0 TECHNICAL INSTRUCTIONS Innovation Anode Retrofit Instructions This kit applies to all Innovation model water heaters ITEM 1: P/N 44173 ANODE MOUNTING BRACKET ITEM 2: P/N 44174 ANODE BLOCK (2 each) ITEM 3: P/N 54107 3/8 16 HEX HEAD CAP SCREW (3 each) ITEM 4: P/N 54106 5/16 24 HEX HEAD CAP SCREW ITEM 5: P/N 56077 HEX NUT 5/16 24 ITEM 6: P/N 53058 LOCKWASHER (3 each) ITEM 7: P/N 88019 O RING, NEOPRENE (4 each) ITEM 8: P/N 54108 1/4-20 HEX HEAD SEAL BOLT (4 each) ITEM 9: P/N GP-18532 HEAD GASKET ITEM 10: P/N GP-18556 HEAD RELEASE GASKET Innovation Heat Exchanger Anode Retrofit Part List ITEM# QTY. P/N DESCRIPTION 1 1 44173 ANODE MOUNTING BRACKET 2 2 44174 ANODE BLOCK 3 3 54107 HEX HEAD CAP SCREW 3/8 16 X 1, NiCu ALLOY 4 1 54106 HEX HEAD CAP SCREW 5/16 24 X 1 1/2 STAINLESS 5 1 56077 HEX NUT 5/16 24 STAINLESS 6 3 53058 LOCKWASHER, EXT TOOTH, STAINLESS 7 4 88019 O RING, NEOPRENE 8 4 54108 HEX HEAD SEAL BOLT 1/4 20 with NEOPRENE RING 9 1 GP-18532 HEAD GASKET 10 1 GP-18556 HEAD RELEASE GASKET Disclaimer The information contained in these instructions are subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material. 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 1 of 6
1. Introduction This Technical Instruction Document (TID) provides instructions for installing the anode assembly in Innovation water heaters in the field. This kit is delivered unassembled. These instructions apply to all Innovation model water heaters. 1/4-20 HEX HEAD SEAL BOLT (4 Each) 5/16-24 HEX CAP SCREW (POSITIONING SCREW) (1 Each) 3/8-16 HEX CAP SCREW O RINGS ANODE MOUNTING BRACKET (2 PARTS) 2. Tools Required Figure 1: Anode Assembly Exploded View Assorted socket or open-end wrenches 3. Preparing the Unit To prepare the unit for the retrofit, perform the following: Preparing the Unit for Retrofit 1. Set the ON/OFF switch on the control panel to the OFF position. Disconnect AC power from the unit by turning off power at the breaker. WARNING! - A high voltage of 120 VAC is used in Innovation water heaters. It is REQUIRED that all power applied to the unit is removed before performing the procedures described below. Use extreme care when accessing circuits and electrical connections within the equipment. Serious personal injury or death may occur if this warning is not observed. Various components may be hot. Care must be exercised to avoid burns. AERCO suggests allowing the unit to cool to room temperature before starting these instructions. 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 2 of 6
Preparing the Unit for Retrofit Continued 2. Turn off the supply gas upstream from the unit. 3. Allow enough time for the unit to return to room temperature. 4. Close the water inlet, outlet, and recirculation shut-off valves to the unit. 5. Carefully open the drain valve while opening the relief valve on the rear of the unit to relieve pressure and allow air into the shell. Do not drain the unit without venting the shell! A vacuum in the unit may displace the head liner causing serious damage not covered by warranty. 6. Remove all panels from the front, top and sides of the unit, to provide access to the heat exchanger top plate. IMPORTANT! Observe local requirements and lockout procedures when working on the unit. 4. Disassembling the Unit Disassembling the Unit 1. Referring to Figure 2, remove the 5/8-11 hex nuts and washers from the upper head and then remove the upper head. 2. Remove the upper head-liner (copper or other material) and retain it for reassembly. 3. Remove the head release gasket and discard it. 4. Remove the head gasket and discard it. CAUTION 5/8-11 HEX NUT UPPER HEAD 5/8-11 X 3-3/4 STUD SHELL FLANGE HEAT EXCHANGER UPPER HEAD LINER (P/N 123077) HEAD RELEASE GASKET (P/N GP-18556) HEAD GASKET (P/N GP-18532) Figure 2: Heat Exchanger Head Configuration 5. Installing the Anode Assembly Once the upper head has been removed, refer to Figure 3, below, and complete the instructions below to install the anode assembly. 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 3 of 6
Anode Assembly Installation 1. Cut a doughnut shaped piece of cardboard that will fit snugly inside the heat exchanger shell and around the combustion chamber head and fit it in place above the heat exchanger tubes. This will act as a shield to prevent any hardware or debris from dropping into the chamber during installation. 2. Thread the 5/16-24 hex nut (P/N 56077) most of the way onto the 5/16 24 hex head cap screw (the positioning screw) (P/N 54106), and then thread the positioning screw a short way into the center hole of the mounting bracket s larger piece. 3. Place the mounting bracket on the combustion chamber head s lifting hook with the positioning screw directly over the lifting hook. 4. Position the smaller, separate piece of the mounting bracket on the opposite side of the lifting hook, and loosely fasten it to the larger piece of the mounting bracket with two 3/8 16 hex head cap screws (P/N 54107) and lock washers (see Figure 3). CAUTION The 3/8 16 hex head cap screw material is softer than steel screws and the threads can strip easily. Take precautions to prevent stripping during installation. This kit includes an extra screw in case one is damaged. 1/4-20 SEAL BOLTS (4 Each) 5/16-24 POSITIONING HEX SCREW (1 Each) 5/16-24 NUT (1 Each) MOUNTING BRACKET 3/8-16 CAP SCREWS & LOCK WASHERS MOUNTING BRACKET, SEPARATE PIECE COMBUSTION CHAMBER HEAD LIFTING HOOK COMBUSTION CHAMBER HEAD Figure 3: Anode Assembly and Combustion Chamber Head 5. Lift the mounting bracket up until the upper 3/8 16 cap screw comes in firm contact with the underside of the lifting hook and level and parallel to the heat exchanger s shell flange, and then fully tighten both screws. 6. Fully tighten the 5/16 24 positioning screw. The lifting hook is now held firmly between the 3/8 16 cap screws and the positioning screw. 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 4 of 6
Anode Assembly Installation Continued 7. Fully tighten the 5/16-24 hex nut on the positioning screw to lock it in place. The mounting bracket is now firmly attached to the lifting hook, ensuring that the anode blocks are electrically connected to the unit. 8. Position the four (4) O rings (P/N 88019) in the circular recesses around the threaded holes in the anode blocks (P/N 44174). The O rings keep water from entering the threaded holes, preventing them from corroding, which would shorten the anode s life. 9. Fasten one anode block to the mounting bracket with two (2) 1/4 20 hex head seal bolts (P/N 54108) and fully tighten them. Note that these are specialized bolts with built-in O rings DO NOT substitute off-the-shelf bolts of the same size. DO NOT over-tighten these bolts. 10. Repeat the previous step to attach the second anode block to the mounting bracket. 11. Remove any hardware or debris that may have fallen on the cardboard shield installed in step 1 and then remove the shield from the chamber. 6. Reassembling the Heat Exchanger Reassembling the Heat Exchanger 1. Place the new head gasket (P/N 18532) on top of the heat exchanger shell flange. 2. Place the new head release gasket (P/N 18556), upper head liner and upper head on, aligning them with the 5/8-11 X 3-3/4 studs in the shell flange. 3. Replace the nuts and washers on the 5/8-11 X 3-3/4 studs. 4. Cross tighten the nuts to approximately 75 ft.-lb. torque to obtain a uniform seating, then progressively tighten the nuts to 200 ft/lbs. minimum. 7. Returning the Unit to Service Returning the Unit to Service 5. Close the drain valve. 6. Reopen the unit s water inlet, outlet, and recirculation shut-off valves. 7. Reinstall the unit s front, top and side panels. 8. Turn on the supply gas upstream to the unit. 9. Reconnect AC power to the unit. 10. Set the ON/OFF switch on the control panel to the ON position. --- END --- 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 5 of 6
Change Log Date Description Changed By 09/08/2014 Rev A: Initial release (reference PIR 1086) Chris Blair 05/21/2015 Rev B: 934-190: Added two gaskets to the instructions: GP- 18532, GP-18556. Chris Blair International Inc. AERCO International, Inc., 2015 05/21/2015 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York 10913 Phone: 800-526-0288 Page 6 of 6