Aerco KC Standard to Low NOx Convertion Instructions Manuel d'utilisateur

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1
INTERNATIONAL, INC.
159 PARIS AVENUE NORTHVALE, NJ 07647 PHONE 201-768-2400
TECHNICAL SERVICE BULLETIN
Date: 08/19/05 Number: 2005-03
Subject: KC1000 LOW NOx CONVERSION KIT INSTRUCTIONS
Page 1 of 42
1. INTRODUCTION
The KC1000 Low NOx Conversion Kit, Part No. 124918 contains all of the assemblies, cables and
attaching parts necessary to upgrade a KC1000 Boiler or Water Heater for Low NOx compliance.
When so equipped, the Boiler or Water Heater complies with the NOx emission standards outlined in:
South Coast Air Quality Management District (SCAQMD), Rule 1146.2.
Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117, Rule
117.465.
NOTE
These Conversion Kit instructions are applicable to all KC1000 units,
regardless of the Control System and/or Safety Shutoff Valve (SSOV) installed
on your unit. Unless otherwise specified, the descriptions and procedures
contained in this Service Bulletin apply to all Natural Gas KC1000 Water
Heater and Boiler configurations. If you are not certain of your current unit
configuration, contact your nearest AERCO Representative.
1.1 General Description
In order to comply with the above-mentioned low NOx emission standards, the existing KC Burner
Assembly must be replaced with a new Low NOx Burner Assembly and a Staged Ignition Assembly.
In addition, several other assemblies must be modified to ensure low NOx emissions.
The Low NOx Conversion procedures provided in this Service Bulletin are divided into the following
main categories:
Equipment Removal
Equipment Modification/Rework
Equipment Replacement/Reinstallation
Post-Installation Setup and Calibration
The procedures in each of these categories are presented in Sections 2 through 5 respectively.
The following paragraphs in this Section describe the contents of the Low NOx Conversion Kit and the
tools and test equipment required to perform all procedures in this Service Bulletin.
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Résumé du contenu

Page 1 - TECHNICAL SERVICE BULLETIN

1 INTERNATIONAL, INC. 159 PARIS AVENUE • NORTHVALE, NJ 07647 • PHONE 201-768-2400 TECHNICAL SERVICE BULLETIN Date: 08/19/05 Number

Page 2 - 1.2 Conversion Kit Contents

10 3. EQUIPMENT MODIFICATION/REWORK The equipment items to be modified are the Air/Fuel Valve and Differential Gas Pressure Regulator. The Air/Fuel

Page 3 - 2. EQUIPMENT REMOVAL

11 AA1/4-20 HEX HEADSCREWS (4)GAS INLETAIR INLETSTEPPERMOTORCOVERVALVE BODY(LOWER)VALVE BODY(UPPER)(SEE FIGURE 9) Figure 8. Air/Fuel Valve Modific

Page 4 - CAUTION

12 VALVE SHAFTSPRING RING-SHAFT SEALSHAFT SEAL-BACKUP WASHERPRE-LOAD SPRINGSHAFT DRIVE PINGAS VALVESHUTTERGAS PLATESHUTTER STOP PINRETAINING RINGFUEL

Page 5

13 9. Next, remove the #8-32 screw securing the existing air butterfly to the Air/Fuel Valve shaft (Figure 11) and remove the butterfly. 10. Apply

Page 6

14 IMPORTANT It is important that the adjustment screw be installed to a depth of 2 inches from the top of the regulator housing. This will simplify

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15 4. EQUIPMENT REPLACEMENT & REINSTALLATION The parts provided in the Low NOx Conversion Kit will differ slightly, depending on whether the KC1

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16 Figure 14. Installation of Combustion Chamber Liner NOTE The next item to be installed is the new Low NOx Burner Assembly provided in the Conve

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17 Figure 15. Low NOx Burner Components

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18 4. Due to space limitations, the new Low NOx Burner Head and Shell must be temporarily separated as described in the previous step and installed

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19 EXHAUSTMANIFOLD2" COMBUSTION CHAMBER LINER5/16-18 X 1-3/4"STUDS (6)BURNERHEADFIBER FRAXGASKETAIR INLETBURNER SHELLSTAGED IGNITION ORIFI

Page 12 - VIEW A - A

2 1.2 Conversion Kit Contents KC1000 Low NOx Conversion Kit, Part No. 124918-( ) is available in four configurations, designated -1, -2, -3 and -4.

Page 13

20 Figure 17. Installation of Staged Ignition Tube and Nipple 5. Reinstall the Exhaust Manifold insulation (Figure 4) using three 1/4-20 screws

Page 14 - IMPORTANT

21 (c) Secure the Gas Inlet Pipe to the Air/Fuel Valve with two 3/8-16 bolts and hex nuts. (d) Secure the Pipe to the Burner with four 1/4-20 hex n

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22 Figure 19. Staged Ignition Assemblies – Part No. 124867 & 124983

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23 NOTE The 1/8” street elbow shown in Figure 19 was previously removed in step 4(f) and attached to the 3” nipple on the Low NOx Burner Shell. 9.

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24 (b) If the KC1000 is equipped with a Siemens SSOV, remove the 1/4” NPT plug from the downstream port on the SSOV. Connect the inlet side (flex ga

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25 Figure 22 Staged Ignition Assembly Inlet Connection For Honeywell SSOV 11. After the Staged Ignition outlet and inlet connections are complet

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26 13. Next, install the Igniter and Flame Detector in the Low NOx Burner (Figure 24) as follows: (a) Prior to installing the Igniter in the Low NO

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27 Figure 24. Igniter and Flame Detector Installation 14. Reinstall the Low Pressure Gas Switch shown in Figure 6 (Siemens SSOV) or Figure 7 (

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28 Figure 25. Condensate Drain Assembly Location 16. Prior to proceeding to the next step, check to ensure that the igniter, flame detector and

Page 22

29 THIS PRODUCT COMPLIES WITH NOx EMISSIONS STANDARDS OUTLINED IN SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT ( SCAQMD ) RULE 1146.2

Page 23

3 1.3 Tools and Test Equipment Required The required tools and test equipment are listed in paragraphs 1.3.1 and 1.3.2 respectively. 1.3.1 Tools Th

Page 24 - KC1000 PARTIAL TOP VIEW

30 Figure 27. Low NOx Labels – Side View 19. This completes replacement or reinstallation of all required parts and assemblies. Proceed to Sec

Page 25

31 5. POST-INSTALLATION SETUP AND CALIBRATION Following installation of all Low NOx Conversion Kit items, it will be necessary to adjust several op

Page 26

32 7. This completes the Post Purge Timer menu setting. 8. If the unit is a Water Heater, go directly to paragraph 5.1.2 (Breakpoints) before the e

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33 5.2 Combustion Calibration Setup Prior to performing Combustion Calibration procedures in paragraph 5.3 or 5.4, the unit must be set up as follow

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34 Figure 29. Analyzer Probe Hole Location 5.2.3 Installing The Differential Regulator Adjustment Tool 1. Remove the cap from the differential p

Page 29 - PARTIAL FRONT VIEW

35 5.3 Combustion Calibration For Units With C-More or Modular Control Systems The Combustion Calibration procedures for KC1000 Boilers or Water H

Page 30

36 NOTE Always approach a firing rate percentage from the same direction, (i.e., 100% to 30%, 30% to 20%, etc.). Whenever going to an increased firin

Page 31

37 16. Oxygen levels at the 16% firing rate should be as shown in Table 2. Also, ensure that the CO and NOx readings do not exceed the values shown

Page 32

38 Figure 31. Air Shutter Locking Nut Location NOTE At 30% firing rate, adjust only the differential pressure regulator. At 100% firing rate, ad

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39 5.4 Combustion Calibration For Units With Digital (CCC) Control Systems The Combustion Calibration procedures for KC1000 Boilers or Water Heaters

Page 34

4 AIR/FUELVALVEDIFFERENTIALGAS PRESSUREREGULATORGAS INLETPIPEBURNERASSEMBLYLOW GASPRESSURESWITCHSSOVI/OBOXCONTROLBOXCOMBUSTIONCHAMBER LINERNOTEILLUST

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40 NOTE Always approach a firing rate percentage from the same direction, (i.e., 100% to 25%, 25% to 20%, etc.). Whenever going to an increased firin

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41 15. Oxygen levels at the 10% (1.4V) firing rate should be as shown in Table 5. Also, ensure that the CO and NOx readings do not exceed the value

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42 NOTE At 25% (2.0V) firing rate, adjust only the differential pressure regulator. At 100% (5.0V) firing rate, adjust only the inlet air shutter. 19

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5 4. Remove the rear covers from the unit. 5. Remove the condensate cup from under the unit and disconnect the condensate drainage tube from the e

Page 40

6 Figure 3. Burner & Air/Fuel Valve Removal 14. Remove the 8-inch Combustion Chamber Liner from the Heat Exchanger (Figure 4). Since this

Page 41

7 INSULATIONCOMBUSTIONCHAMBER LINEREXHAUST MANIFOLD1/4-20 SCREW &FENDER WASHER(3 PLACES) Figure 4. KC1000 With Burner & Air/Fuel Valve Re

Page 42

8 CAUTION USE CARE WHEN REMOVING THE AIR/FUEL VALVE TO AVOID DAMAGING OR LOSING THE FLANGE O-RING. 21. Completely remove the Air/Fuel Valve from

Page 43

9 Figure 6. Low Pressure Gas Switch Location With Siemens SSOV Installed Figure 7. Low Pressure Gas Switch Location With Honeywell SSOV Install

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