Aerco KC1000 Boiler equipped with Mod-Box Controller Manuel d'utilisateur

Printed in U.S.A. REVISED 01/03/05 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 U

INSTALLATION 5 Figure 2.5b Pressure/Temperature Gauge Installation 2.3.5 CONDENSATE PIPING The KC Boiler is designed to condense and the installati

INSTALLATION 6 To avoid damage to the unit, when pressure testing gas piping, isolate the unit from the supply gas piping. At no time should there be

INSTALLATION 7 SSOVACTUATORBLOWERFRAMEELECTRICAL WIRING BOX Figure 2.8 AC Wiring Box Location NOTE: All electrical conduit and hardware should be

INSTALLATION 8 2.6.1 CONSTANT SETPOINT MODE No external field wiring connections other than electrical supply connectins are required for this mode.

INSTALLATION 9 2.9 FLUE GAS VENT INSTALLATION The AERCO Venting and Combustion Air Guide, GF-1050, must be consulted before any flue or inlet air v

CONTROL PANEL OPERATING PROCEDURES10SECTION 3- CONTROL PANEL OPERATING PROCEDURESThe following is a guide to the operation of thecontrol panel. Initia

CONTROL PANEL OPERATING PROCEDURES11The third LED, “ON”, indicates the status of thestart relay, (see Fig. 3.2). The start relay isinternal to the con

CONTROL PANEL OPERATING PROCEDURES12To access the percent of firing rate press theINDEX button while in the primary menu until(Pct) is displayed in th

CONTROL PANEL OPERATING PROCEDURES13Figure 3.7Auto/Manual Display with Manual On3.4 THE SECONDARY MENUThe secondary menu is primarily related totempe

CONTROL PANEL OPERATING PROCEDURES14# CYCLES =“DATE” “TIME”The number of timesthe controller hascompleted it’s startcycle, and the timeand dateSET DA

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

CONTROL PANEL OPERATING PROCEDURES15 Figure 3.9Combustion Safeguard Status Indicator LEDLocation3.7 WATER LEVEL TEST and RESETSWITCHESThe water level

CONTROL PANEL OPERATING PROCEDURES16CONNECTOR149VALVESHUT-OFFSAFETYSWITCHCLOSUREPROOF OF9A148145146147FROM Figure 3.11Proof of Closure Switch Locatio

CONTROL PANEL OPERATING PROCEDURES173.10 AFTER FLAMEOnce the control signal has gone below the stoplevel (see section 3.12 for Stop Levelexplanation)

INITIAL START-UP18SECTION 4 - INITIAL START- UP4.1 INITIAL START- UP REQUIREMENTSThe initial start-up of the KC-1000 boiler iscomprised of the follow

INITIAL START-UP191/4" NPT PLUG(INSTALLMANOMETERHERE)SSOVFigure 4.11/8” Gas Plug Location4.2.2 PREPARING THE FLUE VENTPROBE HOLE1. If the unit

INITIAL START-UP20 3. Using the 16” manometer installed as perSection 4.2.1, adjust the gas supplyregulator until a reading of 12” W.C. staticpressur

INITIAL START-UP2116. Wait for the analyzer reading to settle, thencompare the new reading to Table 1. Repeatadjustment until oxygen is within thespe

INITIAL START-UP22specified range. Firmly tighten the inlet airshutter locking nuts when finished. NOTE:Adjust the inlet air shutter only at 100%firin

INITIAL START-UP239. Remove the combustion analyzer probefrom the vent hole. Seal the probe hole andreplace the vent connection cover. 4.6 OVER TEMP

MODE OF OPERATION 24SECTION 5- MODE OF OPERATION The following is a detailed description of the KC1000’s six modes of operation. Each unit is shippe

CONTENTSiGF-106 THE AERCO KC1000 GAS FIRED BOILEROperating & Maintenance InstructionsFOREWORDSection 1 SAFETY PRECAUTIONS-------------------------

MODE OF OPERATION 255.2 CONSTANT SETPOINT MODE Constant setpoint mode of operation is when a non-changing, fixed, header temperature is desired. Co

MODE OF OPERATION 265. Follow the above directions to change back to remote mode. NOTE: The unit automatically defaults to remote mode upon AC pow

MODE OF OPERATION 27from an external source, the following functions must be correctly set. MENU FUNCTION SETTING Secondary Lore re Secondary FUNC

MODE OF OPERATION 285.6.1 COMBINATION CONTROL SYSTEM FIELD WIRING Wiring for this system is between the BMS panel, the CCP and terminals 2 and 3 in

SAFETY DEVICE TESTING 29SECTION 6-SAFETY DEVICE TESTING PROCEDURES 6.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety devic

SAFETY DEVICE TESTING 30 8. Open the water shut-off valve in the return piping to the unit to fill the shell. 9. Open the water shut-off valve in t

SAFETY DEVICE TESTING 31 1. Disconnect AC power from the unit. 2. Disconnect wire #17 from the air pressure switch located on the air/fuel valve (

SAFETY DEVICE TESTING 32 10. Restore AC power to the unit. 11. Start the unit. WARNING! THIS IS A 120-VOLT AC COMBUSTION SAFEGUARD SYSTEM. POWER M

MAINTENANCE 33SECTION 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability

MAINTENANCE 34 Figure 7.1 Spark Ignitor and Flame Detector Location To inspect or replace the flame detector: 1. Put the green ON/OFF button on the

CONTENTSiiSection 6 SAFETY DEVICETESTING PROCEDURES---------------------------296.1 Testing of Safety Devices6.2 Gas Pressure Fault Test6.3 Low Water

MAINTENANCE 35 Figure 7.2 Grounding Terminal Location 7. Using a 7/16” socket or open end wrench remove the four 1/4”-20 nuts on the gas inlet pipe

MAINTENANCE 36 Figure 7.6 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between t

MAINTENANCE 3726. Beginning with the manifold, reinstall all the components in the reverse order that they were removed. 7.6.1 PROPANE UNITS For

TROUBLESHOOTING 38SECTION 8- TROUBLESHOOTING GUIDE This troubleshooting section is intended to serve as a guideline to determining and solving fault

TROUBLESHOOTING 393. Replace the low gas pressure switch if it does not show continuity. 4. If there is no continuity, check for loose connectors

TROUBLESHOOTING 408.2.1 EXHAUST TEMPERATURE SENSOR Start the unit and wait for the HI EXHAUST TEMP. message to display. 1. Using an accurate temp

TROUBLESHOOTING 418.3.3 WATER LEVEL CIRCUIT 1. Remove AC power from the unit. 2. Open the control box to expose the wiring and internal componen

TROUBLESHOOTING 429. Check the pins of the 15 pin connector for proper insertion or wear. 10. If the connectors, pins, and continuity are okay, re

TROUBLESHOOTING 437. If the flame fault still persists after checking the above, measure the flame detector lead voltage as per Section 8.5.7. 8.

TROUBLESHOOTING 448.5.5 FLAME DETECTOR 1. Disconnect AC power to the unit. 2. Remove the flame detector as per Section 7.3. 3. Check the dete

FOREWORDiiiForewordThe AERCO KC boiler is a true industry advance that meets the needs of today's energy andenvironmental concerns. Designed for

TROUBLESHOOTING 45 29. Reconnect AC power to the unit and start the unit. 30. If the flame fault still persists, replace the combustion safeguard.

TROUBLESHOOTING 464. If the blower starts but the Annunciator displays LOW AIR FLOW, proceed to Section 8.6.4. 5. If the unit has sealed combustio

TROUBLESHOOTING 478.6.5 SOLID STATE RELAY 1. Referring to Appendix I,Item #17, open the control box and locate the solid state relay. 2. Locate

TROUBLESHOOTING 484. Connect an ohmmeter across the blower proof switch and start the unit. 5. The blower proof switch should show continuity whil

TROUBLESHOOTING 4914. If there is no continuity, replace the actuator or switch. 15. Start the unit. If the unit sequence resumes normal operation

TROUBLESHOOTING 505. If the air/fuel valve does not rotate or is extremely difficult to rotate, replace the air/fuel valve. 6. Disconnect the 12 p

APPENDIXAPPENDICESAPPENDIX ATemperature Controller MenusAPPENDIX BTemperature Controller Quick Programming GuideAPPENDIX CTemperature Sensor Resist

APPENDIX A i PRIMARY MENU ITEM DESCRIPTIONS tout pct Setp Auto This is the actual outlet water temperature of

APPENDIX A ii SECONDARY MENU ITEM DESCRIPTIONS CONSTANT SETPOINT FUNC OSAT Oat LLT Hlt Pb1 Int

APPENDIX A iii Drt Addr LOre This is the derivative rate in % /.1°/sec. This adjusts response time to temperature changes at the o

SAFETY PRECAUTIONS1SECTION 1 - SAFETY PRECAUTIONSInstalling or operating personnel MUST, atall times, observe all safety regulations. Thefollowing wa

APPENDIX A iv SECONDARY MENU ITEM DESCRIPTIONS INDOOR-OUTDOOR RESET MODE FUNC REFT RR OSAT Oat LLT

APPENDIX A v Pb1 Int Drt Addr LOre This is the Proportional Band in 0F for the feedback of the controller. This

APPENDIX B viTEMPERATURE CONTROLLER QUICK REFERENCEPROGRAMMING GUIDEThe following is a “How To” guide that quickly shows how to access menu levels a

APPENDIX B viiNOTE: The temperature controller defaults back to the PRIMARY menu from the SECONDARYmenu or the SECURE menu if there is no activity i

APPENDIX B viii• SECURE MENU TO THE MAIN MENUWhile in the SECURE menu press INDEX and the ⇓ arrow key. This will place you in the SECONDARY menu. P

APPENDIX Cix

APPENDIX DxINDOOR\OUTDOOR RESET RATIO CHARTSHeader Temperature for a Building Reference Temperature of 50FRESET RATIOAirTemp0.6 0.8 1.0 1.2 1.4 1.6 1.

APPENDIX DxiRESET RATIOAirTemp0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.46565 65 65 65 65 65 65 65 65 656068 69 70 71 72 73 74 75 76 775571 73 75 77 79 81

APPENDIX DxiiHeader Temperature for a Building Reference Temperature of 75FRESET RATIOAirTemp0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.475F75 75 75 75 75

APPENDIX Dxiii Header Temperature for a Building Reference Temperature of 90FRESET RATIOAirTemp0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.490F90 90 90 90 9

INSTALLATION 2 SECTION 2 - INSTALLATION PROCEDURES 2.1. RECEIVING THE UNIT Each KC unit is shipped as a single crated unit. The shipping weight

APPENDIX ExivBOILER DEFAULT SETTINGS CONSTANT SET POINT MODEMENU LEVEL& CODEDESCRIPTION OF CODE FACTORYDEFAULTPRIMARY MENUtout OUTLET TEMPERATURE

APPENDIX ExvBOILER DEFAULT SETTINGSINDOOR /OUTDOOR RESET MODEMENU LEVEL& CODEDESCRIPTION OF CODE DEFAULTVALUEPRIMARY MENUtout OUTLET TEMPERATURE A

APPENDIX F xvi

APPENDIX F xvii 1/4" CARBON STEEL SHELL, SA-53, GRADE BCU-NI HELICAL TUBE, SB-111, CDA-C706001/4" WALL CU-NI WELDED TUBE SB171, CDA-70635(8

APPENDIX F xviii

APPENDIX F xix

APPENDIX G xx

APPENDIX G xxi

APPENDIX H xxii

APPENDIX H xxiii

INSTALLATION 3 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Figure 2.1. The minimum clearance

APPENDIX I xxiv 13 123446 FAN GUARD 12 123402 #6-32 X 3/8 LG PAN HEAD MACH. SCREW 11 123459 #6-32 X 2 LG PAN HEAD MACH. SCREW 10 123452 #8-

APPENDIX I xxv 18 123280-B_ TEMPERATURE CONTROLLER (NEED STYLE NUMBER ) 17 123803 SOLID STATE TIMER-ARTISAN CORP(123469 FOR SSAC INC.) 16 1

HEAT EXCHANGERS • WATER HEATERS • BOILERSHEAT RECLAMATION SYSTEMS • CONTROL VALVES STEAM GENERATORSHOT WATER SYSTEMSAERCO INTERNATIONAL, INC. • 159 P

INSTALLATION 4 Whether installing single or multiple units, install the piping and accessories as shown in the appropriate piping diagram located in