Aerco GF-116 Manuel d'instructions

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010 C

REPLACING SEALS:Water flowing from weep hole in bracket normally indicates dirt on the seat or seal needs replacement. Before takingpump apart, extend

APPENDIX D D-1 INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 0.6 0.8 1.0 1

APPENDIX D D-2 Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 65 65 65 6

APPENDIX D D-3 Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 75F 75 75

APPENDIX D D-4 Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 90F 90

APPENDIX E E-1 BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Addre

APPENDIX F F-1

APPENDIX F F-2

APPENDIX FF-3

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010 C

APPENDIX FF-4

APPENDIX FF-5

APPENDIX FF-6

APPENDIX G G-1

APPENDIX G G-2

APPENDIX H H-1

APPENDIX H H-2 CONTROL BOX CONNECTORSGAS FIRED BOILER SYSTEMWIRING SCHEMATIC1616131210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 2422

APPENDIX I I-1 KC1000 CONTROL PANEL EXPLODED VIEW

APPENDIX I I-2 KC1000 CONTROL PANEL REAR VIEW

03/01/05 W-1 (C102.0) STANDARD WARRANTY: Gas-Fired Hydronic Boiler Model KC-1000GWB & PWB (Propane) INTERNATIONAL, INC. PRE

12 Flanged5 FlangedInstruction SheetSuction Diffuser “Rear Strainer Pullout” (RSP)302-042SUPERSEDES: New EFFECTIVE: June 1, 2007Plant I.D. 001-3882LOC

03/01/05 W-2 (C102.1) STANDARD WARRANTY: Gas-Fired Hydronic Boiler Model KC-1000GWB & PWB (Propane) INTERNATIONAL, INC. CON

JANUARY, 2009 Instruction No. GF-124AERCO INTERNATIONAL, Inc., Northvale

Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday): 1-800-526-0288

FOREWORD Foreword The Model 5R5-384 Boiler Management System II (BMS II) is the latest model of AERCO’s BMS line of flexible boiler plant controller

FOREWORD Phrases, Abbreviations and Acronyms - Continued Phrase, Abbreviation or Acronym Meaning Hex Hexadecimal Number (0 - 9, A - F) Hz Hertz (C

CONTENTS iii GF-124 – BMS II BOILER MANAGEMENT SYSTEM Operating & Maintenance Instructions TABLE OF CONTENTS CHAPTER 1 - GENERAL INFORMATION ..

CONTENTS TABLE OF CONTENTS (cont.) 3.5 SETUP MENU ...

CONTENTS TABLE OF CONTENTS (cont.) LOAD START PCT...

GENERAL INFORMATION 1-1 CHAPTER 1 - GENERAL INFORMATION 1.1 SAFETY PRECAUTIONS & WARNINGS The Warnings and Cautions appearing throughout thi

DOITONCE. DOITRIGHT.®TACO, INC., 1160 Cranston Street, Cranston, RI 02920 Telephone: (401) 942-8000 FAX: (401) 942-2360.TACO (Canada), Ltd., 6180 Orda

GENERAL INFORMATION Figure 1-1. Boiler Management System II (BMS) 1.4 BMS II FEATURES The following paragraphs briefly describe some of the unique

GENERAL INFORMATION 1-3 Retention of Menu Option Settings By using non-volatile memory, the BMS II retains program and menu settings during shut-down

INSTALLATION 2-1 CHAPTER 2 - INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to mount the BMS II and

INSTALLATION 145 mm (5.7") Figure 2-1. BMS II Mounting Provisions 2.3 GENERAL WIRING REQUIREMENTS All wiring connections to the BMS II are ma

INSTALLATION WARNING THE BMS II CAN BE POWERED BY SINGLE-PHASE AC VOLTAGES RANGING FROM 85 TO 265 VAC. THEREFORE, EXERCISE EXTREME CARE WHEN CONNECTIN

INSTALLATION SENSORS& 4-20 mAINTERLOCKS& SETBACKRS485& RS232AC POWERRELAYS Figure 2-2. BMS II With Wiring Compartment Cover Removed 2

INSTALLATION 2.5 SENSOR INSTALLATION AND WIRING There are two types of sensors that can be installed: a Header Sensor and an Outside Air Sensor. If

INSTALLATION Figure 2-3. Header Sensor Installation Details Outdoor Air Sensor The Outdoor Air Temperature Sensor (part no. GP-122662) is required

INSTALLATION 4. Terminate the cable shield at SHLD terminal 3 of the BMS II. DO NOT terminate the shield at the Sensor end of the cable. Figure 2

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010 C

INSTALLATION 2.6 RS485 (MODBUS) WIRING AT THE BMS II The BMS II communicates with the AERCO Boilers over a RS485 network using Modbus protocol. All

INSTALLATION Figure 2-6. Location of BMS II DIP Switches 2.7 RS485 (MODBUS) WIRING AT THE AERCO BOILERS The RS485 wiring connections at the AER

INSTALLATION 3. DO NOT terminate the shields to the Ground (G) terminal at the Boiler end of the RS485 loop. Connect the shields of the incoming and

INSTALLATION Figure 2-8. RS485 (Modbus) Wiring For KC1000 Boilers RS485 Wiring for Modulex Series Boilers RS485 wiring connections are made at

INSTALLATION 1. Connect the positive lead to terminal 1 (MODBUS B +) of connector Y2. 2. Connect the negative lead to terminal 2 (MODBUS A -) of con

INSTALLATION Figure 2-10. Sample RS485 (Modbus) Network For Benchmark or KC1000 Boilers BMS II485 B (+)485 A (-)SHLD(TERM. 3)TO OTHERNETWORKBOILE

INSTALLATION 2.9 RS232 WIRING AT THE BMS II The BMS II communicates with an external Energy Management System (EMS) or Building Automation System (BA

INSTALLATION 2.10 INTERLOCK WIRING The BMS II is equipped with two interlocks designated Interlock 1 (INT 1) and Interlock 2 (INT 2). Since both inte

INSTALLATION 2-16 NOTE The state of the SYS START, FLT ALARM and AUX Relays are controlled by options contained in the Relay Menu described in Chapter

OPERATION CHAPTER 3 - OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the BMS II using the controls

INTRODUCTION/APPLICATIONThe Taco Plus Two Multi-Purpose Valve incorporates all ofthe functions required on the discharge side of a pump in aHydronic S

OPERATION Table 3-1. BMS II Front Panel Controls and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 VFD Display The Vacuum Fluorescent

OPERATION 3.3 BMS II MENU STRUCTURE The BMS II incorporates an extensive menu structure which permits the operator to set up, and configure the unit.

OPERATION Figure 3-2. BMS II Menu Structure 3-4

OPERATION NOTE Paragraphs 3.4 through 3.12 provide detailed descriptions of the options contained in each of the menus shown in Figure 3-2. The menu o

OPERATION I/O STATUS t) STATUS is displayed as a hexadecimal number. The meaning of each bit is as SD: Bit 7 =(empty) 1 Relay RETURN TEMP (°F) op

OPERATION 3.6 RS232 MENU The RS232 MENU options permit the BMS II to communicate with an external Energy Management System (EMS) or Computer via th

OPERATION RS485 BAUD RATE The RS485 BAUDRATE option Sets the communication baud rate for the Modbus network between the BMS II and the Boilers connec

OPERATION HDR LOW LIMIT The HDR LOW LIMIT menu option sets the minimum temperature setting allowed for the Header Setpt. This setting also defines th

OPERATION Setting Up An Offset Schedule automatic reset schedule consist first selecting the temperature 00. E to 01. rent offset Manual Offset ec

OPERATION Sequential When SEQUENTIAL MODE is selected it provides a greater turn-down ratio than the PARALLEL MODE. This is due to the fact that the

the body “O” ring and the “soft seat” remain in position(inspect the body “O” ring and the “soft seat” for anynicks or cuts and replace as necessary).

OPERATION 3.10 TUNING MENU The TUNING MENU options are used to select PID (Proportional Integral Derivative) control functions incorporated in the

OPERATION DERIVATIVE GAIN Derivative Gain is a function of time. It senses and responds to the rate of change of the setpoint error. A slow rate of

OPERATION FAULT ALRM RELAY This setting tells the BMS II which faults should activate the fault alarm relay. The default is ALL FAULTS. If NO INTERL

OPERATION RAMP DOWN %/MIN This sets the maximum Percent Level ramp down rate for the BMS II. The Percent Level output will follow the PID output if i

OPERATION CONSTANT SETPT MODE (Default) MENU & OPTION ACTION 1. SETUP MENU  ENTER PASSWORD Enter 159  2. RS48

OPERATION OUTDOOR RESET MODE Perform the procedure described for the CONSTANT SETPT MODE and then continue with the steps described below: MENU &

PROGRAMMING BMS II 4-1 CHAPTER 4 - PROGRAMMING BMS II OPERATING MODES 4.1 INTRODUCTION Prior to programming, the BMS-II must be mounted and all req

PROGRAMMING BMS II 4. Using the ▲ or ▼ arrow key, select OUTDOOR RESET. 5. Press the ENTER key to store the change. The reverse video display will rev

PROGRAMMING BMS II Entering System Start Temperature In order to complete the required set-up procedures for the Outdoor Reset Mode, the System Start

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010

PROGRAMMING BMS II 5. Press the ENTER key to store the change. The reverse video display will revert to the normal display format indicating that the

PROGRAMMING BMS II Selecting Boiler Operating Mode el or Sequential Mode operation. The Boiler Operating Mode is MENU key, until CONFIGURATION MENU ap

PROGRAMMING BMS II Selecting Internal Setpoint Temperature in the Field Adjust Menu as follows: RNAL SETPT is The Internal Setpoint Temperature is sel

PROGRAMMING BMS II 4.6 “START ENABLED” OPTION The BMS II can be used to turn on and prove a device such as a fresh air damper, gas booster or the flo

PROGRAMMING BMS II 4-8 4. Next, scroll to the INTERNAL SETPT menu option. The second line of the display will show the current Internal Setpoint temp

TROUBLESHOOTING CHAPTER 5 - TROUBLESHOOTING 5.1 FAULT MESSAGES & COMMON PROBLEMS When a fault occurs in the boiler plant, the BMS II flashes f

TROUBLESHOOTING Table 5-1. Fault Messages – Continued Fault Message Description & Possible cause CURRENT LOOP ERROR The 4-to-20-mA remote

TROUBLESHOOTING Table 5-2 Common Problems Problem Possible Causes Solution Boiler plant not started by BMS II • BMS II not turned ON. • Outside

TROUBLESHOOTING 5-4 Table 5-2 Common Problems - Continued Problem Possible Causes Solution EMS cannot see BMSII • Incorrect address • Incorrect

APPENDIX A APPENDIX A _____________________________ BMS II MENUS AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT

AIR SEPARATORS Qty. 3 Taco Air Separator constructed in accordance with section VIII of the ASME Boiler Pressure Vessel Code and stamped 125 PSI wor

APPENDIX A APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMUM

APPENDIX A A-3 APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MA

APPENDIX A APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMU

APPENDIX B B-1 APPENDIX B _____________________________ STATUS AND FAULT MESSAGES DISPLAY MESSAGES DESCRIPTION STATUS MESSAGES: FAIL SAFE MODE

APPENDIX C C-1 APPENDIX C _____________________________ METHODS FOR DETERMINING RESET SCHEDULE AND OUTDOOR RESET RATIO CHARTS Using the Charts to D

APPENDIX C _____________________________ Table C-1. Header Temperature for a Building Reference Temperature of 50°F RESET RATIO Air Temp 0.6 0.8

APPENDIX C APPENDIX C _____________________________ Table C-3. Header Temperature for a Building Reference Temperature of 65°F RESET RATIO Air Tem

C-4 APPENDIX C _____________________________ Table C-5. Header Temperature for a Building Reference Temperature of 75°F RESET RATIO Air Temp 0.6 0.

APPENDIX C APPENDIX C _____________________________ Table C-7. Header Temperature for a Building Reference Temperature of 90°F RESET RATIO Air Te

Instruction SheetCBX Expansion Tanks402-020SUPERSEDES: New EFFECTIVE: July 9, 2001Plant ID No. 001-11801. Note location on the tank of the system conn

APPENDIX D D-1 APPENDIX D _____________________________ NTC Temperature Sensor Resistance Chart Temperature (°F) Resistance (ohms) Temperatur

APPENDIX E E-1 APPENDIX E _____________________________ BMS II WIRING DIAGRAM

APPENDIX F F-1 APPENDIX F _____________________________ BMS II PARTS AND ACCESSORIES PART NUMBER DESCRIPTION COMMENTS 64053 Boiler Manageme

APPENDIX G G-1 APPENDIX G _____________________________ PROGRAMMING THE BMS II USING RS-232 COMMUNICATION Introduction The RS-232 port located in

APPENDIX G APPENDIX G (cont.) __________________________ Programming Procedure BMS II functions which can be viewed or changed are listed in Ta

APPENDIX G APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS No. COMMAND ENTRY RANGE FACTORY DEFAULT 00 Header Tempe

Qty. 2 Taco IL Series Cartridge Circulators Constructed of Cast Iron, Cast Iron Impeller. The Shaft is constructed of an alloy steel material. T

Do it Once. Do it Right.TACO, INC., 1160 Cranston Street, Cranston, RI 02920 Telephone: (401) 942-8000 FAX: (401) 942-2360.TACO (Canada), Ltd., 6180 O

APPENDIX G APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS No. COMMAND ENTRY RANGE FACTORY DEFAULT 26 Not Used

APPENDIX G G-5 APPENDIX G (cont.) __________________________ Table G-1. BMS COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAULT 86

APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAULT 107 Net Boil

APPENDIX G APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAULT 1

APPENDIX H APPENDIX H __________________________ BMS II MODBUS ADDRESS ASSIGNMENTS H-1 BMS II STANDARD INPUT REGISTER ASSIGNMENMTS The Read Only

APPENDIX H APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Address (He

APPENDIX H APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Address (Hex

APPENDIX H H-4 APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Address

APPENDIX H APPENDIX H (cont.) __________________________ H-2. BMS II Controller Standard Holding Register Assignments The Holding Register address

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex)

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex)

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex) Me

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex) M

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex) M

APPENDIX H APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex) M

APPENDIX H H-12 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (H

APPENDIX I APPENDIX I _____________________________ BOILER START AND BOILER STOP LEVELS The BMS II Configuration Menu contains options for the Bo

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010

Uses: - Special gas vent for mid and high-efficiency gas fired heaters and boilers - ANSI Category I, II, III, or IV appliances and Direct Vent - Neg

Material Selection and DesignThe FasNSeal®W2 Double Wall Special Gas Vent System is manufactured under the most stringentquality control measures util

FasNSeal® W2 Features Built-in Gaskets And Mechanical Locking Bands©2005FasNSeal®W2 is a Heating Contractor’s Dream Come True!3FasNSeal®W2 Technical

4GENERAL VENTINGFasNSeal®W2 Vent LengthA B C D Product PartVent Dia. Eff. Lgth Number Number4.3 100001 W2-60310.3 100015 W2-12033 16.3 100045

5GENERAL VENTINGFasNSeal®W2 Adjustable Vent LengthA B C D Product PartVent Dia. Eff. Lgth Number Number 3 2.0-14.0 18.0 100250 W2-AVL3 4 2.0-

GENERAL VENTINGHORIZONTALVENTINGABDCABAB6FasNSeal® Bird Screen A B C D Product PartVent Dia. Eff. Lgth Number Number 3 2.0 30

HORIZONTAL7FasNSeal® 23 Degree Bird Screen A B C D Product PartVent Dia. Eff. Lgth Number Number 5 4.8 300188 FSBS5 6 5.6 300189 FSBS6 7 6

FasNSeal® Firestop/Flat Flashing A B C D Product PartVent Dia. Number Number 3 4.0 15.0 300296 FSFS4 4 5.0 17.0 300297 FSFS5 5 6.0 17.0

9FasNSeal® Variable Pitch Roof Flashing Vent B C D Product Part Dia. Number Number 3 5.2 8.7 300922 FSVPF3 4 6.2 8.7 300923 FSVPF

Website ConvenienceThe PTS website offers information about products thatdirectly effect consumer safety and efficientperformance of heating equipment

FasNSeal W2C o m p l e t e V e n t i n g S o l u t i o n s Installation InstructionsFasNSeal Double-Wall vent forCategory II, III, and IV applianc

A MAJOR CAUSE OF VENT RELATED FIRES IS FAILURE TO MAINTAIN REQUIRED CLEARANCES (AIR SPACES) TO COMBUSTIBLE MATERIALS. IT IS OF THE UTMOST IMPORTANCE

3CONTENTSIntroduction; General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Vent Size and Length; Adjustable Vent. .

4INTRODUCTIONFasNSeal W2, manufactured by Simpson Dura-Vent, is a Double-Wall special stainless steel vent system for gas red appliances listed as Ca

5appliances are designed for multiple venting. Cat. II, III or IV appliances may not be common vented with Cat. I, natural draft appliances. • FasNSe

6Use the W2-AVL vertically for easy adjustment of the required minimum 1/4” per foot pitch.Technical details about the stand alone W2-AVL: The overall

7Some appliance adapters may require a Single-wall to Double-wall Transition Adapter.CONDENSATE DRAINSIf instructions or local regulations call for a

8opening, gas utility meter, service regulator or the like. It also shall terminate at least 3’ (.9m) above any forced air inlet within 10’ (3.1m) an

9for procedure. (see photos on pg 2) Do not drill through or penetrate any part of the vent system.VERTICAL, THROUGH THE ROOF INSTALLATION• Terminate

1010.To inspect the vent system, open the locking band and remove the Rain Cap.FASNSEAL EXTERIOR WALL BRACKETSPRE-INSTALLATION1. Wall Brackets must b

L1191 2/2010Customer Service Support 800-835-4429 707-446-4740 FAX wwww.duravent.comSimpson Dura-Vent, IncPO Box 1510Vacaville CA 95696-1510Manufa

INSTALLATION, OPERATION & MAINTENANCE DATA JOB: OSU Ardmore Bioscience DATE: December 27, 2010

Special warranty per specification: WARRANTY Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or repl

Printed in U.S.A. REVISED JANUARY, 2009 Instruction No.AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07

Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday) (800) 526-0288

CONTENTS GF-109 - THE AERCO KC1000 GAS FIRED BOILER Operating & Maintenance Instructions FOREWARD A SECTION 1 – SAFETY PRECAUTIONS 1-1 Para. S

SUPERSEDES: 302-012 dated 1994 EFFECTIVE: April 15, 2001Plant ID No. 001-937FI/FE Base MountedPumpsInstallation and Operation Instructions302-012A: IN

CONTENTS SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1 Para. Subject Page6.1 Testing of Safety Devices 6-16.2 Low Gas Pressure Fault Test 6-1

FOREWORD A Foreword The AERCO KC boiler is a true industry advance that meets the needs of today's energy and environmental concerns. De

SAFETY PRECAUTIONS 1-1 SECTION 1 -- SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all

SAFETY PRECAUTIONS 1-2 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure

SAFETY PRECAUTIONS 1-3 Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equi

INSTALLATION 2-1 SECTION 2 - INSTALLATION PROCEDURES 2.1. RECEIVING THE UNIT Each KC1000 Boiler is shipped as a single crated unit. The crated uni

INSTALLATION 2-2 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Figure 2.1. The minimum clearanc

INSTALLATION 2-3 Figure 2.3 Supply and Return Location Whether installing single or multiple units, install the piping and accessories as shown in

Check alignment by placing a slotted straight edge across thecoupling halves at top, bottom and at the sides. If any light isseen between the straight

INSTALLATION 2-4 Figure 2.5a Pressure /Temperature Gauge Installation Figure 2.5b Pressure/Temperature Gauge Installation 2.3.5 CONDENSATE PIPING

INSTALLATION 2-5 The location of the 1-1/4" inlet gas connection is on the right side of the unit as shown in Figure 2.7. All pipe should be d

INSTALLATION 2-6 connection to the unit are made at the Power Box.This box is located on the front right side of the unit as shown in Figure 2.8. Con

INSTALLATION 2-7 2.6.1 CONSTANT SETPOINT MODE The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate.

INSTALLATION 2-8 (Direct Drive Mode) of the Boiler. These formats are: 4 to 20 mA/1 to 5 Vdc 0 to 20 mA/0 to 5 Vdc PWM – (Pulse Width Modulated sig

INSTALLATION 2-9 voltage rather than current is selected as the drive signal, a DIP switch must be set on the PMC Board located inside the Control Bo

INSTALLATION 2-10 normally close set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC. The relay energizes when any fault

CONTROL PANEL OPERATING PROCEDURES 3-1 SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION The information in this Section provides a

CONTROL PANEL OPERATING PROCEDURES 3-2 Table 3-1. Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 LE

CONTROL PANEL OPERATING PROCEDURES 3-3 Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM NO. CONTROL, INDICATOR OR DISPLAY F

To recharge the bearings with fresh grease, shut down pump(completely) and remove grease drain plug. Clean Alemite fittingand apply grease gun using

CONTROL PANEL OPERATING PROCEDURES 3-4 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu will be

CONTROL PANEL OPERATING PROCEDURES 3-5 NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outd

CONTROL PANEL OPERATING PROCEDURES 3-6 Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default I

CONTROL PANEL OPERATING PROCEDURES 3-7 3.7. TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change

CONTROL PANEL OPERATING PROCEDURES 3-8 3. With all required safety switches closed, a purge cycle will be initiated and the following events will occu

CONTROL PANEL OPERATING PROCEDURES 3-9 BLOWERBURNER Figure 3-6. Air/Fuel Valve In Ignition Position 8. With the unit firing properly, it will be con

INITIAL START-UP 4-1 SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the KC-1000 Boiler is comprised of the

INITIAL START-UP 4-2 Figure 4.1 1/8” Gas Plug Location 4.2.3 PREPARING THE FLUE VENT PROBE HOLE 1. If the unit has been installed using the reco

INITIAL START-UP 4-3 1. Open the supply and return valves to the unit and ensure that the system pumps are running. 2. Open the gas supply valve(s)

A. NO DISCHARGE1. Pump not primed2. Speed too low (when direct con-nected to electric motor, deter-mine whether or not motor isacross the line and rec

INITIAL START-UP 4-4 12. If the measured oxygen level is within the range in Table 1, no adjustment is necessary. Proceed to step 17. 13. If the mea

INITIAL START-UP 4-5 22. If the measured oxygen reading is above the oxygen range in Table 3, loosen the two 7/16" locking nuts securing the inl

INITIAL START-UP 4-6 4.5 UNIT REASSEMBLY Once combustion calibration is set properly, the unit can be reassembled for permanent operation as follow

MODE OF OPERATION SECTION 5 - MODE OF OPERATION 5.1 INTRODUCTION The following paragraphs provide detailed descriptions of the six different modes

MODE OF OPERATION 11. Press the CHANGE key. The display will begin to flash. 12. Use the ▲ and ▼ arrow keys to select the reset ratio determined in

MODE OF OPERATION If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modb

MODE OF OPERATION If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modb

MODE OF OPERATION 5-5 5.7 COMBINATION CONTROL SYSTEM (CCS) NOTE Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R

SAFETY DEVICE TESTING 6-1 SECTION 6-SAFETY DEVICE TESTING PROCEDURES 6.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety devi

START UP:Before operating the pump for the first time, check the following:1. Is motor correctly wired for voltage in use? Warranty is void if motor i

SAFETY DEVICE TESTING 6-2 Figure 6.2 High Gas Pressure Switch 6.4 LOW WATER LEVEL FAULT TEST 1. Set the ON/OFF switch in the OFF position. 2. C

SAFETY DEVICE TESTING 6-3 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Inter-lock. Te

SAFETY DEVICE TESTING 6-4 6.8 AIR FLOW FAULT TEST 1. Start the unit in manual mode and set the fire rate between 25% and 30%. 2. Once the unit has

SAFETY DEVICE TESTING 6-5 6.10 PURGE SWITCH OPEN DURING PURGE 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and

SAFETY DEVICE TESTING 6-6 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accor-dance with ASME Boiler and Pressure V

MAINTENANCE 7-1 SECTION 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliabilit

MAINTENANCE 7-2 Figure 7.1 Spark Ignitor and Flame Detector Location 7.3 FLAME DETECTOR The flame detector assembly is located in the body of the

MAINTENANCE 7-3 6. Remove the grounding terminal from the burner by loosening the upper screw and sliding the connector from the grounding rod. (See

MAINTENANCE 7-4 Figure 7.6 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between

MAINTENANCE 7-5 7.6.1 PROPANE UNITS For propane units it will be necessary to remove the air mix assembly in addition to the components outlined in

6. Insert new seal seat. For easy assembly, coat OD of seal rubber (either a cup or an O-ring) withspecial grease provided in small container. Do not

MAINTENANCE 7-6 Figure 7.11 Heat Exchanger 2 ½ Inch Inspection Plug Location 7.8 CONDENSATE DRAIN ASSEMBLY KC Boilers contain a condensate drain

TROUBLESHOOTING 8-1 Chapter 8- TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel i

TROUBLESHOOTING 8-2 TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blow

TROUBLESHOOTING 8-3 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1.

TROUBLESHOOTING 8-4 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FLAME LOSS DURING RUN 1.

TROUBLESHOOTING 8-5 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH WATER TEMP SWITCH OP

TROUBLESHOOTING 8-6 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED DURING P

TROUBLESHOOTING 8-7 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE OUT OF PHA

TROUBLESHOOTING 8-8 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 5. Defective I

TROUBLESHOOTING 8-9 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defectiv

Instruction SheetHorizontal Circulators Nos. 110 thru 120102-052SUPERSEDES: 102-052 February 1, 1986 EFFECTIVE: April 15, 2001DOITONCE. DOITRIGHT.TACO

APPENDIX A A-1 BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperatur

APPENDIX A A-2 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered.

APPENDIX A A-3 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Reset Ratio Permits setting of Reset Ratio when op

APPENDIX A A-4 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Setpt Limiting Allows Setpoint Limiting to be enable

APPENDIX B B-1 STARTUP, STATUS AND FAULT MESSAGES STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DISABLED HH:MM pm MM/DD/YY Displayed if ON/OF

APPENDIX B B-2 FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is open. LOW WAT

APPENDIX B B-3 FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during

APPENDIX C C-1 Temperature Sensor Resistance Chart (Balco)