Aerco KC1000 Heater w/Mod-Box Controller Manuel d'utilisateur

Printed in U.S.A. REVISED 12/30/04 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 US

INSTALLATION PROCEDURES5Figure 2.5Condensate Drain Assembly Location2.4 GAS SUPPLY PIPINGAERCO Gas Fired Equipment Gas Componentsand Supply Design Gu

INSTALLATION PROCEDURES6not exceed 10.5” W.C. at any time when the unitis firing. Proper sizing of the gas supply regulatorin delivering the correct g

INSTALLATION PROCEDURES7Figure 2.8Electrical Wiring Diagram2.6 FIELD CONTROL WIRINGEach unit is fully wired from the factory with aninternal operatin

INSTALLATION PROCEDURES8of the equivalent length. For a natural draftinstallation the draft must not exceed - 0.25”W.C. These factors must be planned

CONTROL PANEL OPERATING PROCEDURES9SECTION 3- CONTROL PANEL OPERATING PROCEDURESThe following is a guide to the operation of theunit’s control panel.

CONTROL PANEL OPERATING PROCEDURES10The third LED, “ON”, indicates the status of thestart relay, (Fig. 3.2). The start relay is internal tothe control

CONTROL PANEL OPERATING PROCEDURES11To access the percent of firing rate press theINDEX button while in the primary menu until(Pct) is displayed in th

CONTROL PANEL OPERATING PROCEDURES12Figure 3.7Auto/Manual Display with Manual ON3.4 SECONDARY MENUThe secondary menu is primarily related totemperatu

CONTROL PANEL OPERATING PROCEDURES13LCD display on the front of the control panel.They are labeled CLEAR, !, ", and AUX.The MAIN display is used

CONTROL PANEL OPERATING PROCEDURES143.6 THE COMBUSTION SAFEGUARDCONTROLLERThe Combustion Safeguard is responsible formonitoring the safety components

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

CONTROL PANEL OPERATING PROCEDURES153.9 START SEQUENCE When the unit is in the standby mode, and thereis a demand for hot water, the following will o

CONTROL PANEL OPERATING PROCEDURES16from the ignition transformer and the MAINLED lights of the combustion safeguard. At this point, the annunciator w

INITIAL START-UP17SECTION 4 - INITIAL START UP4.1 INITIAL START- UP REQUIREMENTSThe Initial Start-Up of the KC-1000 Boiler iscomprised of the followi

INITIAL START-UP181/4" NPT PLUG(INSTALLMANOMETERHERE)SSOVFigure 4.11/8” Gas Plug Location4.2.2 PREPARING THE FLUE VENTPROBE HOLE1. If the unit

INITIAL START-UP193. Using the 16” manometer installed as perSection 4.2.1, adjust the gas supplyregulator until a reading of 12” W.C. staticpressure

INITIAL START-UP20clockwise, 1/4-1/2 turns, to increase gasflow. 16. Wait for the analyzer reading to settle, thencompare the new reading to Table 1.

INITIAL START-UP2126. Allow the analyzer to settle. Repeat theadjustment until the oxygen is within thespecified range. Firmly tighten the inlet airsh

INITIAL START-UP228. Replace the unit’s panels and hood.9. Remove the combustion analyzer probefrom the vent hole. Seal the probe hole andreplace th

INITIAL START-UP234.6.3 MAXIMUM LOAD ADJUSTMENT1. Enter the SECONDARY menu of thetemperature controller by simultaneouslypressing ! and ENTER. 2. P

INITIAL START-UP24200o F water temperature. Do NOT attempt toadjust it’s set point.To adjust the lower over temperature switch limitswitch:1. Remove

CONTENTSi GF-105 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER Operating & Maintenance Instructions FOREWORDSection 1 SAFETY PRECAUTION

SAFETY DEVICE TESTING25SECTION 5-SAFETY DEVICE TESTING PROCEDURES5.1 TESTING OF SAFETY DEVICESPeriodic testing of all controls and safety devicesis r

SAFETY DEVICE TESTING269. Open the water shut-off valve in the supplypiping to the unit. 10. Press the LOW WATER LEVEL RESETbutton to reset the low w

SAFETY DEVICE TESTING272. Disconnect wire #17 from the air pressureswitch located on the air/fuel valve (See Fig.5.4). 3. Restore AC power to the un

SAFETY DEVICE TESTING2810. Restore AC power to the unit. 11. Start the unit.WARNING!THIS IS A 120 VOLT AC COMBUSTIONSAFEGUARD SYSTEM. POWER MUSTBE REM

MAINTENANCE29SECTION 6 – MAINTENANCE6.1 MAINTENANCE SCHEDULEThe KC1000 requires regular routinemaintenance to keep up efficiency andreliability. For

MAINTENANCE305 Prior to reinstalling the ignitor, an anti-seizecompound must be applied to the ignitorthreads. 6 Reinstall the ignitor using the ign

MAINTENANCE316.7 BTU TRANSMITTER ASSEMBLYThe BTU Transmitter is a crucial part of theunit’s temperature control system. It must beinspected and kept

MAINTENANCE3212. Loosen the compression fitting holding thehydraulic zero and control orifice tubeassembly to the pump’s impeller housing,(See Fig. 6.

MAINTENANCE33Figure 6.9BTU Transmitter Shell ComponentsFigure 6.10Impeller Housing Disassembly21 Once the BTU transmitter has beeninspected and clean

MAINTENANCE34Figure 6.11Grounding Terminal Location9. Loosen the hose clamp at the air/fuel valveoutlet and slide the clamp back towards theburner, (

CONTENTSii2/27/99Section 6 MAINTENANCE REQUIREMENTS-------------------296.1 Maintenance Schedule6.2 Spark Ignitor6.3 Flame Detector6.4 Combustion Cali

MAINTENANCE35Figure 6.15Air/Fuel Valve Inlet Hose Clamp16. Using an 11/16” wrench, loosen thecompression fittings on the feedback tubebetween the air/

MAINTENANCE36122537). The use of Permatex or a similargasket adhesive is recommended.26. Replace the gasket between the manifoldand tubesheet (P/N GP-

MAINTENANCE377. Place a shell head gasket on top of the shellring first, then place the release gasket ontop of the shell head gasket. Align thegaske

MAINTENANCE38Figure 6.20Concave Style Head8. Place the shell gasket then the releasegasket on top of the shell ring and align thegasket holes with th

TROUBLESHOOTING39SECTION 7- TROUBLESHOOTING GUIDEThis troubleshooting section is intended to serveas a guideline to determining and solving faultson t

TROUBLESHOOTING405. Referring to system schematic 161412 inthe Appendix, locate and check continuity inwires #20 and #32 from the fifteen pinconnecto

TROUBLESHOOTING415. If 12 VAC is read on the AC voltmeter,disconnect power to the unit and ground theprobe to the unit shell. 6. Restore electrical

TROUBLESHOOTING427. Reset the unit and if necessary, the upperover-temperature limit switch. If the unit willnot reset proceed to section 7.4.2.7.4.2

TROUBLESHOOTING4310. Place the entire length of the sensors in awater bath of known temperature. Measurethe resistance of the probe, and determinethe

TROUBLESHOOTING44 2. If the gas supply valves were open, restartthe unit. 3. Remove the cover to the Air Fuel Valve.Ensure that the Air Fuel Valve r

FOREWORDiiiForewordThe AERCO KC Hot Water Heating System is a true industry advance that meets the needs oftoday’s energy and environmental concerns.

TROUBLESHOOTING4520. Restore electrical power to the unit andrestart the unit. 21. If the safety shutoff valve still does not open,proceed to section

TROUBLESHOOTING4621. If wires #12 and #29 have continuity, inspectthe pin on wire #12 in the 9-pin connector forproper insertion or signs of wear 22.

TROUBLESHOOTING477.6 LOCKOUT RUN AIR FLOWA LOCKOUT RUN AIR FLOW indicates that theair pressure while running is too low foroperation. Oscillations or

TROUBLESHOOTING487. Referring to system schematic 161412 inAppendix F, locate wire #17 and #24 andcheck both for continuity. 8. Check the switch end

TROUBLESHOOTING497.7.3 AIR SUPPLY AND BLOWER PROOFSWITCH1. If the unit has sealed combustion, check theducting for any signs of blockage 2. If combu

TROUBLESHOOTING5012. Reset the actuator onto the valve body whileobserving the ohm meter 13. If continuity is now okay, reconnect wires#21 and #22, re

TROUBLESHOOTING51NOTE:Do not rotate the air/fuel valve with powerapplied to the unit.5. If the air/fuel valve does not rotate or isextremely difficul

APPENDICES APPENDIX A Temperature Controller Menus APPENDIX B Temperature Controller Quick Programming Guide APPENDIX C Temperature Sensor

APPENDIX AiPRIMARY MENU ITEM DESCRIPTIONStoutpctSetpAutoThis is the actual outlet watertemperature of the heater. It isdesignated by the code (tout).P

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

APPENDIX AiiSecondary Menu Item DescriptionFUNCtoutFFtPctSetP SEnSThis indicates the mode of operation thetemperature controller is in. Commonmodes ar

APPENDIX AiiiOFStLLtHLtPb1intdrtThis is minimum load adjust used duringa water heater temperature calibration.It adjusts the controller’s linear offse

APPENDIX AivAddrloreTurns the outlet sensor feedback ON orOFF. Used during factory calibration ofthe BTU transmitter. Feedback shouldalways be in the

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

APPENDIX BviNOTE: The temperature controller defaults back to the PRIMARY menu from the SECONDARYmenu or the SECURE menu if there is no activity in ei

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

APPENDIX Cviii

APPENDIX D ix WATER HEATER DEFAULT SETTINGS MENU LEVEL & CODE DESCRIPTION OF CODE0 FACTORY DEFAULT PRIMARY MENU tout OUTLET TEMPERATURE ACTU

APPENDIX D x bp 7 bp_8 BREAK POINT 8 85 bp 8 bp_9 BREAK POINT 9 81 bp 9 bp_A BREAK POINT 79 bp A bp_B BREAK POINT 77 bp B

APPENDIX E xi

INSTALLATION PROCEDURES2SECTION 2 - INSTALLATION PROCEDURES2.1 RECEIVING THE UNITEach KC unit is shipped as a single crated unit.The shipping weight

APPENDIX E xii 18(45.7)49(124.5)57(144.8)16-3/422-5/871-7/871-7/819(48)15-1/2(39.4)6(15.2) I.D.FLUE CONN.3/4(1.9) DIA.(ENCLOSURE)PRESS./TEMP.RELIEF2

APPENDIX E xiii

APPENDIX E xiv

APPENDIX F xv

APPENDIX F xvi

APPENDIX F xvii

APPENDIX F xviii

APPENDIX F xix

APPENDIX F xx FLOORFLOOR

APPENDIX G xxi

INSTALLATION PROCEDURES32.3 INSTALLATIONThe unit must be installed with the prescribedclearances for service as shown in Fig 2.1These are the minimum

APPENDIX G xxii

APPENDIX H xxiii 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 H xxiv 18 123280-W1 WATER HEATER TEMPERATURE CONTROLLER 17 123803 SOLID STATE TIMER-ARTISAN CORP(123469 FOR SSAC INC.) 16 123438 C

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

INSTALLATION PROCEDURES4for startup and testing. It should be a minimumof 3/4". It cannot be omitted (See Fig. 2.4a)Figure 2.4aHose Bibb Location