1 INTERNATIONAL, INC. 159 PARIS AVENUE • NORTHVALE, NJ 07647 • PHONE 201-768-2400 TECHNICAL SERVICE BULLETIN Date: 08/19/05 Number
10 3. EQUIPMENT MODIFICATION/REWORK The equipment items to be modified are the Air/Fuel Valve and Differential Gas Pressure Regulator. The Air/Fuel
11 AA1/4-20 HEX HEADSCREWS (4)GAS INLETAIR INLETSTEPPERMOTORCOVERVALVE BODY(LOWER)VALVE BODY(UPPER)(SEE FIGURE 9) Figure 8. Air/Fuel Valve Modific
12 VALVE SHAFTSPRING RING-SHAFT SEALSHAFT SEAL-BACKUP WASHERPRE-LOAD SPRINGSHAFT DRIVE PINGAS VALVESHUTTERGAS PLATESHUTTER STOP PINRETAINING RINGFUEL
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
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
15 4. EQUIPMENT REPLACEMENT & REINSTALLATION The parts provided in the Low NOx Conversion Kit will differ slightly, depending on whether the KC1
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
17 Figure 15. Low NOx Burner Components
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
19 EXHAUSTMANIFOLD2" COMBUSTION CHAMBER LINER5/16-18 X 1-3/4"STUDS (6)BURNERHEADFIBER FRAXGASKETAIR INLETBURNER SHELLSTAGED IGNITION ORIFI
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.
20 Figure 17. Installation of Staged Ignition Tube and Nipple 5. Reinstall the Exhaust Manifold insulation (Figure 4) using three 1/4-20 screws
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
22 Figure 19. Staged Ignition Assemblies – Part No. 124867 & 124983
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.
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
25 Figure 22 Staged Ignition Assembly Inlet Connection For Honeywell SSOV 11. After the Staged Ignition outlet and inlet connections are complet
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
27 Figure 24. Igniter and Flame Detector Installation 14. Reinstall the Low Pressure Gas Switch shown in Figure 6 (Siemens SSOV) or Figure 7 (
28 Figure 25. Condensate Drain Assembly Location 16. Prior to proceeding to the next step, check to ensure that the igniter, flame detector and
29 THIS PRODUCT COMPLIES WITH NOx EMISSIONS STANDARDS OUTLINED IN SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT ( SCAQMD ) RULE 1146.2
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
30 Figure 27. Low NOx Labels – Side View 19. This completes replacement or reinstallation of all required parts and assemblies. Proceed to Sec
31 5. POST-INSTALLATION SETUP AND CALIBRATION Following installation of all Low NOx Conversion Kit items, it will be necessary to adjust several op
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
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
34 Figure 29. Analyzer Probe Hole Location 5.2.3 Installing The Differential Regulator Adjustment Tool 1. Remove the cap from the differential p
35 5.3 Combustion Calibration For Units With C-More or Modular Control Systems The Combustion Calibration procedures for KC1000 Boilers or Water H
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
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
38 Figure 31. Air Shutter Locking Nut Location NOTE At 30% firing rate, adjust only the differential pressure regulator. At 100% firing rate, ad
39 5.4 Combustion Calibration For Units With Digital (CCC) Control Systems The Combustion Calibration procedures for KC1000 Boilers or Water Heaters
4 AIR/FUELVALVEDIFFERENTIALGAS PRESSUREREGULATORGAS INLETPIPEBURNERASSEMBLYLOW GASPRESSURESWITCHSSOVI/OBOXCONTROLBOXCOMBUSTIONCHAMBER LINERNOTEILLUST
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
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
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
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
6 Figure 3. Burner & Air/Fuel Valve Removal 14. Remove the 8-inch Combustion Chamber Liner from the Heat Exchanger (Figure 4). Since this
7 INSULATIONCOMBUSTIONCHAMBER LINEREXHAUST MANIFOLD1/4-20 SCREW &FENDER WASHER(3 PLACES) Figure 4. KC1000 With Burner & Air/Fuel Valve Re
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
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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