Aerco KC Series Manuel d'instructions

REVISED JANUARY, 2009 n No. InstructioAERCO INTERNATIONAL, Inc., Northvale, New Jersey, 076

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

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

INSTALLATION 2-3 Figure 2.3 Supply and Return Location 2.3.3 PRESSURE RELIEF AND DRAIN VALVE INSTALLATION An ASME rated Relief Valve is supplied w

2-4 Figure 2.5b Pressure/Temperature Gauge Installation 2.3.5 CONDENSATE PIPING The KC Boiler is designed to condense. There-fore, the install

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

2-6 2.4.2 MANUAL GAS SHUTOFF VALVE A 1-1/4” manual gas shut-off valve is furnished with each unit. The valve should be positioned as shown in Figur

INSTALLATION 2-7 Figure 2.10 Input/Output (I/O) Box Location 2.6.1 CONSTANT SETPOINT MODE The Constant Setpoint Mode is used when it is desired to

2-8 2.6.3 BOILER MANAGEMENT SYSTEM (BMS) MODE NOTE BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signaling to the B

INSTALLATION 2-9 shield is to be connected only to the terminals labeled SHEILD in the I/O Box. The sensor end of the shield must be left free and un

2-10 NOTE: Both the Delayed Interlock and Remote Interlock must be in the closed position to allow the unit to fire. 2.7.9.1 REMOTE INTERLOCK IN The

INSTALLATION 2-11 square inches of free area. The free area must take into account restrictions such as louvers and bird screens. 2.10.2 COMBUSTION

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

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

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 Outdo

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 (a) Blower relay energizes and turns on blower. (b) Air/Fuel Valve rotates to the full-open purge position an

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

CONTENTS i GF-109LN - AERCO KC1000 GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWORD A SECTION 1 – SAFETY PRECAUTIONS 1-1

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

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 re

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

INITIAL START-UP 4-4 18. Oxygen levels at the 16% firing rate should be as shown in Table 2 (page 4-5). Also, ensure that the CO and NOx readings do

INITIAL START-UP 4-5 Table 1 Combustion Oxygen Levels for a 30% Firing Rate Inlet Air Temp Oxygen (±0.2%) Carbon Monoxide *NOx -25°F 7.8% <10

INITIAL START-UP 4-6 1. Open the supply and return valves to the unit and ensure that the system pumps are running. 2. Open the gas supply valve(

INITIAL START-UP 4-7 17. Once the oxygen level is within the specified range at 30%, change the firing rate to 16%. 18. Oxygen levels at the 16% fir

INITIAL START-UP 4-8 4.6 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS There are two Over-Temperature Limit switches that turn off the unit when the o

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

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

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 Combination Control System (CCS) is one that The theory behind this type of system is that the When the combo units are satisfy

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

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 the Delayed Interlock.

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

FOREWORD A Foreword This system can be operated using natural gas or propane fuel. A simple spring change in the differential regulator and com

SAFETY DEVICE TESTING 6-6 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the unit’s Safety Pressure Relief Valve in accordance with ASME Boiler and Pres

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

MAINTENANCE 7-2 7.3 FLAME DETECTOR The flame detector assembly is located in the body of the burner (Figure 7.1). The flame detector may be HOT. A

MAINTENANCE 7-3 7. Loosen the 1/4” NPT union on the low NOx staged ignition assembly (Figure 7.3). 8. Disconnect the staged ignition assembly 1/8”

MAINTENANCE 7-4 19. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between the air/fuel valve and the differential press

MAINTENANCE 7-5 RELIEF VALVEDRAIN VALVEREDUCING1/4" PLUGHOT WATERHOT WATERSUPPLY (OUTLET)RETURN (INLET)BUSHINGREDUCINGBUSHING Figure 7.9 Heat Ex

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. Blowe

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

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

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

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)

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

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

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

APPENDIX FF-4

APPENDIX FF-5

APPENDIX F F-6

APPENDIX GG-1

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

APPENDIX GG-2

APPENDIX GG-3

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

APPENDIX J J-1 KC1000 LOW NOx DUAL-FUEL SWITCH-OVER INSTRUCTIONS The KC1000 Low NOx Boiler is shipped from the factory configured for either natur

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