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SmartPlate Installation, Operation & Maintenance Manual

OMM-0069_0E AERCO International, Inc.  100 Oritani Dr.  Blauvelt, NY 10913 Page 1 of 138

SP-100 Phone: 800-526-0288 PRI: 11/26/2013

USER MANUAL

Installation, Operation and Maintenance

SmartPlate ™

Domestic Hot Water Heaters

Last Update: 11/26/2013

Single & Double-Wall Heater Models:

SP23, SP33, SP45, SP69, SP150

SPDW23, SPDW32, SPDW42,

SPDW61, SPDW113

Summary of content (138 pages)

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SmartPlate Installation, Operation & Maintenance Manual USER MANUAL Installation, Operation and Maintenance SmartPlate ™ Domestic Hot Water Heaters Single & Double-Wall Heater Models: SP23, SP33, SP45, SP69, SP150 SPDW23, SPDW32, SPDW42, SPDW61, SPDW113 Last Update: 11/26/2013 OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual Technical Support (Mon-Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer The information contained in this Installation, Operation & Maintenance manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.
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SmartPlate Installation, Operation & Maintenance Manual 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 ..................
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7. TROUBLESHOOTING........................................................................................ 47 7.1 INTRODUCTION ................................................................................................................................. 47 7.2 TROUBLESHOOTING PROCEDURES ................................................................................................... 47 CHAPTER 8. CORRECTIVE MAINTENANCE ..............
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION CHAPTER 1. GENERAL INFORMATION 1.1 INTRODUCTION This Instruction Manual provides detailed coverage for the AERCO SmartPlate line of Water-toWater Heaters. Each SmartPlate Heater Model is equipped with AERCO’s Electronic Control System (ECS) specifically designed for SmartPlate (ECS/SP) and an Electronic Control Valve, MXG-461.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION 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 220°F. 1.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 1 – GENERAL INFORMATION P&T RELIEF VALVE 3-WAY CONTROL VALVE HEAT EXCHANGER AIR VENT ISOLATION BALL VALVES (4 PLCS) BOILER WATER OUT COLD WATER IN BOILER WATER DIFF. PRESSURE GAUGE BOILER WATER IN RECIRC. PUMP DHW OUT STRAINERS W/BLOWDOWN VALVES (2 PLCS) MANIFOLD DRAIN VALVE Figure 1-3. Typical SmartPlate Piping Assembly, 2” ELECTRONICS MODULE HANDWHEEL PORT A VALVE BODY PORT AB PORT B Figure 1-4.
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SmartPlate Installation, Operation & Maintenance Manual 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 SmartPlate from its shipping container  Position and secure the SmartPlate Water Heater at the site.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION local building codes require additional clearances, these codes shall supersede AERCO’s recommendations.  Sides: 24 in. (61 cm)  Front:24 in. (61 cm)  Rear: 24 in. (61 cm)  Top: 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 SmartPlate Heater assemblies/parts or inhibit service or maintenance of the unit.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion. Figure 2-2 a. Single-Wall Model Figure 2-2 b. Double-Wall Model Figure 2-2. SmartPlate Lifting Provisions OMM-0069_0E SP-100 AERCO International, Inc.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION CAUTION For Single-Wall Models, DO NOT attempt to reposition the ECS/SP Control Box with the panel displays facing the SmartPlate Heater Piping Assembly. Attempting to do so will prevent the Control Box door from being fully opened due to the location of the SmartPlate lifting tabs (Figure 2-2 a). 2.3.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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 SmartPlate Water Heater being installed. Refer to the Pipe Sizing Chart in Table 2-1 for applicable piping sizes. Table 2-1. Pipe Sizing Chart SmartPlate Model No. Pipe Diameter Single-Wall SP23 1.5 inches SP33 1.5 inches SP45 2.0 inches SP69 2.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.5 SMARTPLATE ELECTRICAL WIRING CONNECTIONS The ECS/SP Control Box and all other ECS/SP components are installed on the SmartPlate Water Heater prior to shipment from the factory. Therefore, electrical connections to the SmartPlate 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 or 220 VAC, 50 Hz.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION PANEL CAPTIVE SCREW OVER TEMP SWITCH F 2408 SET F OUT SET AUTO RUN MAN HOLD F IN SET TEMP CONTROLLER BOILER WATER TEMP WATER HEATER 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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 7. If the ECS was ordered with the Modbus Communication Option, proceed to step 8.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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 8.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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 2-7. Temperature Controller (Eurotherm 2408) Terminal Connection Diagram Page 20 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION CHAPTER 3. FUNCTIONAL DESCRIPTION 3.1 INTRODUCTION 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.
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SmartPlate Installation, Operation & Maintenance Manual 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 Water Heater outlet temperature.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 3 – FUNCTIONAL DESCRIPTION Figure 3-1. SmartPlate Water Heater Functional Block Diagram OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 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).
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SmartPlate Installation, Operation & Maintenance Manual 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: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT 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. Figure 4-5. Temperature Controller Page 30 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT Table 4-2.
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SmartPlate Installation, Operation & Maintenance Manual 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: 1.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 4 – ADJUSTMENT Table 4-3. Over-Temperature Switch Controls and Indicators CONTROL or INDICATOR LED Display RST SET OMM-0069_0E SP-100 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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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION CHAPTER 5. OPERATION 5.1 INTRODUCTION This Chapter provides the pre-operational checks, initial start-up and operating procedures for the SmartPlate Water Heater. 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.
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SmartPlate Installation, Operation & Maintenance Manual 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: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION 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: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 5 – OPERATION 6. After the boiler water and domestic water have been drained from the Heater, replace the 1/4" plug removed in step 4 and tighten the Victaulic coupling loosened in step 3. CAUTION Step 7 applies to SmartPlate Double-Wall Models ONLY. Skip this step for all Single-Wall Models. 7. For SmartPlate Double-Wall Models, it is also advisable to separate and clean the plates using the procedures in Chapter 8, paragraph 8.6.2.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE CHAPTER 6. SCHEDULED MAINTENANCE 6.1 INTRODUCTION The SmartPlate Water Heater requires 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 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, refer to Chapter 6 – Corrective Maintenance to repair or replace the Differential Pressure Gauge. 5.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 2. Check for leakage between the Plate Pack and Frame [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, paragraphs 8.7 and 8.8 to correct the cause of the leakage. 3.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 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 SmartPlate Water Heater. Perform the following steps for each Strainer: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 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 PARAGRAPH. 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE 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).
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 6 – SCHEDULED MAINTENANCE Figure 6-2. Domestic Water Differential Pressure Check Set-Up OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual 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: 1.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING 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 Fault Indication System not operating. Control Valve is closed and outlet water temp. is far below setpoint. Probable Cause Corrective Action 1. No power supplied to Control Valve 1.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly – Cont. No. T3 Fault Indication Probable Cause System outlet water temperature is below desired setpoint 1. Boiler water inlet strainer is clogged 2. Boiler water temp is too low. 3. Boiler water flow rate too low. 4. Temp controller is not properly set. T3 (Continued) 5. Control Valve is not opening properly. 6.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-1. Troubleshooting – Control Valve MXG-461 and Piping Assembly – Cont. No. T5 Fault Indication Probable Cause Rapid fluctuations in heater outlet temperature which do not follow load changes Corrective Action 1. Temp. Controller is not functioning properly. 1. Refer to Table 7-2 and troubleshoot the Temp. Controller. Table 7-1A.
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SmartPlate Installation, Operation & Maintenance Manual 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 Corrective Action 1. External 120 VAC power disconnected. 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-2. Troubleshooting – Electronic Control System (ECS/SP) – Cont. No. T6 Fault Indication Probable Cause Over-Temp. Alarm condition cannot be cleared. Over-Temp Switch displays erroneous temperature readings T7 Outlet water temp. far below Setpoint 1. Shorted Outlet Temp. Sensor. 2. Defective OverTemp. Switch. 3. 3-Way Control Valve not closing fully during no-load conditions. 4.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-2. Troubleshooting – Electronic Control System (ECS/SP) – Cont. No. Fault Indication T9 Temperature control not within specifications. Items T1 – T8 check out OK. Wide fluctuations in outlet water temperature under low flow conditions. T1 0 T1 0 Wide fluctuations in outlet water temperature under low flow conditions. Probable Cause 1. Unexpected system dynamics. 2. Outlet Temp Corrective Action 1.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-3. Troubleshooting Guide for Temperature Control Issues No. Observation Probable Cause T91 Too much valve oscillations or too wide outlet temperature oscillation at low flow T92 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 7 – TROUBLESHOOTING Table 7-3A.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE CHAPTER 8. CORRECTIVE MAINTENANCE 8.1 INTRODUCTION This Chapter provides the procedures necessary to correct and repair faults detected during operation or isolated during troubleshooting of the SmartPlate Water Heater.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE AIR VENT ISOLATION BALL VALVES BOILER WATER OUTLET MANIFOLD COLD WATER INLET ISOLATION BALL VALVES BOILER WATER INLET DHW OUTLET DRAIN VALVE RECIRC. PUMP HEAT EXCHANGER (BEHIND SUPPORT ASSY) 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Table 8-1. AERCO HydroSkrub Solution Required For De-Scaling Heat Exchanger SmartPlate Model Heat Exchanger Volume (gallons) HydroSkrub Required (Gallons) Single-Wall Heat Exchangers SP23 1.70 0.90 SP33 2.40 1.20 SP45 3.40 1.70 SP69 5.20 2.60 SP150 11.30 5.70 SPDW23 2.00 1.00 SPDW32 2.80 1.40 SPDW42 3.70 1.90 SPDW61 5.50 2.80 SPDW113 10.20 5.10 Double-Wall Heat Exchangers 6.
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SmartPlate Installation, Operation & Maintenance Manual 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: 1. Turn OFF the POWER Switch on the side of the ECS/SP Control Box. 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).
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8. At the rear of the SmartPlate 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. If the SmartPlate is a Model SP150, remove the two support brackets at the rear of the Heat Exchanger. 10.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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 Page 62 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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 paragraphs 8.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 4. Open the valve on the Strainer and drain the boiler water from the Heater. 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. Remove the 1/4” plug on the side of the Strainer to allow air into the pipe during draining. 6.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 10. Table 8-2 lists the recommended cleaning methods for the type of Heat Exchanger fouling encountered. Table 8-2. Recommended Cleaning Procedures TYPE OF FOULING Incrustation Scaling (Lime Deposits) Sediment CAUSE CLEANING METHOD Calcium 1. Soft brush & running water Carbonate, NOTE: Avoid Gasket Calcium Damage Sulphate, 2. High pressure hose. Silicates 3.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE A Figure 8-8. Measurement of Plate Pack Dimension "A" 10. If the unit is a Model SPDW113, remove the U-bolt securing the heat exchanger support bar (see paragraph 8.9 and Figure 8-18). If the unit is a Model SPDW61, remove the Ubolt and "L" bracket at the rear of the heat exchanger mount to permit the pressure plate to be moved. 11.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-11. Insertion of Plates in Heat Exchanger 8.7.3 CLOSING HEAT EXCHANGER Closing the Heat Exchanger is accomplished as follows: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-12. 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 paragraph 8.7.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-13. 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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%.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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) 1. Obtain two standard plate gaskets (Part No. 81128). 2. Cut the gaskets as indicated in Figure 8-15. 3.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-16. End Plate with Gasket Installed 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: 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-17. Domestic Water Side - Double-Wall Partial View 8. If the SmartPlate is a Model SPDW61 or SPDW113 (largest size), remove the U-bolt securing the Heat Exchanger support bar. Also, for SmartPlate Model SPDW61, remove the "L" bracket. 9. If the SmartPlate is not a Model SPDW113 or SPDW61, use a 3/4" socket wrench to remove the horizontal hex head screw and washer shown in Figure 8-18.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-18. Double-Wall Heat Exchanger Mounting Details - Rear OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE WARNING THE DOUBLE-WALL HEAT EXCHANGER CAN WEIGH UP TO 850 POUNDS, DEPENDING ON THE SMARTPLATE MODEL SIZE. THEREFORE, USE EXTREME CARE WHEN REMOVING IT FROM ITS MOUNT. A SUITABLE SLING MUST BE USED TO LIFT AND REMOVE THE HEAT EXCHANGER FROM ITS MOUNT. 10. Insert a sling through the four (4) holes in the frame plate and pressure plate, as shown in Figure 8-19, to safely lift the Heat Exchanger off its mount.
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SmartPlate Installation, Operation & Maintenance Manual 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 8-20). The procedures for removing this Module or replacing the complete Control Valve are provided in paragraphs 8.3.1 and 8.3.2. Figure 8-20.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 5. Pull straight up to unplug the Module from the Valve Head. 6. Install the replacement Electronics Module on the Valve Head and resecure it with the three socket head screws removed in step 4. 7. Refer to Figure 8-7 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 8.10.2 Control Valve Replacement To remove the complete Control Valve Assembly from the SmartPlate Water Heater: 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 8-21). 3. Remove the Module cover to access the wiring terminals (Figure 8-7).
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 10. Using two (2) pipe wrenches, resecure the Control Valve unions to the Boiler Water piping. 11. Refer to Figure 8-7 and ensure that the three (3) DIP switches on the Electronics Module of the replacement Valve are all in the OFF (down) position. 12. Reconnect the power and control signal wire leads to the Electronics Module of the replacement Control Valve. 13.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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 SmartPlate Water Heater to service use. Figure 8-24. Domestic Water Piping Components 8.12 STRAINERS All SmartPlate Water Heater Models utilize Combination Strainers and Ball Valves to prevent fouling of the Heat Exchanger by trapping foreign material before it enters the Heater.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE b. c. Hose and wash off screen. Reinstall screen and replace Strainer end cap. 1. Close both Isolation Ball Valves in the Boiler Water piping (Figure 8-23). 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.
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SmartPlate Installation, Operation & Maintenance Manual 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 PARAGRAPHS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN SERIOUS PERSONAL INJURY. 8.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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 SmartPlate Water Heater. 5. Control Box replacement is accomplished by reversing the previous steps. 8.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE Figure 8-27a. Over-Temperature Switch & Temperature Indicator 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.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 2. Open the swing-down panel and locate the 24 VAC Transformer on the back interior wall of the Control Box (Figure 8-13, View D - D). 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. Figure 8-28.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE 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 8-28. ECS/SP Control Box Assembly 69096 (Sheet 2 of 3) OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual CHAPTER 8 – CORRECTIVE MAINTENANCE ECS/SP CONTROL BOX ASSEMBLY 69096 PARTS LIST ITEM QUANTITY PART NO.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION APPENDIX A MODBUS CONTROL AND COMMUNICATION TEMPERATURE CONTROLLER (Eurotherm 2408) PROCEDURES MODBUS COMMUNICATION INFORMATION & PROCESS / DIAGNOSTIC ALARM MESSAGES OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION A.1 TEMPERATURE CONTROLLER (EUROTHERM 2408) PROCEDURES The following paragraphs 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-[ ] b. Temperature Indicating Controller, P/N: 64008-[ ] c.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION 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 Butto Up/Down Arrow Keys Figure A-3 5. The Controller will report a hardware error as indicated in Figure A-3.
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SmartPlate Installation, Operation & Maintenance Manual 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 for all panel navigation instructions. Up Arrow Down Arrow Scroll Page Button Map 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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SmartPlate Installation, Operation & Maintenance Manual 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.
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SmartPlate Installation, Operation & Maintenance Manual 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.
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SmartPlate Installation, Operation & Maintenance Manual 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.
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SmartPlate Installation, Operation & Maintenance Manual 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.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX A – MODBUS CONTROL AND COMMUNICATION DIAGNOSTIC ALARMS - continued 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.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX B – ECS/SP WIRING DIAGRAM APPENDIX B – ECS/SP WIRING DIAGRAM & TERMINAL BLOCK CONNECTIONS OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX B – ECS/SP WIRING DIAGRAM Drawing Number: 69008-2 rev D Page 102 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual 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 OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX B – ECS/SP WIRING DIAGRAM (This page left intentionally blank) Page 104 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS APPENDIX C – SMART PLATE PIPING DRAWINGS OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-772 rev C Page 106 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-773 rev C OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-774 rev D Page 108 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-775 rev D OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-776 rev C Page 110 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-777 rev C OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-796 rev C Page 112 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-792 rev C OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-793 rev C Page 114 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-794 rev D OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-783 rev D Page 116 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX C – SMARTPLATE PIPING DRAWINGS Drawing Number: SD-A-784 rev C OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS APPENDIX D – SMARTPLATE DRAWINGS DIMENSIONALS & PARTS LISTS OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS Drawing Number: AP-A-846 rev A Page 120 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS Drawing Number: AP-A-847 rev B OMM-0069_0E SP-100 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS BASE COMPONENTS AND LABELS Item # Qty Part # Description 1 2 3 4 5 6 7 8 9 11 12 13 1 1 1 1 1 1 1 1 2 1 1 1 34026 35015 33083 24198 72010‐18 72010‐19 72010‐17 72010‐20 74010 SEE TABLE SEE TABLE SEE TABLE BASE: SMARTPLATE SUPPORT A‐FRAME: SMARTPLATE BRACKET: MIXING BOX SUPPORT BRACKET ASSEMBLY: BRAZED HX LABEL: DOMESTIC INLET LABEL: BOILER INLET LABEL: DOMESTIC OUTLET LABEL:
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS 1.5 " PIPING ASSY.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 Page 124 of 138 PRI: 11/26/2013 SmartPlate – Single Wall Part List 07/15/2013 29116-TAB rev E (PL-A-160) Sheet 3 of 6 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS 2.0 " PIPING ASSY.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 Page 126 of 138 PRI: 11/26/2013 SmartPlate – Single Wall Part List 07/15/2013 29116-TAB rev E (PL-A-160) Sheet 5 of 6 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS * * * * * * * * * * Item # 94 95 96 97 98 99 100 101 * CONTROL BOX ASSEMBLY Qty 1 1 Part # Description 65082 TRANSFORMER, X075CBA, 120/240 TO 24 VAC 64028‐7 TEMPERATURE INDICATOR CONTROLLER ‐ SMARTPLATE SP23 64028‐8 TEMPERATURE INDICATOR CONTROLLER ‐ SMARTPLATE SP33 64028‐9 TEMPERATURE IN
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS BASE COMPONENTS AND LABELS Item # Qty Part # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 5 1 1 1 2 1 34026 33099 33098 33102 72010‐18 72010‐19 72010‐17 72010‐20 74010 SEE TABLE SEE TABLE SEE TABLE SEE TABLE SEE TABLE SEE TABLE SEE TABLE SEE TABLE SEE TABLE 33091 33105 33106 BASE: SMARTPLATE PIPING F
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0069_0E SP-100 SmartPlate – Double Wall Part List 07/15/2013 29117-TAB rev C (PL-A-161) Sheet 2 of 7 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS 1.5 " PIPING ASSY.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0069_0E SP-100 SmartPlate – Double Wall Part List 07/15/2013 29117-TAB rev C (PL-A-161) Sheet 4 of 7 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS 2.0 " PIPING ASSY.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0069_0E SP-100 SmartPlate – Double Wall Part List 07/15/2013 29117-TAB rev C (PL-A-161) Sheet 6 of 7 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – SMARTPLATE DRAWINGS CONTROL BOX ASSEMBLY Item # Qty Part # Description * * * * * * * * * * 102 103 104 105 106 107 108 109 * 1 1 65082 TRANSFORMER, X075CBA, 120/240 TO 24 VAC 64028‐7 TEMPERATURE INDICATOR CONTROLLER ‐ SMARTPLATE SP23 64028‐8 TEMPERATURE INDICATOR CONTROLLER ‐ SMARTPLATE SP33 64028‐9 TEMPERATURE INDICATOR CON
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX E – RECOMMENDED SPARE PARTS APPENDIX E – RECOMMENDED SPARE PARTS NOTE Refer to the SmartPlate Parts List Illustrations in Appendix D for the locations of the recommended and optional spare parts listed in the following Tables. Table E-1.
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SmartPlate Installation, Operation & Maintenance Manual APPENDIX D – RECOMMENDED SPARE PARTS Table E-4. Optional Spare Parts DESCRIPTION PART NUMBER Over-Temperature Switch BW Temp Indicator 64056 Boiler Water Sensor 61018 Table E-5. Spare Parts Recommended for Control Valve DESCRIPTION PART NUMBER Gasket, 1-1/2” 81181 Gasket, 2” 81182 Page 136 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.
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SmartPlate Installation, Operation & Maintenance Manual WARRANTY WARRANTY: AERCO’S STANDARD WARRANTY: 18 MONTHS FROM SHIPMENT The heater shall carry the following manufacturer's warranty from date of shipment: The Heat Exchanger and all accessories shall carry an 18-month guarantee against mechanical failure or workmanship from the date of shipment.
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SmartPlate Installation, Operation & Maintenance Manual Change Log Date Description Changed By 08/05/2013 Rev D: Added table E-5 in Appendix E, gaskets 81181 & 81182 for the Control Valve, per PIR 893. Chris Blair 11/26/2013 Rev E: Modified and added to Spare Parts list in Appendix E, table E2 (PIR 814) Chris Blair © AERCO International, Inc., 2013 Page 138 of 138 PRI: 11/26/2013 AERCO International, Inc.  100 Oritani Dr.