type of
dynamic system
variation.
Decrease Proportional and/or
decrease Integral (I1 and/or I2).
Note: This may increase outlet
temperature oscillations at lower
flows.
T9-6
Over-temperature alarm
or water temperature
more than 10°F above
the setpoint after a long
period of non-usage.
Control valve not closing
fully, allowing some hot
boiler water to enter the
heat exchanger without
demand
Recalibrate the valve stroke using
the auto-calibration method
described in Chapter 4, section
4.2.1.
Page 54 of 134
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Low flow condition may
be unsteady or at a
critical value for the
control system.
Increase the Proportional value (Pb
and/or Pb2). Note: This may cause
wider temperature deviation with
change in domestic flow.
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CHAPTER 7 – TROUBLESHOOTING
TABLE 7-3A. Dynamic Temperature Control Settings for SmartPlate Single- Water Heaters
Unit Size
(SP or
SPDW)
Feed
Boiler Water
Proportional
*Gain Schedule
Proportional
Forward
*Integral 2 *Derivative 2
*Integral 1 * Derivative 1
Temp
Band 1
Cutoff Temp
Band 2
Parameter
(D1)
(I2)
(D2)
(I1)
(Tbw)
(Pb2)
(Pb)
(Gsch)
(FFPb)
<=180 °F
-40
40
20
5
30
20
5
145
SP23
<=200 °F
-40
50
20
5
40
20
5
145
SPDW23
<=220 °F
-50
50
20
5
40
20
5
145
<=250 °F
-50
60
20
5
50
20
5
145
<=180 °F
-50
50
20
5
40
20
5
145
SP33
<=200 °F
-50
60
20
5
50
20
5
145
SPDW32
<=220 °F
-60
60
20
5
50
20
5
145
<=250 °F
-60
70
20
5
60
20
5
145
<=180 °F
-60
60
20
5
50
20
5
145
SP45
<=200 °F
-60
70
20
5
60
20
5
145
SPDW42
<=220 °F
-70
70
20
5
60
20
5
145
<=250 °F
-70
80
20
5
70
20
5
145
<=180 °F
-80
60
20
5
55
20
5
145
SP69
<=200 °F
-80
70
20
5
65
20
5
145
SPDW61
<=220 °F
-95
70
20
5
65
20
5
145
<=250 °F
-95
80
20
5
75
20
5
145
<=180 °F
-100
60
20
5
60
20
5
145
SP150
<=200 °F
-100
70
20
5
70
20
5
145
SPDW113
<=220 °F
-120
70
20
5
70
20
5
145
<=250 °F
-120
80
20
5
80
20
5
145
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CHAPTER 8 – CORRECTIVE MAINTENANCE
CHAPTER 8. CORRECTIVE MAINTENANCE
8.1 INTRODUCTION
This chapter provides the procedures to correct and repair faults detected during operation or
isolated during troubleshooting of SmartPlate Water Heaters. The procedures in this chapter are
divided into four sections as follows:
• Section I - SmartPlate Single-Wall Water Heater models: Single-Wall heat exchangers do
not include any serviceable assemblies and components. Therefore, the procedures in
this section are limited to heat exchanger cleaning (de-scaling) removal and replacement.
• Section II – Double-Wall Heat Exchanger Corrective Maintenance. This section provides
cleaning and corrective maintenance procedures for serviceable internal components of
the double-wall heat exchanger.
• Section III – SmartPlate Wetted Components - All models. This section provides
corrective maintenance for major assemblies and components which come in contact with
boiler water or domestic hot water during Water Heater operation. These assemblies and
components are used on all SmartPlate models (Single-Wall and Double-Wall).
• Section IV – SmartPlate Electronic Control System (ECS/SP). This section provides
removal and replacement procedures for the internally mounted assemblies and
components contained in the ECS/SP Control Box.
SECTION I
SMARTPLATE SINGLE-WALL HEAT EXCHANGER MODELS
8.2 SINGLE WALL HEAT EXCHANGER MAINTENANCE
Since the Single-Wall heat exchanger does not contain any serviceable items, the procedures in
this section are limited to cleaning (de-scaling) and removal/replacement. These procedures are
provided in sections 8.3 and 8.4 which follow.
8.3 HEAT EXCHANGER CLEANING & DE-SCALING
Heat exchanger cleaning and de-scaling is accomplished "in-place" using the following
procedure:
NOTE:
The "in-place" cleaning and de-scaling procedure described below can also be used for
Double-Wall heat exchangers (Section II) which are not clogged with hardened scale
deposits.
HEAT EXCHANGER CLEANING Instructions
1. Set the POWER Switch on the ECS/SP Control Box to the OFF position to stop the
Recirculation Pump.
2. Close all four Water Heater Isolation Ball Valves (Figure 8-1).
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CHAPTER 8 – CORRECTIVE MAINTENANCE
HEAT EXCHANGER CLEANING Instructions
3. Connect a hose to the Drain Valve near the DHW Outlet.
4. Remove the 1” NPT Air Vent from the top of the Mixing Box.
RELIEF VALVE
ECS
CONTROL
BOX
ISOLATION
BALL VALVES
AIR VENT
VALVE
BOILER
WATER
INLET
INTAKE MIXING
BOX
COLD
WATER
INLET
ISOLATION
BALL
VALVES
BOILER
WATER INLET
DHW
OUTLET
HEAT EXCHANGER
(BEHIND SUPPORT ASSY)
DRAIN
VALVE
RECIRCULATION
PUMP
Figure 8-1. SmartPlate Isolation Valve Locations
5. Refer to Table 8-1 to determine the approximate amount of water to drain from the heat
exchanger.
IMPORTANT!
The De-Scaling Solution used must be compatible with wetted materials of stainless steel,
copper, brass and bronze. AERCO recommends the AERCO HydroSkrub de-scaler.
Contact your AERCO representative for more information.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
HEAT EXCHANGER CLEANING Instructions
TABLE 8-1. AERCO HydroSkrub Solution Required For De-Scaling Heat
Exchanger
Heat Exchanger
Volume (gallons)
SmartPlate Model
HydroSkrub Required
(Gallons)
Single-Wall Heat Exchangers
SP23
1.7
0.9
SP33
2.4
1.2
SP45
3.4
1.7
SP69
5.2
2.6
SP150
11.3
5.7
SPDW23
2.0
1.0
SPDW32
2.8
1.4
SPDW42
3.7
1.9
SPDW61
6.0
3.0
SPDW113
10.2
5.1
Double-Wall Heat Exchangers
6. Drain at least half of the heat exchanger volume shown in the above Table for the
SmartPlate model being de-scaled.
7. While making sure that the Drain Valve is tightly closed, pour the correct amount of
HydroSkrub into the Air Vent opening in the Mixing Box.
8. Add water as needed until the Mixing Box is full.
9. Replace the 1” NPT Air Vent.
10. Set the Control Box POWER Switch to the ON position and ensure that the Recirculation
Pump is operating.
11. Allow the HydroSkrub/Water solution to circulate through the heat exchanger and piping for
1 to 3 hours, depending on the amount of scale deposit that is inside the heat exchanger.
Since the amount of scaling will be hard to estimate, it should be based on the time in
service and water hardness.
12. Upon completion of the previous step, turn the POWER Switch on the Control Box to OFF
to stop the Recirculation Pump.
13. Remove the 1” NPT Air Vent and open the unit’s Drain Valve.
14. Flush with fresh water for at least 3 minutes.
15. Next, close the Drain Valve and fill with fresh water.
16. Apply new thermal sealant (Loctite 565 or equiv. NSF61 approved) to the threads of the 1”
NPT Air Vent and install it in the Mixing Box.
17. Open the four Isolation Ball Valves on the unit.
18. Turn the Control Box POWER Switch to ON to restart the unit and place it back in service
using the start-up instructions in Chapter 5.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
8.4 SINGLE-WALL HEAT EXCHANGER REPLACEMENT
The heat exchanger used in each SmartPlate Single-Wall model is removed and replaced using
the following basic procedure:
SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
1. Turn the POWER switch on the side of the ECS/SP Control Box to OFF.
2. Close all four of the Isolation Ball Valves (Figure 8-1).
3. Connect a hose to the Strainer on the Boiler Water side of the piping assembly (Figure 82). Open the valve on the Strainer and drain the boiler water from the unit. It will be
necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe
during draining.
4. Next, connect a hose the Drain Valve on the DHW Side of the piping assembly and then
open the Relief Valve to allow air into the pipe during draining.
RELIEF VALVE
ISOLATION VALVE
AIR VENT
VALVE
DOMESTIC WATER
STRAINER
BOILER WATER
STRAINER
DRAIN VALVE
Figure 8-2. Draining the SmartPlate Water Heater
5. After the boiler water and domestic water have been drained from the unit, proceed to step
6 to remove the installed heat exchanger.
6. Close the Relief Valve opened in step 4.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
7. Using a ratchet wrench with an extension and a 3/4” deep socket, loosen, but do not
remove, the four (4) Victaulic couplings (Figure 8-3). Two (2) couplings are located on the
Domestic Water Side (Figure 8-3) and two (2) are located on the Boiler Water Side.
8. At the rear of the Water Heater, place a wooden block, or other suitable support, under the
Brazed Plate heat exchanger to provide support while removing the mounting bolts in the
following steps.
9. For SmartPlate model SP150, remove the two support brackets at the rear of the heat
exchanger.
10. Use a ratchet with a 9/16” socket through the hand holes in the sides of the heat
exchanger mounting bracket and a 9/16” wrench on the outside to remove the four (4)
bolts, washers and nuts secure the heat exchanger to the Support Frame.
WARNING!
THE SINGLE-WALL HEAT EXCHANGER CAN WEIGH UP TO 300 POUNDS,
DEPENDING ON THE SMARTPLATE MODEL. THEREFORE, USE EXTREME CARE
WHEN REMOVING IT FROM THE MOUNTING BRACKET.
11. Carefully pull the heat exchanger away from the mounting bracket. It may be necessary to
jiggle it to separate the grooved pipes from the Victaulic couplings.
12. To replace the heat exchanger with a new assembly, simply reverse the previous steps.
Support the replacement heat exchanger and ensure it is properly aligned when installing
the bolts squarely in the holes of the Support Frame. Tighten the bolts and all four Victaulic
couplings.
VICTAULIC
COUPLINGS
(4)
Figure 8-3. Domestic Water Side – Partial View
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CHAPTER 8 – CORRECTIVE MAINTENANCE
SINGLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
SUPPORT
FRAME
A
A
MOUNTING
ATTACHMENT
4 PLACES
(VIEW “A - A”)
HAND HOLE
CUTOUT
(BOTH SIDES)
HEAT
EXCHANGER
(HX)
REAR VIEW
HEAT
EXCHANGER
SUPPORT
FRAME
HEX HEAD
BOLT
HEX
NUT
FLAT
WASHER
HEAT EXCHANGER
MOUNTING TAB
(4 PLACES)
VIEW “A - A”
Figure 8-4. Heat Exchanger Mounting Details
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SECTION II SMARTPLATE DOUBLE-WALL HEAT EXCHANGER MODELS
8.5 DOUBLE-WALL HEAT EXCHANGER MAINTENANCE
The maintenance procedures for SmartPlate Double-Wall models (Figure 8-5) include
procedures for:
• Cleaning (in-place or by disassembly)
• Opening/closing heat exchanger and removal/replacement of plate
• Replacement of gaskets
• Heat exchanger replacement
The procedures listed above are provided in sections 8.6 through 8.9.
PRESSURE RELIEF VALVE
ISOLATION
BALL VALVES
HEAT EXCHANGER
INTAKE
MIXING BOX
BOILER
WATER
INLET
ISOLATION
BALL
VALVES
COLD
WATER
INLET
BOILER WATER INLET
DHW OUTLET
DRAIN
VALVE
RECIRCULATION PUMP
Figure 8-5. SmartPlate Double-Wall (Model SPDW61 Shown)
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8.6 DOUBLE-WALL HEAT EXCHANGER CLEANING
The Double-Wall heat exchanger can be cleaned in-place by circulating cleaning agents through
the unit, or by disassembly.
8.6.1 HEAT EXCHANGER CLEANING AND DE-SCALING (IN-PLACE METHOD)
If the heat exchanger is not encrusted with hardened scale deposits, it can normally be cleaned
by circulating cleaning agents (AERCO HydroSkrub or equivalent) through the assembly.
Perform the procedures specified in Section I, section 8.3 of this chapter.
8.6.2 HEAT EXCHANGER CLEANING BY DISASSEMBLY
If the heat exchanger is encrusted with hardened scale or sediment, the Water Heater will have
to be drained and the Double-Wall heat exchanger opened as follows:
HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions
1. Set the POWER Switch on the ECS/SP Control Box to the OFF position to stop the
Recirculation Pump.
2. Close all four Water Heater Isolation Ball Valves (see Figure 8-5, above).
3. Connect a hose to the Strainer on the Boiler Water side of the piping assembly (Figure 86).
CONTROL VALVE
BOILER WATER
STRAINER
RELIEF VALVE
DRAIN VALVE
DOMESTIC WATER
STRAINER
Figure 8-6. Draining the SmartPlate Double-Wall Water Heater
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HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions
4. Open the valve on the Strainer and drain the boiler water from the unit. It will be necessary
to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe during
draining.
5. Next, connect a hose to the Drain Valve on the DHW Side of the piping assembly. Open
the Relief Valve to allow air into the pipe during draining
6. Open the Drain Valve to drain the domestic water from the unit.
7. After the boiler water and domestic water have been drained from the unit, close the Relief
Valve opened in step 5 and tighten the Victaulic coupling loosened in step 4.
8. To prevent possible damage, ensure that all of the following precautions are observed:
• Under no circumstances should hydrochloric acid be used with STAINLESS STEEL
PLATES.
• Water of more than 300 ppm chlorine may not be used in the preparation of cleaning
solutions.
• It is very important that carrying bars and support columns in aluminum are protected
against chemicals.
• Do NOT use brushes with carbon steel bristles or steel wool. A fiber type brush is
recommended. As a last resort, use a brush of similar material to the thermal plate.
Be careful not to scratch the plates or damage gaskets if they are to be reused.
• After brushing, rinse each plate with water.
• For better sealing, wipe all gaskets dry.
CAUTION!
THE FOLLOWING SOLVENTS SHOULD NOT BE USED IN CONTACT WITH GASKETS:
• Ketones (e.g. Acetone, Methyletylketone, Methylisobutylketone
• Esters (e.g. Ethyl acetate, Butyl acetate)
• Halogenated hydrocarbons (e.g. Chlorothene, Carbon Tetrachloride, Freons)
• Aromatics (e.g. Benzene, Toluene)
WARNING!
CARE MUST BE EXERCISED WHEN HANDLING CERTAIN FLUIDS. FOLLOW
MANUFACTURER'S INSTRUCTIONS. USE EYE AND SKIN PROTECTION. WEAR A
RESPIRATOR WHEN REQUIRED.
9. To open the Double-Wall heat exchanger and remove plates, refer to the procedures in
sections 8.7.1 and 8.7.2.
10. Table 8-2 lists the recommended cleaning methods for the type of heat exchanger fouling
encountered.
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HEAT EXCHANGER CLEANING BY DISASSEMBLY Instructions
TABLE 8-2. Recommended Cleaning Procedures
TYPE OF
FOULING
Incrustation
Scaling
(Lime
Deposits)
CAUSE
CLEANING METHOD
Calcium
1. Soft brush & running
Carbonate,
water
NOTE: Avoid Gasket
Calcium
Damage
Sulphate,
Silicates
2. High pressure hose.
3. Chemical cleaning
CHEMICAL
CLEANING
Nitric Acid
Sulfamic Acid
Citric Acid
NOTES
Maximum
concentration:
4%
Phosphoric Acid
Complex
Agents
(EDTA, NTA)
Max. Temp:
140°F
Sodium Polyphosphates
Sediment
Corrosion
Products
Metal
Oxides
1. Soft brush & running
water
NOTE: Avoid Gasket
Damage
Silt
2. High pressure hose.
Alumina
3. Chemical cleaning
4. Addition of surfactants
can improve cleaning
effect
Nitric Acid
Sulfamic Acid
Citric Acid
Maximum
concentration:
8%
Phosphoric Acid
Complex
Agents
(EDTA, NTA)
Max. Temp:
140°F
Sodium Polyphosphates
11. Upon completion of the cleaning process, reinstall all plates and gaskets and close the
heat exchanger using the procedure in section 8.7.3.
8.7 DOUBLE-WALL HEAT EXCHANGER OPENING AND CLOSING
The following sections provide the instructions to open the Double-Wall heat exchanger,
remove/replace channel plates and close the heat exchanger.
WARNING!
THE UNIT MUST BE SHUT DOWN AND DRAINED PRIOR TO PERFORMING THE
PROCEDURES DESCRIBED IN SECTIONS 8.7.1 THROUGH 8.7.3 WHICH FOLLOW .
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8.7.1 OPENING HEAT EXCHANGER
Perform the following steps to shut down, drain and open the Double-Wall Heat exchanger:
OPENING HEAT EXCHANGER Instructions
1. Ensure that the Water Heater has been shut down and drained using the procedures in
section 8.6.1, steps 1 through 7.
2. If the Heat exchanger is hot (over 100°F), allow it to cool sufficiently before proceeding.
3. Remove the protective splash guard cover from the Double-Wall heat exchanger.
4. Inspect the sliding surfaces of the upper and lower support bars (Figure 8-7) and wipe
clean.
Figure 8-7. Double-Wall Heat Exchanger
5. Brush the threads of the tightening bolts clean using a steel wire brush.
6. Lubricate the threads of the tightening bolts with a thin layer of grease, such as
molybdenum disulfide or equivalent.
7. Remove the protective splash guard to provide access to the plate pack assembly (see
Figure 8-8, below).
8. Mark the plate pack assembly with a diagonal line as shown in Figure 8-8 or number the
plates in sequence.
IMPORTANT!
Measurement of tightening dimensions is critical to reassembly. Carefully measure and
record before loosening the tightening bolts.
9. Measure and record the lateral dimension "A" between the frame plate and pressure plate
as shown in Figure 8-8.
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OPENING HEAT EXCHANGER Instructions
Figure 8-8. Measurement of Plate Pack Dimension "A" – Splash Guard Removed
10. If the unit is a model SPDW113, remove the U-bolt securing the heat exchanger support
bar (see section 8.9 and Figure 8-18). If the unit is a model SPDW61, remove the U-bolt
and "L" bracket at the rear of the heat exchanger mount to permit the pressure plate to be
moved.
11. Opening of the heat exchanger is now possible by loosening diagonally-opposite pairs
(Figure 8-9). Opening must be carried out evenly so that the pressure plate is not out-ofparallel with the frame plate by more than 3/8" (2 turns per bolt) in the horizontal plane and
1" in the vertical plane.
5
3
1
5
4
2
3
9
7
6
5
8
10
4
2
1
3
6
1
4
2
6
SINGLE WALL
DOUBLE WALL
DOUBLE WALL 200 PSI
Figure 8-9. Required Bolt Loosening Pattern
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OPENING HEAT EXCHANGER Instructions
12. With the tightening bolts removed, the pressure plate can be slid back (Figure 8-10) and
channel heat transfer plates can also be slid back for inspection or cleaning.
Figure 8-10. Heat Exchanger with Pressure Plate Slid Back
8.7.2 REMOVAL AND INSERTION OF PLATES
To remove and insert the channel (heat transfer plates), proceed as follows:
WARNING!
TO AVOID HAND INJURIES WHEN HANDLING PLATES, USE PROTECTIVE GLOVES.
NOTE:
If defective gaskets are detected during removal of plates, they must be replaced using the
procedures in section 8.8.
REMOVAL AND INSERTION OF PLATES Instructions
1. Push the pressure plate back away from the plate pack.
2. When removing the plates, number or stack them in sequence.
3. Hang the plates with their backs towards the pressure plate (the side without gasket),
unless otherwise specified.
4. Always consult the plate pack numbering or markings to insure the proper plate sequence.
5. Install plates one at a time and push them towards the frame plate (Figure 8-11).
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REMOVAL AND INSERTION OF PLATES Instructions
Figure 8-11. Insertion of Plates in Heat Exchanger
8.7.3 CLOSING HEAT EXCHANGER
Closing the heat exchanger is accomplished as follows:
CLOSING HEAT EXCHANGER Instructions
1. Check that all the sealing surfaces (i.e. surfaces in contact with the heat transfer medium)
are clean.
2. Check that connection fittings are in position and are in good condition.
3. Clean and lubricate the sliding surfaces of the upper and lower support bars.
4. If the plates are correctly assembled, the edges form a “honey comb" pattern as shown
below.
.
Figure 8-12. Heat Exchanger Plates
5. Slide the pressure plate forward and press the plates together (Figure 8-13). If the plate
pack was previously marked on the outside (Figure 8-8), check to ensure that the plate
arrangement agrees with the markings.
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CLOSING HEAT EXCHANGER Instructions
Figure 8-13. Closing the Heat Exchanger
6. Brush the threads of the bolts clean, using a steel wire brush.
7. Lubricate the threads with a thin layer of grease.
8. Place the bolts in position and tighten the plate pack using diagonally opposite bolt pairs,
(the opposite of the opening procedure in section 8.7.1, step 10) until the plate pack length
is reduced to ±1% of dimension "A" in the channel plate assembly instructions supplied
with unit. During tightening. The pressure plate must not be out-of-parallel to the frame
plate by more than 3/8" in the horizontal plane and 1" in the vertical plane. See Figure 814.
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CLOSING HEAT EXCHANGER Instructions
Figure 8-14. Tightening Plate Pack Bolts
9. Check the plate pack length ("A") during closing in at least four locations close to the bolts
being used.
10. Place the remaining bolts in position and tighten them.
11. Next, insert the corner bolts and tighten, maintaining dimension "A" of drawing- To avoid
damaging the channel plate corners, it is important that the corner bolts are not used for
closing the heat exchanger.
12. The nominal plate pack length "A" can be exceeded in some cases. The tightening can be
stopped at "A" + 2% and pressure tested.
NOTE:
When a pneumatic tightening device is used, it should be set at the maximum tightening
torque of 550 ft-lbs for DW for 3/4" bolts.
Dimension "A" must, however, must s t i l l be measured during tightening.
When the bolts are tightened by hand using a wrench, the tightening moment is estimated.
IF DIMENSION "A" IS NOT REACHED WITH APPLICATION OF MAXIMUM
TIGHTENING TORQUE:
• Check the number of plates and dimension "A".
• Check that all nuts are running freely. If not, clean and lubricate or replace.
• Fit all bolts and tighten alternately.
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CLOSING HEAT EXCHANGER Instructions
13. Perform the following final checks:
a) Inspect the washers.
b) When fully tightened. The bolts should all be equally tensioned
c) The difference between the plate pack lengths measured at adjacent bolts should
not exceed: 0.079 inches.
d) The plate pack length at all bolts must not differ more than 1%.
e) If the unit does not seal fully, it can be tightened to give dimension "A" - 1%.
However, the maximum tightening torque must not be exceeded.
14. Install the protective splash guard.
8.8 DOUBLE-WALL HEAT EXCHANGER GASKET REPLACEMENT
All sizes of the Double-Wall heat exchanger utilize "Clip-Type" glueless gaskets. The following
sections provide the instructions to replace gaskets on channel plates and on the end plate (first
plate against frame plate)
Refer to the appropriate procedures in sections 8.7.1 and 8.7.2 to open the heat exchanger and
remove the required plates. Following gasket replacement, close the heat exchanger using the
procedures in section 8.7.3.
8.8.1 REPLACING GASKETS ON CHANNEL PLATES
Replacing Gaskets on Channel Plates Instructions
1. Peel old gasket off of plate making sure all parts of gasket are removed.
2. Wipe gasket groove clean making certain that no foreign material remains that would
cause gasket to seat unevenly.
3. Clip-type glueless gaskets (Figure 8-15) are attached to the plate using the prongs which
slip under the edge of the plate to hold the gasket securely in the gasket groove. The
prongs are situated at regular intervals around the perimeter of the plate.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
Replacing Gaskets on Channel Plates Instructions
Figure 8-15. Clip-Type Glueless Gasket Installation
4. When the plates of the heat exchanger are assembled and tightened, the gasket provides
a tight seal around the plate.
5. Before closing the plate pack, check to ensure that the gasket prongs are in the correct
position.
8.8.2 REPLACING GASKETS ON END PLATE (FIRST PLATE AGAINST FRAME
PLATE)
Replacing Gaskets on End Plate Instructions
1. Obtain two standard plate gaskets (P/N 81128 for DW units).
2. Cut the gaskets as indicated in Figure 8-16, below.
3. Attach gasket to plate as indicated in Figure 8-17, below.
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Replacing Gaskets on End Plate Instructions
Figure 8-16. Cutting Gaskets For End Plate
Figure 8-17. End Plate with Gasket Installed
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CHAPTER 8 – CORRECTIVE MAINTENANCE
8.9 DOUBLE-WALL HEAT EXCHANGER REPLACEMENT
The heat exchanger used in each SmartPlate Double-Wall model is removed and replaced
using the following basic procedure:
DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
1. Turn OFF the POWER Switch on the side of the ECS/SP Control Box.
2. Slowly close all four of the Isolation Ball Valves (Figure 8-5).
3. Connect a hose to the Strainer on the Boiler Water side of the piping assembly (Figure 86). Open the valve on the Strainer and drain the boiler water from the unit. It will be
necessary to loosen a Victaulic coupling by the heat exchanger to allow air into the pipe
during draining.
4. Next, connect a hose the Drain Valve on the DHW Side of the piping assembly. Open the
Relief Valve to allow air into the pipe during draining.
5. After the boiler water and domestic water have been drained from the unit, close the Relief
Valve opened in step 4 and proceed to step 6 to remove the installed heat exchanger.
6. Using a ratchet wrench with an extension and a 3/4” deep socket, remove, the four (4)
Victaulic couplings (Figure 8-19). Two (2) couplings are located on the Domestic Water
Side and two (2) are located on the Boiler Water Side.
7. Next, remove the two (2) bolts securing the front "L" brackets on the heat exchanger to the
heat exchanger mount (Figure 8-18).
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DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
HEAT
EXCHANGER
VICTAULIC
COUPLINGS
(4 PLACES)
“L” BRACKETS
(2 PLACES)
HEAT EXCHANGER
MOUNT
Figure 8-18. Domestic Water Side - Double-Wall Partial View
8. For larger SmartPlate units (models SPDW61, SPDW113) remove the U-bolt securing the
heat exchanger support bar (not shown above) and, if there is an “L” bracket, remove it.
9. For smaller SmartPlate units (models SPDW23, SPDW32 SPDW42) use a 3/4" socket
wrench to remove the horizontal hex head screw and washer shown in Figure 8-19. Also,
remove the hex nut securing the "L" bracket to the heat exchanger mount.
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DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
SEE
DETAIL “A”
DETAIL “A”
Figure 8-19. Double-Wall Heat Exchanger Mounting Details - Rear
WARNING!
DEPENDING ON THE SMARTPLATE MODEL, THE DOUBLE-WALL HEAT EXCHANGER
WEIGHS BETWEEN 350 AND 800 POUNDS. YOU MUST THEREFORE USE EXTREME
CARE WHEN REMOVING THE HEAT EXCHANGER FROM ITS MOUNT. USE A STRAP
SUITABLE FOR SUCH WEIGHT TO LIFT AND REMOVE THE HEAT EXCHANGER
FROM ITS MOUNT.
10. Insert a lifting strap through the four (4) holes in the frame plate and pressure plate, as
shown in Figure 8-20, to safely lift the heat exchanger off its mount. You may also wrap the
lifting strap around the threaded bolts instead of through the holes in the Pressure Plate.
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DOUBLE-WALL HEAT EXCHANGER REPLACEMENT Instructions
LIFTING STRAP
THREADED BOLTS
PRESSURE PLATE
PRESSURE PLATE
Figure 8-20. Heat Exchanger Lifting Strap
To replace the heat exchanger with a new assembly, simply reverse the previous steps.
Support the replacement heat exchanger using a suitable lifting strap (shown in Figure 8-20,
above) and lower into position on the heat exchanger mount. Ensure it is properly aligned with
the Piping Assembly and heat exchanger mount. Ensure that the bolts on all four Victaulic
couplings or flange connectors are securely tightened. For model SPDW61 or SPDW113, reinstall the rear support bracket and verify that adjustable legs are properly positioned.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
SECTION III SMARTPLATE WETTED COMPONENTS - ALL MODELS
8.10 CONTROL VALVE ELECTRONIC MODULE REPLACEMENT AND
VALVE REMOVAL
The only replaceable item on the 3-Way Control Valve (Siemens MXG-461) is the Electronics
Module located at the top of the Valve (Figure 8-21). The procedures for removing this Module
or replacing the complete Control Valve are provided in sections 8.10.1 and 8.10.2, below.
ELECTRONICS
MODULE
HANDWHEEL
VALVE
BODY
Figure 8-21. Control Valve (Siemens MXG-461)
8.10.1 ELECTRONICS MODULE REPLACEMENT
To remove and replace the Control Valve Electronics Module:
ELECTRONICS MODULE REPLACEMENT Instructions
1. Turn OFF the POWER Switch on the side of the ECS/SP Control Box.
2. Loosen the two (2) captive screws securing the Electronics Module cover (Figure 8-22).
3. Remove the Module cover to access the wiring terminals (Figure 8-23). Disconnect and tag
the power and control signal wire leads from the Module terminals.
4. Using a 3 mm Allen key, loosen the three (3) socket head screws securing the blue
Electronics Module to the black Valve Head. These socket head screws are recessed and
the Allen key must be inserted into the holes shown in Figure 8-23 to engage the screw
heads.
5. Pull straight up to unplug the Module from the Valve Head.
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ELECTRONICS MODULE REPLACEMENT Instructions
6. Install the replacement Electronics Module on the Valve Head and secure it with the three
socket head screws removed in step 4.
7. Refer to Figure 8-23 and ensure that the three (3) DIP switches on the replacement
Module are all in the OFF (down) position.
8. Reconnect the power and control signal wire leads to the Electronics Module.
9. Turn ON the POWER Switch on the side of the ECS/SP Control Box.
10. Recalibrate the Control Valve using the procedures in Chapter 4, section 4.2.1.
11. Replace the cover on the Electronics Module after the Valve has been successfully
calibrated.
12. Return the unit to service.
COVER
SCREWS (2)
HAND-WHEEL
Figure 8-22. Control Valve Electronics Module Cover – Top View
WIRING
TERMINAL
CONNECTIONS
DIP SWITCHES (3)
(SET TO OFF POSITION)
MODULE
MOUNTING
HOLES
Figure 8-23. Electronics Module with Cover Removed
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8.10.2 CONTROL VALVE REPLACEMENT
To remove the complete Control Valve Assembly from the SmartPlate Water Heater:
CONTROL VALVE REPLACEMENT Instructions
1. Turn the POWER Switch on the side of the ECS/SP Control Box to OFF.
2. Loosen the two (2) captive screws securing the Electronics Module cover (Figure 8-22).
3. Remove the Module cover to access the wiring terminals (Figure 8-23). Disconnect and tag
the power and control signal wire leads from the Module terminals.
4. Connect a hose to the Blow-Down Valve/Drain on the lower pipe Strainer (Figure 8-24).
5. Close both Isolation Ball Valves on the Boiler Water pipe side of the unit.
6. Open the Blow-Down/Drain Valve on the Strainer.
CONTROL
VALVE
HEAT EXCHANGER
DIFFERENTIAL
PRESSURE GAUGE
ISOLATION
BALL VALVES
BLOW-DOWN VALVE
(Connect Drain Hose Here)
Figure 8-24. Boiler Water Piping Components
7. While supporting the Control Valve from above, loosen all three (3) unions securing the
Valve.
8. Inspect the union seals and seats.
9. Install the replacement Control Valve and ensure that the seals are not pinched. Handtighten the unions.
CAUTION!
Two (2) pipe wrenches MUST be used when tightening the Valve unions to prevent pipe
rotation and avoid leaks
10. Using two (2) pipe wrenches, secure the Control Valve unions to the Boiler Water piping.
11. Refer to Figure 8-23 and ensure that the three (3) DIP switches on the Electronics Module
of the replacement Valve are all in the OFF (down) position.
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CONTROL VALVE REPLACEMENT Instructions
12. Reconnect the power and control signal wire leads to the Electronics Module of the
replacement Control Valve.
13. Turn ON the POWER Switch on the side of the ECS/SP Control Box.
14. Recalibrate the Control Valve using the procedures in Chapter 4, section 4.2.1.
15. Replace the cover on the Electronics Module after the Valve has been successfully
calibrated.
16. Return the unit to service.
8.11 RECIRCULATION PUMP REPLACEMENT
The SmartPlate Recirculation Pump is a wet rotor, continuous-duty Pump which has an
expected service life of 5 years. The Pump is located in the DHW side of the piping assembly
(Figure 8-25) to continuously circulate domestic water through the unit, even when there is no
DHW demand. If the Pump fails, it must be replaced to ensure proper Water Heater operation.
Replacement is accomplished as follows:
RECIRCULATION PUMP REPLACEMENT Instructions
1. Turn OFF the external power circuit breaker to the Water Heater and also turn OFF the
POWER Switch on the side of the ECS/SP Control Box.
2. Connect a hose to the DHW Drain Valve (Figure 8-25).
3. Close both Isolation Ball Valves on the DHW piping.
4. Open the DHW Drain Valve.
5. Open the Relief Valve to allow air to enter the piping while draining.
6. Disconnect the power leads from the Pump Head.
7. Remove the bolts on the Pump flanges and slide the Pump out from between the flanges.
8. When installing the replacement Recirculation Pump, ensure that the seals are in place
and are not pinched.
9. Reinstall the flange bolts and reconnect the power leads to the Pump Head.
10. Close the Relief Valve opened in step 5.
11. Close the DHW Drain Valve that was opened in step 4.
12. Connect a hose to the Blow-Down Valve on the Inlet Strainer. Open this Blow-Down Valve
on the Strainer to vent air during the filling process.
13. Open the lower Isolation Ball Valve (DHW Outlet).
14. Next, close the Blow-Down Valve on the Inlet Strainer and open the upper Isolation Ball
Valve (DHW Inlet).
15. Reconnect the power leads to replacement Recirculation Pump Head.
16. Turn ON the external circuit breaker and set the POWER Switch on the side of the ECS/SP
Control Box to the ON position to return the unit to service use.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
RECIRCULATION PUMP REPLACEMENT Instructions
RELIEF VALVE
AIR ELIMINATOR (200 PSI SHOWN)
INLET STRAINER
HEAT
EXCHANGER
ISOLATION
BALL VALVES
STRAINER
BLOW-DOWN
VALVE
DHW DRAIN VALVE
RECIRCULATION PUMP
Figure 8-25. Domestic Water Piping Components
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CHAPTER 8 – CORRECTIVE MAINTENANCE
8.12 STRAINERS
All SmartPlate Water Heater models utilize Combination Strainers and Ball Valve on the boiler
side, and a strainer on the DHW side to prevent fouling of the heat exchanger by trapping
foreign material before it enters the unit. In addition, SmartPlate provides a Differential Pressure
Gauge on the Boiler Water Inlet to aid in determining when to blow-down the Strainer. If this
Gauge becomes inoperable, it should be replaced using the following procedure.
NOTE:
If normal maintenance does not clear the Water Heater flow path, it will be necessary to
remove and manually clean the screens in the Boiler Water and DHW piping as follows:
a. Remove Strainer end cap and remove screen.
b. Hose and wash off screen.
c. Reinstall screen and replace Strainer end cap.
DIFFERENTIAL PRESSURE GAUGE REPLACEMENT Instructions
1. Close both Isolation Ball Valves in the Boiler Water piping (Figure 8-24).
2. Connect a hose to the Blow-Down/Drain Valve at the lower Strainer and open it to drain the
piping. It may be necessary to temporarily loosen a union on the Control Valve to allow air
into the piping.
3. Refer to Figure 8-26 and loosen the two compression fitting nuts on the Differential
Pressure Gauge tubes which are inserted into the brass Strainer body.
4. Pull and wiggle the tubes and Gauge and lift the assembly straight upward to remove it
from the Strainer.
5. Next, loosen the nuts on the Gauge body fittings and extract the tubes for use on the
replacement Differential Pressure Gauge.
NOTE:
The tube fittings are pass-thru type fittings that allow the tube to slide through the fitting
without hitting a stop. Prior to installation, make sure that the replacement Gauge has the
same type of fittings.
6. Install the tubes on the replacement Differential Pressure Gauge.
7. Insert the free ends of the tubes into the Strainer body and tighten the compression fittings.
DO NOT over-tighten the compression fittings.
8. Tighten the Control Valve union that was loosened in step 2.
9. Close the Blow-Down Drain Valve and open both Isolation Ball Valves (Figure 8-24).
10. Place the unit back in service and check for leaks. If the Strainer is clean and the flow is
within specification for the SmartPlate Water Heater model, the pointer on the Differential
Pressure Gauge should be in the Green zone on the dial.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
DIFFERENTIAL PRESSURE GAUGE REPLACEMENT Instructions
DIFFERENTIAL
PRESSURE GAUGE
GAUGE BODY
FITTINGS (2 PLCS)
COMPRESSION
FITTINGS (2 PLCS)
ISOLATION
BALL VALVE
STRAINER BODY
BLOW-DOWN VALVE
Figure 8-26. Differential Pressure Gauge/Strainer/Ball Valve Combo – Boiler
Side
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CHAPTER 8 – CORRECTIVE MAINTENANCE
SECTION IV SMARTPLATE ELECTRONIC CONTROL SYSTEM (ECS/SP)
WARNING!
TURN OFF THE CONTROL BOX POWER SWITCH AND DISCONNECT AC POWER
PRIOR TO PERFORMING ANY CORRECTIVE MAINTENANCE PROCEDURES IN THE
FOLLOWING SECTIONS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN
SERIOUS PERSONAL INJURY.
8.13 ECS/SP CONTROL BOX ASSEMBLY AND COMPONENTS
Corrective maintenance for the Control Box and internally-mounted components consist of
removing and replacing the following items:
• Control Box Assembly
• Temperature Controller
• Over-Temperature Switch
• Temperature Indicators
• 24 VAC Step-Down Transformer
The following sections reference figures in previous chapters as well as figures in this chapter.
Refer to the applicable figures as necessary when performing the replacement procedures
which follow.
8.14 CONTROL BOX ASSEMBLY REPLACEMENT
If necessary, the complete ECS/SP Control Box Assembly can be removed and replaced as
follows:
CONTROL BOX ASSEMBLY REPLACEMENT Instructions
1. Loosen the captive screws on the Control Box door and the recessed panel (Figures 2-3,
2-4).
2. Open the swing-down recessed panel. Locate and disconnect the Line, Neutral and
Ground leads connected to Terminal Block TB-2 on the bottom interior surface of the
Control Box chassis (Figure 2-5).
3. Refer to Figures 1-1 and 1-2 and disconnect the Control Box cables from the following
devices:
a) Disconnect Control Valve (Siemens MXG-461) power and signal leads from terminal
strip TB-1.
b) Disconnect the external AC power leads from terminal strip TB-2.
c) Disconnect the Recirculation Pump power leads from terminal strip TB-2.
d) Disconnect the Mixed Inlet Temp cable from the Mixed Inlet Temp Sensor on the top
of the unit’s Mixing Box.
e) Disconnect the Hot Water Outlet Temp cable from the Dual Outlet Temp Sensor at
the unit’s DHW outlet.
f)
Disconnect BOILER TC IN and TC OUT leads (2-pin Molex connectors) connected
to the heating fluid (boiler water) inlet and outlet Temperature Sensors.
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CHAPTER 8 – CORRECTIVE MAINTENANCE
CONTROL BOX ASSEMBLY REPLACEMENT Instructions
4. After all Control Box cables have been disconnected, remove the four mounting screws
securing the bottom of the Control Box to the mounting bracket. Completely remove the
Control Box from the unit.
5. Control Box replacement is accomplished by reversing the previous steps.
8.15 TEMPERATURE CONTROLLER REPLACEMENT
The Temperature Controller is located on the recessed panel behind the Control Box door as
shown in Figure 4-4. Removal and replacement is accomplished as follows:
TEMPERATURE CONTROLLER REPLACEMENT Instructions
1. Switch power off and open the Control Box door to access the Temperature Controller.
2. The Temperature Controller is installed in a sleeve as shown in Figure 8-27. To unplug and
remove the Controller from its sleeve, simply pry the latching ears outward and pull the
Controller out of the panel.
3. To install a replacement Temperature Controller, simply slide it into the front panel sleeve
until the latching ears click into place. Following replacement, switch power on adjust the
setpoint temperature to the required value using the Adjustment procedures in Chapter 4.
4. Close and secure Control Box front door.
TERMINAL COVERS
SLEEVE
RATCHETS
DISPLAY
LABEL
PANEL RETAINING
CLIPS
LATCHING
EARS
PANEL SEALING
GASKET
Figure 8-27. Temperature Controller Installation
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8.16 OVER-TEMPERATURE SWITCH AND TEMPERATURE
INDICATORS
The Over-Temperature Switch and Temperature Indicators are actually identical devices,
however they perform different functions. As the name implies, the Over-Temperature Switch,
performs a switching function and generates an alarm when the preset temperature limit is
exceeded. However, the Temperature Indicators are Indicator-Only devices and are not factory
wired to perform any switching functions. The locations of the Over-Temperature Switch and
Temperature Indicator are shown in Figure 4-4. Removal and replacement for each device are
performed using the following identical steps:
Figure 8-28. Over-Temperature Switch & Temperature Indicator
OVER-TEMPERATURE SWITCH and TEMPERATURE INDICATOR
REPLACEMENT Instructions
1. Open the Control Box door to locate the Switch or Indicator to be replaced.
2. Loosen the captive screw on the recessed panel behind the door. Open the swing-down
panel to access the Switch/Indicator wiring connections and panel retaining clips.
3. Remove the Switch/Indicator rear cover and loosen the terminal wiring connection screws.
Disconnect the wires.
4. To remove the Over-temperature Switch assembly, push in tab of each of two side
retaining clips (Figure 8-29), slide toward rear and remove.
5. Insert the replacement Over-Temperature Switch or Temperature Indicator into the panel
cutout.
6. Slide the removable retaining clip onto the replacement Switch/Indicator from the rear.
Push the retaining clip forward until the Switch/Indicator is firmly secured in the panel
cutout.
7. Reconnect the wiring to the rear of the unit and tighten the terminal screws. Replace the
terminal cover.
To uninstall, push tab to
release clip retainer. Slide
clip back and off. Remove
assembly through front
panel.
Figure 8-29. Removing Over-Temperature Switch Assembly
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CHAPTER 8 – CORRECTIVE MAINTENANCE
OVER-TEMPERATURE SWITCH and TEMPERATURE INDICATOR
REPLACEMENT Instructions
8. If the replaced unit is an Over-Temperature switch, set the desired over-temperature alarm
limit using the adjustment procedures in Chapter 4, section 4.2.4.
9. Following adjustment (if necessary), raise and secure the swing-down panel. Close and
secure the Control Box door.
8.17 24 VAC STEP-DOWN TRANSFORMER REPLACEMENT
The 24 VAC Transformer is mounted on the back interior wall of the Control Box (Figure 8-30,
View D-D). Replacement is accomplished as follows:
STEP-DOWN TRANSFORMER REPLACEMENT Instructions
1. Open the Control Box door and loosen the captive screw on the recessed panel behind the
door.
2. Open the swing-down panel and locate the 24 VAC Transformer on the back interior wall of
the Control Box (Figure 8-30, sheet 2).
3. Disconnect the Transformer wire leads from terminal strips TB-1 and TB-2.
4. Remove the mounting hardware and 24 VAC Transformer from the Control Box.
5. Replacement is accomplished by reversing the previous steps.
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STEP-DOWN TRANSFORMER REPLACEMENT Instructions
Figure 8-30. ECS/SP Control Box Assembly 69096 (Sheet 1 of 2)
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CHAPTER 8 – CORRECTIVE MAINTENANCE
STEP-DOWN TRANSFORMER REPLACEMENT Instructions
OVERTEMP SWITCH
1 2
7 8 9 10 11
TEMPERATURE
CONTROLLER
1A
1B
2
L
N
3
G
3
1 2
7 8 9 10 11
1 2
7 8 9 10 11
OUT
3
3A
IN
3D
V+
V-
BOILER WATER TEMP
FRONT PANEL – VIEWED FROM BACK
VIEW C – C
1
24 VAC
TRANSFORMER
TERMINAL
BLOCK TB-1
7
INTERIOR BACK WALL
VIEW D - D
Figure 8-30. ECS/SP Control Box Assembly 69096 (Sheet 2 of 2)
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CHAPTER 8 – CORRECTIVE MAINTENANCE
STEP-DOWN TRANSFORMER REPLACEMENT Instructions
ECS/SP CONTROL BOX ASSEMBLY 69096 PARTS LIST
Item
Qty.
1
1
65082
TRANSFORMER, X075CBA, 120/240 TO 24 VAC
2
1
64008
TEMPERATURE INDICATOR CONTROLLER
3
2
64056
OVER-TEMP SWITCH/TEMP INDICATOR
4
3
60003
ON/OFF SWITCH
6
1
65087
TERMINAL BLOCK, 12-POSITION (TB-2)
7
1
65008
TERMINAL BLOCK, 20-POSITION (TB-1)
12
1
63047
AC WIRE HARNESS
13
1
63048
CONTROL WIRING HARNESS
15
1
63009-3
EXTERNAL HARNESS
22
5
62003
PLUG
23
1
65094-1
FUSE
30
1
60014
OVER-TEMPERATURE SWITCH
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
APPENDIX A
MODBUS CONTROL AND COMMUNICATION
TEMPERATURE CONTROLLER
(Eurotherm 2408) PROCEDURES
MODBUS COMMUNICATION INFORMATION
&
PROCESS / DIAGNOSTIC ALARM MESSAGES
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
A.1 TEMPERATURE CONTROLLER (EUROTHERM 2408) PROCEDURES
The following sections provide the procedures to add a Modbus Communication board to the
Temperature Controller and change communication addresses.
A.1.1 Adding a Communication Board to the Temperature Controller
Parts Needed:
a. ECS/SP Control Box Assembly, P/N: 69096-TAB]
b. Temperature Indicating Controller, P/N: 64008
c. Communications Board, P/N: 64009-TAB
ADDING A COMMUNICATION BOARD Instructions
1. Turn off power to ECS/SP Control Box Assembly
2. Slide out Temperature Indicating Controller (P/N: 64008) from Control Box Assembly by
gently pushing the indicated latching ears to the side (See Figure A-1).
LATCHING
EARS (2)
Figure A-1
3. Slide Communications Board (P/N 64009-TAB) into Temperature Indicating Controller slot
(COMMS 1). See Figure 2. Make sure to push Communications Board all the way in to
ensure it is firmly seated in its slot.
COMMUNICATIONS
BOARD
Figure A-2
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
ADDING A COMMUNICATION BOARD Instructions
4. Place Temperature Indicating Controller back into Control Box Assembly and power up
unit. The following screen will appear. (See Figure A-3)
Page
Button
Scroll
Button
Up/Down Arrow
Keys
Figure A-3
5. The Controller will report a hardware error as indicated in Figure A-3. Press the ▲(up)
arrow key located on the right side of the Temperature Controller until “8” appears on the
lower half of the screen.
6. Press the page button located on the left side of the Temperature Indicating Controller until
“Exit” appears on the top half of the screen.
7. Press the ▲ / ▼ (up/down) arrow key to choose “yes”.
8. Wait a moment as the screen updates. The hardware error will no longer be displayed.
9. This completes installation of the Communications Board.
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
A.1.2 Changing the Temperature Controller Communication Addresses
NOTE:
Refer to the button map at the bottom of the display, Figure A-4, for all panel navigation
instructions.
Up Arrow
Down Arrow
Scroll
Page
Button Map
Figure A-4
The Temperature Controller address is defaulted to 1 from the factory. To change the MODBUS
address, proceed as follows:
1. Page to the ACCS list and Scroll
down to codE.
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
2. Enter 24 using the Up Arrow. The
number will flash and display PASS.
3. Scroll to Goto (current value is
OPEr) and use the Down Arrow to
enter a value of Full. The entry
confirms by flashing the lower
display momentarily off and then on.
4. Go to the home screen by pressing
the Page and Scroll buttons at the
same time.
5. Page to the cmS list.
6. Scroll to the Addr screen.
7. Use the Up Arrow to select the
desired address number.
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
8. Go to the home screen by pressing
the Page and Scroll buttons at the
same time.
9. Page to the ACCS list and change
the code to anything other than 24.
The codE number you enter will
flash off and then on to 0 to confirm
that access is now set to the OPEr
level and it is safe to return to use.
10. Confirm that the Addr is set properly
by pressing the Page button until the
cmS list is displayed. Scroll to Addr.
If the value is correct you are done;
if not, repeat the steps in this
procedure.
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
A.2 MODBUS COMMUNICATION INFORMATION
NOTE:
The Eurotherm 2400 Controller supports the MODBUS RTU mode of transmission. The
default settings are as follows: 9600 Baud Rate, one start bit, eight data bits, one stop bit, &
no parity bit.
EUROTHERM SERIES 2400 CONTROLLER MODBUS POINTS
MODBUS
Data
Address
Menu
Item
Menu Item
Description
Units & Range
5
w.SP
Setpoint
40-205°F
24
SP 1
Setpoint
40-180°F
1
Top
Value
Outlet Temp
40-205°F
133
LoGH
Peak Temp
40-205°F
135
LoGA
Average
Temp
40-205°F
134
LoGL
Low Temp
40-205°F
AL 1
Over Temp
Alarm
AL 2
(FSH)
Full Scale
High Alarm
13 (set)
74 (status,
0 = safe
1 = alarm)
14 (set)
74 (status,
0 = safe
1= alarm)
Feedback
Sensor
Break
Feedback
Sensor
Temp
Default/Comments
140°F, Address to
read value
140°F, Address to
change value
Same value as front
display
Resets on Power
Loss
Resets on Power
Loss
Resets on Power
Loss
Register
Type
Ref. 1
Comm.
Guide
Read
Only
5-4
Write
5-11
Read
Only
Read
Only
Read
Only
Read
Only
5-3
5-15
5-15
5-15
40-205°F
20°F above setpoint;
Alarm Type 17:
Deviation High
Read
Only
5-7
5-20
205°F
205 ° F
Alarm Type 2: Full
Scale High
Read
Only
5-7
5-20
Read
Only
5-18
Read
Only
5-14
Status:
0: Good
1: Failed
Denotes Feedback
Sensor Failure/Open
Circuit
Sensor input to
controller, same as
display temp.
258
Sbr
289
Li 1
290
Li 2
Feed Forward
Temperature
40-180°F
Sensor input to
controller
Read
Only
5-14
3
OP
Control
Output
Signal
%
Correlates to valve
position
Read
Only
5-4
40-180°F
REFERENCE DOCUMENTS:
1. Eurotherm 2000 Series Communications Handbook, # HA026230
2. Eurotherm 2404/2408 Control Setpoint Programmer Installation and Operation
Handbook, # HA025132
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
A.3 PROCESS & DIAGNOSTIC ALARMS
The Process and Diagnostic Alarms that can appear in the Temperature Controller display are
listed in the following Tables.
PROCESS ALARMS
DISPLAY
MEANING
_FSL*
PV Full Scale Low Alarm.
_FSH*
PV Full Scale High Alarm.
_dEu*
PV Deviation Band Alarm
_dHi*
PV Deviation High Alarm
_dLo*
PV Deviation Low Alarm
DIAGNOSTIC ALARMS
DISPLAY
MEANING
WHAT TO DO`
EE.Er
Electrically Erasable Memory
Error: The value of an
operator, or configuration,
parameter has been
corrupted.
This fault will automatically take you into
Configuration level. Check all of the configuration
parameters before returning to Operator level.
Once in Operator level, check all of the operator
parameters before resuming normal operation. If
the fault persists, or occurs frequently, contact
your supplier
S.br
Sensor Break: Input sensor is
unreliable or the input signal
is out of range.
Check that the sensor is correctly connected
Hw.Er
Hardware Error
Indication that a module is of
the wrong type, missing, or
faulty.
Check to ensure that the correct items are
installed. See page A-4 for procedure to clear the
Hardware Error.
no. i o
No I/O
None of the expected I/O
items are installed
This error message normally occurs when
pre-configuring a controller without installing any
of the required I/O modules.
rmt . F
Remote input failure.
The remote DC input is open
or shorted
Check for open or short circuit wiring on the
remote DC input.
LLLL
Out of range low reading
Check the value of the input
HHHH
Out of range high reading
Check the value of the input
Err1
Error 1: ROM self-test fail
Return Controller for repair
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
DIAGNOSTIC ALARMS
DISPLAY
MEANING
WHAT TO DO`
Err2
Error 2: RAM self-test fail
Return Controller for repair
Err3
Error 3: Watchdog fail
Return Controller for repair
Err4
Error 4: Keyboard failure.
Stuck button or button was
pressed during power-up
Switch power off and then on, without touching
any of the controller buttons
Err5
Error 5: Faulty internal
communication
Check printed circuit board interconnections. If
the fault cannot be cleared, return the controller
for repair.
Err6
Digital filter chip faulty or
loose board inside controller
Return Controller for repair
Err7
PV ID failure
Return Controller for repair
Err8
Module 1 ID failure
Faulty or loose module, or isolation problem
Err9
Module 2 ID failure
Faulty or loose module, or isolation problem
Er r A
Module 3 ID failure
Faulty or loose module, or isolation problem
dCF
DC output failure
Return Controller for repair
Secondary Input Missing or
Disconnected
This error may result from no power to the flow
meter (check for green power light on rear of
meter or 0-5V flowmeter signal connections), or a
disconnection of the Molex connector between
feedforward sensor and the Eurotherm controller.
O PEn
A3.1. Clearing Hardware Error (Hw.Er) Display
To clear a Hardware Error and reset the Temperature Controller, proceed as follows:
CLEARING HARDWARE ERROR Display Instructions
1. Display flashes Hw.Er after adding or removing comm. bd.
2. Simultaneously press the Page (
Controller.
) and Scroll (
) buttons on the Temperature
3. Using the Up (▲) arrow button, change the password to “8”.
4. Simultaneously press the Page (
) and Scroll (
) buttons again and observe the
Temperature Controller display. The top line will display “8” and the bottom line will display
“NO”.
5. Press the Up (▲) arrow button to toggle the display from “NO” to “YES”.
6. Simultaneously press the Page (
) and Scroll (
Temperature Controller and clear the Hardware Error.
OMM-0069_0G
SP-100
) buttons to “Reset” the
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APPENDIX A – MODBUS CONTROL AND COMMUNICATION
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX B – ECS/SP WIRING DIAGRAM
APPENDIX B – ECS/SP WIRING DIAGRAM
& TERMINAL BLOCK CONNECTIONS
Drawing Number: 69008-2 rev F
OMM-0069_0G
SP-100
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APPENDIX B – ECS/SP WIRING DIAGRAM
INTERNAL RECIRC. PUMP
TRANSFORMER
120/24 VAC
220/24 VAC
120/240 VAC
POWER IN
FOR 220 VAC, WIRE #100
MUST BE CONNECTED
TO THIS TERMINAL
POWER
SWITCH
FROM
FUSE
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX C – SMARTPLATE PIPING DRAWINGS
APPENDIX C – SMART PLATE PIPING DRAWINGS
Drawing Number: SD-A-772 rev C
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-773 rev C
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-774 rev D
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-775 rev D
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-776 rev C
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-777 rev C
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-796 rev D
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-792 rev D
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-793 rev D
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-794 rev E
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-783 rev D
OMM-0069_0G
SP-100
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APPENDIX C – SMARTPLATE PIPING DRAWINGS
Drawing Number: SD-A-784 rev C
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APPENDIX D – DIMENSIONAL DRAWINGS
APPENDIX D – DIMENSIONAL DRAWINGS
Drawing Number: AP-A-846 rev C
OMM-0069_0G
SP-100
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APPENDIX D – DIMENSIONAL DRAWINGS
Drawing Number: AP-A-847 rev E
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APPENDIX E – PART LISTS
APPENDIX E – PART LISTS
SmartPlate SINGLE WALL – Base Components
Item # Qty Part #
1
2
3-A
3-B
3-C
4-A
4-B
4-C
5
6
7
8
9
10
20
22
31
34026
SEE TABLE
1
SEE TABLE
1
SEE TABLE
1
1
1
2
1
2
1
1
1
24198
35015
33084-1
33084-2
33083
33085
33086
73072
69096
Description
SP-23
SP-33
SP-45
SP-69
SP-150
Description
1
1
120V 60 Hz
220V 50 Hz
220V 60 Hz
120V 60 Hz
220V 50 Hz
220V 60 Hz
120V 60 Hz
220V 50 Hz
220V 60 Hz
120V 60 Hz
220V 50 Hz
220V 60 Hz
120V 60 Hz
220V 50 Hz
220V 60 Hz
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0069_0G
SP-100
BASE: SMARTPLATE
BRAZED PLATE HEAT EXCHANGER
PIPING ASSY, 1.5" 120V 60 Hz (See assembly drawings below)
PIPING ASSY, 1.5" 220V 50 Hz (See assembly drawings below)
PIPING ASSY, 1.5" 220V 60 Hz (See assembly drawings below)
PIPING ASSY, 2" 120V/60 Hz (See assembly drawings below)
PIPING ASSY, 2" 220V/50 Hz (See assembly drawings below)
PIPING ASSY, 2" 220V/60 Hz (See assembly drawings below)
SUPPORT BRACKET ASSEMBLY, BRAZED HEAT EXCHANGER
SUPPORT A-FRAME, SMARTPLATE
BRACKET UPPER PIPES
ADJUSTER PIPE SUPPORT
BRACKET, MIXING BOX
BRACKET LOWER PIPES SUPPORT
SUPPORT CONTROL BOX
PLATE, RATING
CONTROL BOX ASSY, SMARTPLATE
Item 2
Item 3-A
Item 3-B
Item 3-C
Item 4-A
Item 4-B
Item 4-C
22263-1
28121-1
22263-3
22263-5
22263-1
28121-2
22263-3
22263-5
22264-1
28121-3
22264-3
22264-5
22264-1
28121-4
22264-3
22264-5
22264-1
28121-5
22264-3
22264-5
SmartPlate Single Wall Part List
02/27/2017
29381-TAB rev F
Sheet 1 of 2
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APPENDIX E – PART LISTS
31
2
3&4
9
6
10
5
8
22
7
1
AERCO
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Blauvelt, NY 10913
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SmartPlate Single Wall Part List
02/27/2017
29381-TAB rev F
Sheet 2 of 2
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OMM-0069_0G
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX E – PART LISTS
SmartPlate DOUBLE-WALL – Base Components
Item #
Qty
Part #
Description
1
2
3-A
3-B
4-A
4-B
5
6
7
8
9
10
12
18
20
1
1
SEE TABLE
34026
1
SEE TABLE
1
SEE TABLE
1
2
1
1
1
1
1
1
1
33102
33105
33091
SEE TABLE
33098
33099
69096
73072
33106
DOUBLE WALL HEAT EXCHANGER
BASE, SMARTPLATE
PIPING ASSY, 1.5" SPDW – 120V/60 Hz
PIPING ASSY, 1.5" SPDW – 220V/50 Hz
PIPING ASSY, 2" SPDW – 120V/60 Hz
PIPING ASSY, 2" SPDW – 220V/50 Hz
BRACKET, MIXING BOX DW
BRACKET LOWER PIPES SUPPORT
HX MOUNT, SMARTPLATE DW
DW HX END SUPPORT BRACKET (Not Shown Below)
PIPING FRAME, LEFT, SMARTPLATE DW
PIPING FRAME, RIGHT, SMARTPLATE DW
CONTROL BOX ASSY, SMARTPLATE
PLATE, RATING
BRACKET, ADJUSTER PIPING SUPPORT
Pressure
Description
SPDW-23
SPDW-32
150 PSI
Pressure
SPDW-42
SPDW-61
SPDW-113
SPDW-23
SPDW-32
200 PSI
Pressure
SPDW-42
SPDW-61
SPDW-113
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0069_0G
SP-100
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
120V 60 Hz
220V 50 Hz
Item 1
28104-1
28104-2
Item 3-A Item 3-B
Item 8
22263-4
22263-2
22263-4
22264-2
22264-4
22264-2
28104-4
22264-4
22264-2
28104-5
28104-7
Item 4-B
22263-2
28104-3
28104-6
Item 4-A
22264-4
33095
33095
22263-2
22263-4
22263-2
22263-4
28104-8
28104-9
28104-10
22264-2
22264-4
22264-2
22264-2
22264-4
22264-4
33095
33095
SmartPlate Double Wall Part List
02/22/2017
29382-TAB rev E
Sheet 1 of 2
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APPENDIX E – PART LISTS
9
20
18
1
12
7
6
5
3&4
10
2
AERCO
International, Inc.
Blauvelt, NY 10913
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SmartPlate Double Wall Part List
02/22/2017
29382-TAB rev E
Sheet 2 of 2
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OMM-0069_0G
SP-100
SmartPlate Installation, Operation & Maintenance Manual
APPENDIX E – PART LISTS
SmartPlate Installation Kits
SmartPlate Water Heater units are shipped with one of the following installation kits:
Kit #
58128-1
58128-2
58128-3
58128-4
58128-5
58128-6
SmartPlate Models
SP23, SP33, SP45, SP69, SP150
SPDW23, SPDW32, SPDW42, SPDW61,
SPDW113
SP23, SP33, SP45, SP69, SP150
SPDW23, SPDW32, SPDW42, SPDW61,
SPDW113
SP23, SP33, SPDW23, SPDW32
SP45, SP69, SP150, SPDW42, SPDW61,
SPDW113
SP23, SP33, SPDW23, SPDW32
SP45, SP69, SP150, SPDW42, SPDW61,
SPDW113
HX Type
Single Wall
Pressure
Double Wall
NYC Option
150 PSI
No
Single Wall
Double Wall
200 PSI
Double Wall
Double Wall
150 PSI
Yes
Double Wall
Double Wall
200 PSI
The contents of each kit are shown in the table below.
Quantity Per Kit
150 PSI Kits
Part #
92070
92130
92065-1
92134-1
92111
93521
93505
93451
Description
58128-1 58128-3 58128-4 58128-2 58128-5 58128-6
Air Vent Valve ¾", 150 PSI
Air Vent Valve ¾", 200 PSI
Relief Valve, ¾M X ¾F, 150 PSI
Relief Valve, 200 PSI
Relief Valve (NYC Only)
Reducing Bushing, 1 ½” to ¾“
Reducing Bushing 1" to ¾"
Nipple, ¾", 2" Lg., 200 PSI
Air Vent Valve
P/N 92070
Reducing Bushing,
1 ½” to ¾“
P/N 93521
200 PSI Kits
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Relief Valve,
P/N 92134-1
Relief Valve, ¾M X ¾F
P/N 92065-1
Relief Valve
P/N 92111
Reducing Bushing, Nipple, ¾", 2" Lg.
1” to ¾“
P/N 93451
P/N 93505
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0069_0G
SP-100
Air Vent Valve
P/N 92130
SmartPlate Accessory Kits
11/15/2016
58128-TAB rev D
Sheet 1 of 1
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APPENDIX E – PART LISTS
P/N 22263-TAB – SmartPlate 1.5 " Piping Assemblies
1.5 inch piping assemblies are used in the following SmartPlate models:
Pressure *
Piping Assembly P/N SmartPlate Models
Type
150 PSI
22263-1
SP23, SP33
Single Wall
200 PSI
150 PSI
22263-2
SPDW23, SPDW32
Double Wall
200 PSI
150 PSI
22263-3
SP23, SP33
Single Wall
200 PSI
150 PSI
22263-4
SPDW23, SPDW32
Double Wall
200 PSI
Power
120V 60 Hz
220V 50 Hz
* Appropriate add-on kit differentiates overall product for given DHW side operating pressure
The table below lists the parts and quantities in each piping assembly:
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX E – PART LISTS
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0069_0G
SP-100
SmartPlate 1.5” Piping Assembly
11/15/2016
22263-TAB rev D
Sheet 2 of 2
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APPENDIX E – PART LISTS
P/N 22264-TAB – SmartPlate 2.0 " Piping Assemblies
2.0 inch piping assemblies are used in the following SmartPlate models:
Piping Assy. P/N
SmartPlate Models
22264-1
SP45, SP69, SP150
22264-2
SPDW42, SPDW61, SPDW113
22264-3
SP45, SP69, SP150
22264-4
SPDW42, SPDW61, SPDW113
22264-5
SPDW42, SPDW61, SPDW113
Pressure *
150 PSI
200 PSI
150 PSI
200 PSI
150 PSI
200 PSI
150 PSI
200 PSI
200 PSI
Type
Single Wall
Double Wall
Power
120V 60 Hz
Single Wall
Double Wall
Double Wall
220V 50 Hz
220V 60 Hz
* Appropriate add-on kit differentiates overall product for given DHW side operating pressure
The table below lists the parts and quantities in each piping assembly:
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX E – PART LISTS
AERCO
International, Inc.
Blauvelt, NY 10913
OMM-0069_0G
SP-100
SmartPlate 2.0” Piping Assembly
11/15/2016
22264-TAB rev D
Sheet 2 of 2
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APPENDIX E – PART LISTS
CONTROL BOX ASSEMBLY – SINGLE WALL & DOUBLE WALL
Item # Qty Part #
Description
1
65082
TRANSFORMER, X075CBA, 120/240 TO 24 VAC
64028-7
TEMPERATURE INDICATOR CONTROLLER - SP23, SPDW23
64028-8
TEMPERATURE INDICATOR CONTROLLER: SP33, SPDW32
2
1
64028-9
TEMPERATURE INDICATOR CONTROLLER: SP45, SPDW42
64028-10
TEMPERATURE INDICATOR CONTROLLER: SP69, SPDW61
64028-11
TEMPERATURE INDICATOR CONTROLLER: SP150, SPDW113
3
2
64056
BOILER WATER TEMPERATURE INDICATOR
4
1
60003
ON/OFF SWITCH
15
1
63009-3
EXTERNAL HARNESS (COMPLETE HARNESS)
THE FOLLOWING PART NUMBERS ARE SUB-COMPONENTS OF 63009-3:
1
63009-52
HOT WATER OUT-TO-TEMP CTRL. WIRING HARNESS
1
63009-53
HOT WATER OUT-TO-OVER TEMP SW. WIRING HARNESS
1
63009-55
BOILER WATER IN WIRING HARNESS
1
63009-57
BOILER WATER OUT WIRING HARNESS
1
63009-58
MIXED INLET TEMP WIRING HARNESS
1
63009-61
RECIRCULATION PUMP WIRING HARNESS
1
63009-64
CONTROL VALVE WIRING HARNESS
THE FOLLOWING PART NUMBERS ARE SUB-COMPONENTS OF 63009-64:
63009-62
ACTUATOR SIGNAL WIRING HARNESS
63009-63
ACTUATOR POWER WIRING HARNESS
23
1
65094-1
FUSE
24
1
65095
FUSE HOLDER
30
1
60014
OVER TEMPERATURE SWITCH
NOT SHOWN IN DRAWING
*
*
*
*
*
*
*
*
*
*
*
1
Model
Programmed Control Box
SP23
SP33
SP45
SP69
SP150
Model
28047-8
28047-9
28047-10
28047-11
28047-12
Programmed Control Box
SPDW23
SPDW32
SPDW42
SPDW61
SPDW113
28047-21
28047-21
28047-22
28047-23
28047-24
4
1
23
30
24
2
3
INSIDE VIEW OF BACK
PANEL OF CONTROL BOX
CONTROL BOX
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SmartPlate Control Box Part List
09/24/2015
69096 rev J
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OMM-0069_0G
SP-100
SmartPlate Installation, Operation & Maintenance Manual
APPENDIX F – RECOMMENDED SPARE PARTS
APPENDIX F – RECOMMENDED SPARE PARTS
NOTE
Refer to the SmartPlate Parts List illustrations in Appendix E for the locations of the
recommended and optional spare parts listed in the following Tables.
TABLE F-1. Recommended Emergency Spare Parts
DESCRIPTION
Heat Exchanger (Single-Wall)
PART NUMBER
See Appendix E,
Part Lists Item 2, Sheet 1,
Valve Electronic Module
65092
Temperature Controller
See Control Box, previous page
Circulator Pump (120 VAC, 60 Hz)
69259-1
Circulator Pump (220 VAC, 50 Hz)
69259-2
Circulator Pump (220 VAC, 60 Hz)
69259-3
Domestic Water Inlet Thermocouple
99042-1
Domestic Water Outlet Thermocouple
99042-2
TABLE F-2. Spare Parts Recommended for Maintenance
DESCRIPTION
PART NUMBER
Boiler Water Differential Pressure
Gauge with Compression Fittings
67002
Strainer Screen
99085
SPDW Thermal Plate with Gasket,
Double-Wall Heat Exchanger
SPDW Gasket
Double-Wall Thermal Plate
Call AERCO representative
81128
SPDW 4-Hole Endplate with Gasket
42204
SPDW No Hole Endplate with Gasket
42205
OMM-0069_0G
SP-100
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SmartPlate Installation, Operation & Maintenance Manual
APPENDIX F – RECOMMENDED SPARE PARTS
TABLE F-3. Spare Parts Recommended for Pump Maintenance
DESCRIPTION
PART NUMBER
Pump Flange Gasket Set
89011-1
Pump Casing O-Ring
89011-2
Pump Capacitor (120 VAC)
89011-3
Pump Capacitor (220 VAC)
89011-4
Pump Cartridge Assembly
89011-5
Pump Fuse
69098-3
TABLE F-4. Optional Spare Parts
DESCRIPTION
PART NUMBER
Over-Temperature Switch
BW Temp Indicator
64056
Boiler Water Sensor
61018
TABLE F-5. Spare Parts Recommended for Control Valve
DESCRIPTION
PART NUMBER
Gasket, 1-1/2”
81181
Gasket, 2”
81182
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SmartPlate Installation, Operation & Maintenance Manual
NOTES:
OMM-0069_0G
SP-100
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Change Log
Date
Description
Changed By
10/15/2015
Rev F Changes:
825: Make units lead free
1062: Changed and/or added to numerous figures, split Parts
Lists into separate Appendix E.
1090: Changed piping assemblies, added 200 PSI option.
Updated kit contents, sections 2.6 and Appendix E, changed
code plate from P/N 73020 to P/N 73072.
1147: Replace Air Vent Valve 92070 with P/N 92116.
Chris Blair
07/14/2017
Rev G Changes:
1320: Added 220 V 60 Hz option, plus various updates
(reference DIR 393)
DIR 17-001: Added recommendation in Section 2.4 to use 2
pipe wrenches when tightening pipe connections
Chris Blair
© AERCO International, Inc., 2017
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SP-100
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