AERCO C-More Controls User Manual

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AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

No.

GF-112

C-MORE CONTROL PANEL

OPERATION

For

Benchmark Series

KC Series

Systems

Printed in U.S.A. REVISED JANUARY, 2009

C-MORE CONTROL PANEL OPERATION

TABLE OF CONTENTS

PARA. PAGE

SECTION 1 – GENERAL INFORMATION 1

1.1 INTRODUCTION 1

1.2 SAFETY PRECAUTIONS AND WARNINGS 1

1.3 FEATURES AND BENEFITS 1

1.4 CONTROL PANEL DESCRIPTION 2

SECTION 2 – CONTROL PANEL MENU STRUCTURE 6

2.1 CONTROL PANEL MENUS 6

2.2 MENU PROCESSING PROCEDURES 6

2.3 OPERATING MENU 7

2.4 SETUP MENU 7

2.5 CONFIGURATION MENU 8

2.6 TUNING MENU 10

2.7 CALIBRATION MENU 11

2.8 DIAGNOSTICS MENU 11

SECTION 3 – CONTROL PANEL MENU DESCRIPTIONS 13

3.1 MENU ITEM DESCRIPTIONS 13

3.2 FACTORY DEFAULTS 13

SECTION 4 – CONTROL PANEL DISPLAY MESSAGES 21

4.1 STARTUP AND STATUS MESSAGES 21

4.2 FAULT MESSAGES 21

SECTION 5 –INPUT/OUTPUT INTERFACES & OPERATING MODES 24

5.1 INTRODUCTION 24

5.2 I/O INTERFACES 24

5.3 MODES OF OPERATION 26

5.4 START SEQUENCE 31

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TABLE OF CONTENTS - Continued

SECTION 6 – CALIBRATION AND DIAGNOSTIC MENUS 33

6.1 INTRODUCTION 33

6.2 CALIBRATION PROCEDURES 33

6.3 DIAGNOSTICS PROCEDURES 35

SECTION 7 – RS232 COMMUNICATION 38

7.1 INTRODUCTION 38

7.2 RS232 COMMUNICATION SETUP 38

7.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION

7.4 DATA LOGGING 39

APPENDIX A - C-MORE CONTROL PANEL VIEWS A-1

APPENDIX B - TROUBLESHOOTING GUIDE B-1

APPENDIX C - INDOOR/OUTDOOR RESET RATIO CHARTS C-1

APPENDIX D - TEMPERATURE SENSOR RESISTANCE CHART D-1

APPENDIX E - WIRING DIAGRAMS E-1

APPENDIX F - C-MORE CONTROL PANEL DIP SWITCH SETTINGS

F-1

C-MORE CONTROL PANEL OPERATION

SECTION 1 - GENERAL INFORMATION

1.1 INTRODUCTION

The information in this Section provides a guide to the operation of KC and Benchmark Series

units using the C-More Control Panel. In

addition, it provides information describing the numerous types of external sensors and control devices which can be interfaced to the unit using terminals provided in the Input/Output (I/O) Box utilized with the Control Panel. Information regarding the set up of all Water Heater and Boiler Operating Modes is also included herein.

1.2 SAFETY PRECAUTIONS AND WARNINGS

It is imperative that the initial startup of KC and Benchmark Series units be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel will void the equipment warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all times.

CAUTION:

All initial installation procedures must be satisfied before attempting to start the unit.

WARNING:

ELECTRICAL VOLTAGES IN KC SERIES UNITS INCLUDE 120 AND 24 VOLTS AC. VOLTAGES IN BENCHMARK SERIES UNITS MAY ALSO INCLUDE 460 AND 220 VOLTS AC. THEREFORE, THESE UNITS MUST BE SERVICED ONLY BY FACTORY CERTIFIED

SERVICE TECHNICIANS.

WARNING:

DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN PERSONNEL INJURY OR PROPERTY DAMAGE. THIS SITUATION WILL VOID ANY WARRANTY.

FEATURES AND BENEFITS

KC and Benchmark Series units equipped the new C-More Control Panel include a number of additional features and benefits. These include:

1.3.1 System Start Temperature

The Sy tem Start Temperature feature s allows a boiler to be enabled or disabled based on the outside air temperature. When the outside air temperature goes below the System Start Temperature, the boiler is enabled. When the outside air temperature is above the System Start Temperature, the boiler is disabled. This feature may be used in any boiler mode of operation. It requires that an outdoor air temperature sensor be connected to the boiler.

1.3.2 Setpoint Low Limit

This option allows the user to unit’s setpoint can be set. The allowable range is 40°F to 240°F. The factory default is set at 60°F.

limit how low the

1.3.3 Setpoint High Limit

This option has two functions. In the Indoor/Outdoor Reset, Constant Setpoint and 4 to 20 mA Remote Setpoint Modes, the Setpoint High Limit option limits how high the unit’s setpoint can be set. The allowable range is 40°F to 240°F.

In the 4 to 20 mA Direct Drive, Combination or BMS Mode of operation, the Setpoint High Limit acts as a temperature limiting governor. Should the unit’s outlet temperature equal the Setpoint High Limit Setting, a PID function will intervene and maintain the outlet temperature at the Setpoint High Limit minus the Setpoint Limit Band.

To use the Setpoint High Limit feature, the Setpoint Limiting option must be enabled and a Setpoint Limit Band selected. This Band is preset at 5°F, however it is adjustable from 0°F to 10°F.

1.3.4

with

1.3

C-MORE CONTROL PANEL OPERATION

Temp Hi Limit

The Temp Hi Limit is a te e The F that will shut down the unit and generate an alarm if the if the outlet temperature exceeds its setting. It is preset at 210°F, however it is adjustable from 40°F to 240°F.

mperature limit featur

1.3.5 Max Fire Rate

This feature allows the firing rate. This feature can be useful if site or equipment limitations require that less BTU’s be input into the system. This feature is meant to be used only on a temporary basis until the system or equipment limitations are resolved.

user to limit the unit’s

1.3.6 Pump Delay Timer

The C-More control system a turn a pump on and off as the boiler cycles on and off on demand. The Pump Delay Timer feature allows the user to keep the pump running up to 30 minutes after the unit has shut down and the demand satisfied.

llows the user to

1.3.7 Aux Start On Delay

The AUX START ON DELAY conjunction with the Auxiliary Relay. When a call for heat is produced, the Aux Relay will energize and can be used to start a system or gas booster pump, open a louver or valve, or start some other necessary system process. The Aux Start On Delay is a timer that can be set from 0 to 120 seconds. It tells the combustion control system to wait a specified period of time for the device started by the Aux Relay to come up to speed, open or make a proving switch. Once the waiting period expires, the start sequence will resume. Should the device not prove within the preset time interval, the unit will shut down and generate an alarm.

feature works in

1.3.8

Failsafe Mode

whether the unit shuts down or switches to the Constant Setpoint mode of operation in the event that a loss of signal causes the unit to become inoperable. For example, if a 4 to 20 mA Remote Setpoint signal is being sent, but is not seen by the unit, the unit will shut down or automatically switch to the Constant Setpoint mode and work off the unit’s internal setpoint. The default setting for this option is Shutdown.

1.3.9 RS232 Monitoring

This feature allows a laptop co suitable device to be connected to the RS232 port on the Control Panel front panel. This permits the unit to be monitored either locally or remotely via a Modem.

1.3.10 Aux Temp

This feature permits a connected to the Aux Sensor In terminals in the I/O Box. The sensor must be within the resistance range used with the C-More Control system. It can be used to monitor the user’s parameter of choice. This feature is always enabled. This is strictly a monitoring function and plays no role in control of the unit.

1.4 CONTROL PANEL DESCRIPTION

The C-More Control Panel is available in t models. One model has a horizontal panel control layout as shown in Figure 1-1A and is used on KC Series units. The other model has a vertical panel control layout as shown in Figure 1-1B and is used on Benchmark Series units. These models contain identical controls, indicators and displays and are functionally identical. These controls, indicators and displays are listed and described in Table 1-1.

ailsafe mode allows

temperature sensor to be

the user to select

mputer or other

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Figure 1-1A. C-More Control Panel For KC Series Units

Figure 1-1B. C-More Control Panel For Benchmark Series Units

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Table 1-1. Operating Controls, Indicators and Displays

ITEM

NO.

CONTROL, INDICATOR

OR DISPLAY

1 LED Status Indicators Four Status LEDs indicate the current operating status as

follows:

COMM

MANUAL

REMOTE

DEMAND

2 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines each

OUTLET

TEMPERATURE

Display

RS232 Port

READY Indicator

ON/OFF Switch

LOW WATER LEVEL

TEST/RESET Switches

FAULT Indicator Red FAULT LED indicator lights when a boiler alarm

CLEAR Key

10 MENU Keypad Consists of 6 keys which provide the following functions for

BACK

Lights when RS232 communication is occurring Lights when the unit is being controlled using the front panel

keypad. Lights when the unit is being controlled by an external signal

from an Energy Management System Lights when there is a demand for heat.

capable of displaying up to 16 alphanumeric characters. The information displayed includes:

Startup Messages Alarm Messages Operating Status Messages Menu Selections

3–Digit, 7–Segment LED display continuously displays the outlet water temperature. The °F or °C LED next to the display lights to indicate whether the displayed temperature is in degrees Fahrenheit or degrees Celsius.

Port permits a Laptop Computer or External Modem to be connected to the unit’s Control Panel.

Lights when ON/OFF switch is set to ON and all Pre-Purge conditions have been satisified.

Enables and disables boiler operation.

Allow the operator to test the operation of the water level monitor.

Pressing TEST opens the water level probe circuit and simulates a Low Water Level alarm.

Pressing RESET resets the water level monitor circuit. Pressing CLEAR resets the display.

condition occurs. An alarm message will appear in the VFD.

Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid. Lockout type alarms will be latched and cannot be cleared by simply pressing this key. Troubleshooting may be required to clear these types of alarms

the Control Panel Menus: Steps through the main menu categories shown in Figure 2-1.

The Menu categories wrap around in the order shown. Allows you to go back to the previous menu level without

changing any information. Continuously pressing this key will bring you back to the default status display in the VFD. Also, this key allows you to go back to the top of a main menu category.

FUNCTION

ITEM

NO.

(Cont.)

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Table 1-1. Operating Controls, Indicators and Displays - Continued

CONTROL, INDICATOR

OR DISPLAY

▲ (Up) Arrow When in one of the main menu categories (Figure 1-2),

pressing this key will select the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, pressing the ▲ arrow key will increment the selected setting.

▼ (Down) Arrow When in one of the main menu categories (Figure 1-2),

pressing this key will select the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, pressing the ▼ (Down) arrow key will increment the selected setting.

FUNCTION

CHANGE

ENTER

AUTO/MAN Switch

FIRE RATE Bargraph

Permits a setting to be changed (edited). A valid password must be entered before changing most menu items. When the CHANGE key is pressed, the displayed menu item will begin to flash. Pressing the ▲ or ▼ arrow key when the item is flashing will increment or decrement the displayed setting.

Saves the modified menu information in memory. The display will stop flashing.

This switch toggles the boiler between the Automatic and Manual modes of operation. When in the Manual (MAN) mode, the front panel controls are enabled and the MANUAL status LED lights.

When in the Automatic (AUTO) mode, the MANUAL status LED will be off and the front panel controls disabled.

20 segment red LED bargraph continuously shows the Fire Rate in 5% increments from 0 to 100%

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SECTION 2 - CONTROL PANEL MENU STRUCTURE

2.1 CONTROL PANEL MENUS

The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of six major menu categories as shown in Figure 2-1. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by two different password levels to prevent unauthorized use.

Password Level 1 allows viewing of all menu categories and also allows the Setup, Configuration and Tuning Menu options to be changed.

Password Level 2 allows viewing and changing of all Level 1 menu categories and also allows access to the Calibration and Diagnostic Menus. These two additional menu categories should only be used by factory trained personnel to calibrate and troubleshoot the unit.

A third Password Level called the Factory Password also exists. However, access to this menu is restricted to Factory Authorized personnel only.

Prior to entering the correct password, the options contained in the Operating, Setup, Configuration and Tuning Menu categories can be viewed. However, except for Internal Setpoint Temperature (Configuration Menu), none of the viewable menu options can be changed.

Once the valid Level 1 (159) or Level 2 (6817) password is entered, the options listed in the available menus can be viewed and changed, if desired.

2. Press the MENU key. The display will show the Setup Menu which is the next menu category shown in Figure 2-1. This menu contains the Password option which must be entered if other menu options will be changed.

3. Continue pressing the MENU key until the desired menu is displayed.

4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu will be displayed.

OPERATING

LEVEL 1 PWD

SETUP

CONFIGURATION

TUNING

LEVEL 2 PWD

CALIBRATION

2.2 MENU PROCESSING PROCEDURE

Accessing each menu and option is accomplished using the Menu Keys shown in Figure 1-1. Therefore, it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu processing procedures.

1. The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status. Pressing the ▲ or ▼ arrow key will display the other available data in the Operating Menu.

DIAGNOSTICS

Figure 2-1. Menu Structure

C-MORE CONTROL PANEL OPERATION

5. Continue pressing the ▲or ▼ arrow key until the desired menu option is displayed. Pressing the ▲ arrow key will display the available menu options in the Top-Down sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence. The menu options will wraparound after the first or last available option.

6. To change the value or setting of a displayed menu option, press the CHANGE key. The displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the available menu option choices for the option to be changed. The menu option choices do not wrap around.

7. To select and store a changed menu option, press the ENTER key.

NOTE:

Paragraphs 2.3 through 2.8 provide brief descriptions of the options contained in each menu. Refer to Section 3 for detailed descriptions of each menu option.

2.3 OPERATING MENU

The Operating Menu displays the unit status and a number of key operating parameters for the unit as listed in Table 2-1. This menu is “ReadOnly” and does not allow personnel to change or adjust any of the displayed items. Since this

menu is “Read-Only”, it can be viewed at any time without entering a password. Press the ▲ arrow key to display the menu item in the order listed (Top-Down). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up).

2.4 SETUP MENU

The Setup Menu (Table 2-2) permits the operator to set the unit password which is required to change any of the menu options. To prevent unauthorized use, a previously entered password entry will time-out after 1 hour.

Therefore, the password must be reentered when required. In addition to permitting password entries, the Setup Menu is also used to enter date and time, language to be used for display messages, units of temperature measurements and entries required for external communication and control of the unit via the RS232 port. A view-only software version display is also provided to indicate the current Control Box software version,

NOTE

The Outdoor Temp display item shown with an asterisk in Table 2-1 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 2-3).

Table 2-1. Operating Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Status Message Active Setpoint 40°F 240°F Aux Temp 30°F 245°F Outdoor Temp* -70°F 130°F Fire Rate In 0% Max Fire Rate Flame Strength 0% 100% Run Cycles 0 999,999 Run Hours 0 999,999 Fault Log 0 9 0

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Table 2-2. Setup Menu

Available Choices or Limits Menu Item Display Minimum Maximum Default

Passsword Level 1 = 159 Level 2 = 6817 Language English English Time 12:00 am 11:59 pm Date 01/01/00 12/31/99 Unit of Temp Fahrenheit

Comm Address 0 127 0 Baud Rate 2400

Software Ver 0.0 Ver 9.9

2.5 CONFIGURATION MENU

The Configuration Menu shown in Table 2-3 permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the Constant Setpoint mode. The remaining options in this menu require the valid password to be entered, prior to changing existing entries. This menu contains a number of other configuration settings which may or may not be displayed, depending on the current operating mode setting.

0 9999 0

Celsius

4800 9600

19.2K

The Configuration Menu settings shown in Table 2-3 are Factory-Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required.

Fahrenheit

9600

NOTE:

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Table 2-3. Configuration Menu

Available Choices or Limits Menu Item Display Minimum Maximum Default

Internal Setpt Lo Temp Limit Hi Temp Limit 130°F Unit Type Boiler

Unit Size 0.5 MBTU

Boiler Mode (If Unit Type = Boiler)

Heater Mode (If Unit Type = Water Heater) Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination)

Bldg Ref Temp (If Boiler Mode = Outdoor Reset) Reset Ratio (If Boiler Mode = Outdoor Reset) Outdoor Sensor Enabled or Disabled Disabled System Start Tmp (If Outdoor Sensor = Enabled) Setpt Lo Limit 40°F Setpt Hi Limit 60°F Setpt Hi Limit Setpt Lo Limit 240°F 200°F Temp Hi Limit 40°F 240°F 210°F Max Fire Rate 40% 100% 100% Pump Delay Timer (If Unit Type = Boiler) Aux Start On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown mA Output Setpoint

Low Fire Timer 2 sec 120 sec 2 sec Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0°F 10°F 5°F

Boiler

Water Heater

1.0 MBTU

1.5 MBTU

2.0 MBTU

2.5 MBTU

3.0 MBTU

Constant Setpoint

Remote Setpoint

Direct Drive

Combination

Outdoor Reset

Constant Setpoint

Remote Setpoint

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (BMS)

Network

40°F 230°F 70°F

0.1 9.9 1.2

30°F 100°F 60°F

0 min 30 min 0 min

Outlet Temp

Fire Rate Out

Off

Constant Setpoint

Constant Setpoint 4 to 20 mA/ 1-5V

Off

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2.6 TUNING MENU

The Tuning Menu items in Table 2-4 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel.

The Breakpoint Menu items shown in the following Table with an asterisk are displayed only if Unit Type = Water Heater and the Heatr Bkpt Dsp option in the Calibration Menu (Table 2-5) is Enabled. These Breakpoint values correspond to a 130°F default setpoint

Table 2-4. Tuning Menu

Available Choices or Limits Menu Item Display Minimum Maximum Default

Prop Band 1°F 120°F 70°F (Boiler)

Integral Gain 0.00 2.00 1.00 (Boiler)

Derivative Time (If Unit Type = Boiler) Min Load Adj (If Unit Type = Water Heater) Max Load Adj (If Unit Type = Water Heater) FFWD Temp (If Unit Type = Water Heater) Outlet Feedback (If Unit Type = Water Heater) Feedback Gain (If Unit Type = Water Heater & Heatr Tuning Dsp is Enabled) Breakpt at 100%* 30°F 240°F 77°F Breakpt at 90%* 30°F 240°F 81°F Breakpt at 80%* 30°F 240°F 85°F Breakpt at 70%* 30°F 240°F 91°F Breakpt at 60%* 30°F 240°F 95F Breakpt at 50%* 30°F 240°F 102F Breakpt at 40%* 30°F 240°F 110°F Breakpt at 30%* 30°F 240°F 112°F Breakpt at 20%* 30°F 240°F 114°F Breakpt at 10%* 30°F 240°F 130°F Breakpt at 0%* 30°F 240°F 135°F Reset Defaults? Yes

0.00 min 2.00 min 0.00 min (Boiler)

-50°F 50°F 0°F

30°F 245°F

.01 1.00 0.05

Are You Sure?

NOTE

On (Yes)

Off (No)

8°F (Water Heater)

1.60 (Water Heater)

0.10 min (Water Heater)

On (Yes)

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2.7 CALIBRATION MENU

The Calibration Menu is used by Factory Trained Service personnel to adjust or reset the parameters listed in Table 2-5.

Table 2-5. Calibration Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Stepper Fbk (Not adjustable via RS232 serial communication) PWM In Adj -5.0% 5.0% 0.0% Analog In Adj -5.0% 5.0% 0.0% Flow In Adj -5.0% 5.0% 0.0% CO In Adj -5.0% 5.0% 0.0% O2 In Adj -5.0% 5.0% 0.0% mA Out Adj -1.0 mA 1.0 mA 0.0 mA A/F Sensitivity 1% 5% 2% Power Reset Automatic

Water Temp Reset Automatic

Gas Press Reset Automatic

Min Off Time 0 Min 15 Min 1 Min (Boiler)

Heatr Tuning Dsp (If Unit Type = Water Heater) Heatr Bkpt Dsp (If Unit Type = Water Heater) Stop Level 0% Start Level 16 Start Level Stop Level 40% 20

Cal 100%

Verify 50%

Enabled or Disabled Disabled

Cal 0%

Manual

Cal 0%

Automatic

Manual

0 Min (Water Heater)

2.8 DIAGNOSTICS MENU

The Diagnostics Menu shown in Table 2-6 is used by Factory-Trained Service personnel to troubleshoot the unit. This menu category contains a number of Built In Test (BIT) test routines to be used to check the operational status of the Control Panel displays and keypad keys. It also allows the operator to activate relays, view switch status and increment the stepper motor contained in the Air/Fuel Valve.

NOTE

With the exception of the Sensor Log Interval (Int) setting, none of the following Diagnostic Menu items can be initiated via a remote serial communications link.

C-MORE CONTROL PANEL OPERATION

Table 2-6. Diagnostics Menu

Available Choices or Limits Menu Item Display Minimum Maximum Default

Display Test Off

LEDs

7-Seg

Bar-graph

Keypad Test Off

Manual, Menu

Up, Down

Change, Enter

Clear

(Back Key exits test mode) Relay Test (Allows user to force outputs ON or OFF)

Switch Test (Allows user to view the status of all switch inputs)

Stepper Test (Allows user to adjust the stepper motor position using

the ▲ and ▼ keys) Sensor Log Int

(Allows user to set the time interval for logging Sensor inputs in Database)

Igniter ON/Igniter OFF

Blower ON/Blower OFF

Pump ON/Pump OFF

Aux ON/Aux OFF

Fault ON/Fault OFF

Exhaust sw ON/Exhaust sw OFF

SSOV sw ON/SSOV sw OFF

Blower Proof ON/Blower Proof OFF

Ignition sw ON/Ignition sw OFF

Over Temp sw ON/Over Temp sw OFF

Low Gas Pres ON/Low Gas Pres OFF

Hi Gas Pres ON/Hi Gas Pres OFF

Water Lev sw ON/Water Lev sw OFF

Rem Int sw ON/Rem Int sw OFF

Front Pnl sw ON/Front Pnl sw OFF

Delayed Int ON/Delayed Int OFF

Purge sw ON/Purge sw OFF

0% 100% 0%

12 Hrs, or 24 Hrs

Off

1 Min, 5 Min

15 Min, 30 Min

1 Hr, 6 Hrs

Off

30 Min.

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SECTION 3 - CONTROL PANEL MENU DESCRIPTIONS

3.1 MENU ITEM DESCRIPTIONS

Descriptions of the menu items and options contained in each of the six major menu categories are listed and described in Table 3-1. Factory Default values for each of these items are summarized in Table 3-2.

3.2 FACTORY DEFAULTS

The factory default values for each menu item are summarized in Table 3-2.

Table 3-1. Menu Item Descriptions

MENU LEVEL & OPTION DESCRIPTION

OPERATING MENU Active Setpoint This is the setpoint temperature to which the control

is operating when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset (Boiler Only) Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu. When in the Remote Setpoint Mode, this value is the setpoint equivalent to the remote analog signal supplied to the unit. When operating a Boiler in the Outdoor Reset Mode, this is

the derived value from the charts in Appendix C. Aux Temp For monitoring purposes only Outdoor Temp Displayed only if outdoor sensor is installed and

enabled. Fire Rate In Desired input fire rate. This would normally be the

same as the fire rate shown on the bar-graph (fire

rate out) when the boiler is operating. Flame Strength Displays flame strength from 0 to 100%. Run Cycles Displays the total number of run cycles from 0 to

999,999. Run Hours Displays total run time of unit in hours from 0 to

999,999. Fault Log Displays information on the last 10 faults (numbered

0 through 9).

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Table 3-1. Menu Item Descriptions - Continued

MENU LEVEL & OPTION DESCRIPTION

SETUP MENU

Password

Level 1

Level 2

Language English is the ONLY language available Time Displays time from 12:00am to 11:59pm. Date Displays dates from 01/01/00 to 12/31/99 Unit of Temp Permits selection of temperature displays in degrees

Comm Address For RS485 MODBUS communications (0 to 127).

Baud Rate Allows the RS232 communication Baud Rate to be

Software Version Identifies the current software version of the control

Allows Level 1 or 2 password to be entered.

Entering the Level 1 Password (159) allows options in

the Setup, Configuration and Tuning Menus to be

modified.

Entering the Level 2 Password (6817) allows options

in the Calibration and Diagnostics Menus to be

changed/activated, in addition to all Level 1 Menu

options.

Fahrenheit (°F) or degrees Celsius (°C). Default is

°F.

Default address is 0.

set (2400 to 19.2K). Default is 9600.

box (Ver 0.0 to Ver 9.9).

CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set (40°F to 240°F).

Unit Type Allows selection of Boiler or Water Heater. Default is

Unit Size Sets unit size from 0.5 to 3.0 MBTUs. Default is 1.0

Boiler Mode (If Unit Type = Boiler)

Heater Mode (If Unit Type = Water Heater) Remote Signal (If Mode = Remote Setpoint,

Direct Drive or Combination)

Bldg Ref Temp (If Boiler Mode = Outdoor

Reset)

Default is 130°F.

Boiler.

MBTU.

Allows selection of: Constant Setpoint, Remote

Setpoint, Direct Drive, Combination, or Outdoor Reset

Mode. Default is Constant Setpoint Mode.

Allows selection of Constant Setpoint or Remote

Setpoint Mode. Default is Constant Setpoint Mode.

Used to set the type of external signal which will be

used when operating in the Remote Setpoint, Direct

Drive or Combination Mode. Default is 4 to 20 mA /

1 to 5V.

Allows the building reference temperature to be set

when operating a Boiler in the Outdoor Reset Mode.

Default is 70°F

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Table 3-1. Menu Item Descriptions - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU

(Continued) Reset Ratio (If Boiler Mode = Outdoor

Reset) Outdoor Sensor Allows outdoor sensor function to be enabled or

System Start Tmp (If Outdoor Sensor is Enabled)

Setpoint Lo Limit Used to set the minimum allowable setpoint (40°F to

Setpoint Hi Limit Used to set the maximum allowable setpoint (Setpoint

Temp Hi Limit This is the maximum allowable outlet temperature

Max Fire Rate Sets the maximum allowable fire rate for the unit

Pump Delay Timer (If Unit Type = Boiler)

Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.)

Failsafe Mode Allows the Failsafe Mode to be set to either Constant

mA Output Can be set to allow this output to monitor Setpoint,

Low Fire Timer Specifies how long (2 to 120 sec.) to remain in the

Setpt Limiting Allows Setpt Limiting to be enabled or disabled.

Setpt Limit Band When Setpt Limiting is enabled, this menu item

Permits setting of Reset Ratio when operating Boiler

in the Outdoor Reset Mode. Reset Ratio is

adjustable from 0.1 to 9.9. Default is 1.2.

disabled. Default is Disabled.

If outdoor sensor is enabled, this menu item allows

the system start temperature to be set from 30°F to

100°F. Default is 60°F.

Setpoint Hi Limit). Default is 60°F

Lo Limit to 240°F). Default is 200°F.

(40°F to 240°F). Any temperature above this setting

will turn off the unit. The temperature must then drop

5°F below this setting to allow the unit to run. Default

Hi Limit is 210°F.

(40% to 100%). Default is 100%.

Specifies the amount of time (0 to 30 min.) to keep

the pump running after the unit turns off. Default is

zero.

between activating the Aux Relay (due to a demand)

and checking the pre-purge string to start the unit.

Default is 0 sec.

Setpoint or Shutdown. Default is Shutdown.

Outlet Temperature, Fire Rate Out, or be set to OFF.

Default is OFF.

low fire position after ignition, before going to the

desired output. Default is 2 sec.

Default is disabled.

allows the Setpt Limit Band to be set from 0°F to

10°F. Default is 5°F.

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MENU LEVEL & OPTION DESCRIPTION

`Table 3-1. Menu Item Descriptions - Continued

TUNING MENU

Prop Band Generates a fire rate based on the error that exists

Integral Gain This sets the fraction of the output, due to setpoint

Derivative Time This value (0.00 to 2.00 min.) responds to the rate of

Min Load Adj (If Unit Type = Water Heater)

Max Load Adj (If Unit Type = Water Heater)

FFWD Temp (If Unit Type = Water Heater) Outlet Feedback Used to Enable or Disable feedback. Disable this

Feedback Gain (If Unit Type = Water Heater) Breakpoint at 100% Thru Breakpoint at 0% (If Unit Type = Water Heater)

Reset Defaults? Resets Tuning Menu options to Factory Defaults

between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%. If the error is equal to or greater than the proportional band setting, the fire rate will be 100%. Defaults are 70°F (Boiler), 8°F (Water Heater)

error, to add or subtract from the output each minute to move towards the setpoint. Gain is adjustable from 0.00 to 2.00 (Defaults are 1.00 for Boilers, 1.60 for Water Heaters).

change of the setpoint error. This is the time that this action advances the output. (Defaults are 0.0 min. for Boilers, 0.10 min. for Water Heaters)

Setting is adjustable from -50°F to +50°F (Default is zero). It adjusts the output by adding an offset to the breakpoint chart at minimum flow. This is used to fine tune Feed-Forward (FFWD) output at low flow levels.

Setting is adjustable from -50°F to +50°F (Default is zero). It adjusts the output by changing the scaling of the breakpoint chart at maximum flow.

Displays the Feed-Forward temperature.

function for Feed-Forward control only. Adjustable from 0.01 to 1.00 (Default is 0.05).

Allows breakpoint temperature settings to be entered for 100% to 0% in 10% increments. The Bkpt Dsp options in the Calibration Menu must be enabled to view breakpoint temperatures. See Table 2-4 for breakpoint default values.

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Table 3-1. Menu Item Descriptions – Continued

MENU LEVEL & OPTION DESCRIPTION

CALIBRATION MENU

Stepper Fbk (Not adjustable via RS232

serial communication)

PWM In Adj Allows the Pulse Width Modulation (PWM) duty cycle

Analog In Adj Allows adjustment of the analog input from -5.0% to

Flow In Adj Allows adjustment of the water Flow Rate Input from

CO In Adj Allows adjustment of the Carbon Monoxide level from

O2 In Adj Allows adjustment of the Oxygen level from -5.0% to

mA Out Adj Allows adjustment of the milliamp output from -5.0

A/F Sensitivity Allows adjustment of the Air/Fuel (A/F) Valve stepper

Power Reset Allows the Power Reset Option to be set to Auto or

Water Temp Reset Allows the Water Temperature Reset function to be

Gas Press Reset Allows the Gas Pressure Reset function to be set to

Min Off Time Allows the minimum Off time to be set from 0 to 10

Heatr Tuning Dsp (Water Heater Only)

Heatr Bkpt Dsp Allows Heater Breakpoint Display to be Enabled or

Stop Level Allows the Stop Level to be set to a firing rate ranging

Start Level Allows the Start Level to be set to a firing rate ranging

Allows the Air/Fuel Valve stepper motor feedback

current to be calibrated at the 0% (fully closed) and

100% (fully open) positions. Verification can also be

accomplished at the 50% position.

to be adjusted from -5.0% to +5.0% in 0.1%

increments. Default = 0.0%.

+5.0%. Default = 0.0%.

-5.0% to +5.0%. Default = 0.0%.

-5.0% to +5.0% in 0.1 % increments. Default = 0.0%.

+5.0% in 0.1% increments. Default = 0.0%

mA to +5.0 mA. Default = 0.0 mA

motor sensitivity to be adjusted from 1% to 5% in 1%

increments. Default is 2%.

Manual. Default is Auto.

set to Auto or Manual. Default is Auto.

Auto or Manual. Default is Manual.

minutes. Default = 1 min.(Boiler), 0 min. (Water

Heater).

Allows Heater Tuning Display to be Enabled or

Disabled. Default is Disabled.

Disabled. When Enabled, Breakpoints can be viewed

and/or changed. Default is Disabled.

from 0% to the presently set Start Level. Default is

16%.

from the presently set Stop Level to a maximum of

40%. Default is 20%.

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Table 3-1. Menu Item Descriptions – Continued

MENU LEVEL & OPTION DESCRIPTION

DIAGNOSTICS MENU

Display Test*

Keypad Test*

Relay Test*

Switch Test*

Stepper Test*

Sensor Log Int Allows the Sensor Log Interval to be set to: 1 Min, 5

* Not adjustable via RS232 serial communication

Allows testing of the front panel LED indicators, 3character, 7-segment LED display and 20-segment LED Bargraph.

Allows testing of the operational status of each front panel key. The VFD will display the name of each key as it is pressed.

Allows user to force relay outputs ON or OFF. The relays tested include: Igniter, Blower, Pump, Aux and Fault relay.

Allows the ON/OFF status of all switch inputs to be viewed. These switches include: Exhaust, SSOV, Blower Proof, Ignition, Over-Temp, Low Gas Pres, Hi Gas Pres, Water Lev, Rem Int, Front Pnl, Delayed Int and Purge switches.

Allows adjustment of the Air/Fuel Valve stepper motor position using the ▲ and ▼ keys. The Bargraph

display will light to indicate the current stepper motor position.

Min, 15 Min, 30 Min, 1 Hr, 6 Hrs, 12 Hrs or 24 Hrs. Default setting is 30 Min.

Table 3-2. Default Settings

MENU & OPTION

Setup Menu

Password Language Unit of Temp Comm Address Baud Rate

Configuration Menu

Internal Setpt Unit Type Unit Size Boiler Mode

(If Unit Type = Boiler) Heater Mode

(If Unit Type = Water Heater) Remote Signal

(If Mode = Remote Setpoint, Direct Drive or

Combination)

Bldg Ref Temp (If Boiler Mode = Outdoor Reset)

Reset Ratio (If Boiler Mode = Outdoor Reset)

Outdoor Sensor System Start Tmp

(If Outdoor Sensor = Enabled) Temp Hi Limit Max Fire Rate Pump Delay Timer (If Unit Type = Boiler) Aux Start On Dly Failsafe Mode mA Output Low Fire Timer Setpt Limiting Setpt Limit Band

Tuning Menu

Prop Band Integral Gain Derivative Time Min Load Adj (If Unit Type = Water Heater) Max Load Adj (If Unit Type = Water Heater) FFWD Temp Adj (If Unit Type = Water Heater) Outlet Feedback (If Unit Type = Water Heater) Feedback Gain (If Unit Type = Water Heater)

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FACTORY DEFAULT

English

Fahrenheit

9600

130°F Boiler

1.0 MBTU

Constant Setpoint

4 – 20 mA / 1-5V

70°F

1.2

Disabled

60°F

210°F 100%

0 min 0 sec

Shutdown

Off

2 sec

Disabled

5°F

70°F (Boiler), 8°F (Water Heater)

1.00 (Boiler), 1.60 (Water Heater)

0.00 min (Boiler), 0.10 min (Water Heater) 0°F 0°F

N/A

0.05

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Table 3-2. Default Settings – Continued

MENU & OPTION

Breakpoint At 100% (If Unit Type = Water Heater) Breakpoint At 90% (If Unit Type = Water Heater) Breakpoint At 80% (If Unit Type = Water Heater) Breakpoint At 70% (If Unit Type = Water Heater) Breakpoint At 60% (If Unit Type = Water Heater) Breakpoint At 50% (If Unit Type = Water Heater) Breakpoint At 40% (If Unit Type = Water Heater) Breakpoint At 30% (If Unit Type = Water Heater) Breakpoint At 20% (If Unit Type = Water Heater) Breakpoint At 10% (If Unit Type = Water Heater) Breakpoint At 0% (If Unit Type = Water Heater) Reset Defaults?

Calibration Menu

Stepper Fbk PWM Adj Analog In Adj Flow In Adj CO In Adj O2 In Adj mA Out Adj A/F Sensitivity Power Reset Water Temp Reset Gas Press Reset Min Off Time Heatr Tuning Dsp (If Unit Type = Water Heater) Heatr Bkpt Dsp (If Unit Type = Water Heater) Stop Level Start Level

Diagnostics Menu

Display Test Keypad Test Relay Test Switch Test Stepper Test Sensor Log Int

FACTORY DEFAULT

77°F 81°F 85°F 91°F

95°F 102°F 110°F 112°F 114°F 130°F 135°F

Cal 0%

0.0%

0.0 mA 2%

Auto Auto

Manual

1 Min (Boiler), 0 Min (Water Heater)

Disabled Disabled

16 20

Off Off Off Off

30 min.

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SECTION 4 - CONTROL PANEL DISPLAY MESSAGES

4.1 STARTUP & STATUS MESSAGES.

Startup and status messages are displayed on the VFD display on the front panel of the C-More Control Panel. This display is comprised of two lines with 16 characters per line. The startup and status messages which may appear in the display are listed in Tables 4-1.

Table 4-1. Startup and Status Messages

MESSAGE DESCRIPTION

DISABLED

HH:M D/YY

M pm MM/D

STANDBY

DEM AY AND DEL

XX sec

URGING Displayed during the purge cycle during startup. The

XX sec

IGNI IAL

TION TR Displayed during ignition trial of startup sequence. The

XX sec

FLAME PROVEN

W he initial warm-up only. ARMUP

XX sec

WAIT Prompts the oper tor to wait. a

Displayed if ON/OFF switch is set to OFF. The displ shows the time and date that the unit was disabled. Displayed when ON/OFF switch is in the ON position, but there is no demand for heat. The time displayed. Displayed if Demand Delay is active.

duration of the purge cycle counts up in seconds.

duration of cycle counts up in seconds. Displayed after flame has been detected for a period of 2 seconds. Initially, the flame strength is shown in %. After 5 seconds has elaps of flame strength. Displayed for 2 minutes during t

FAULT MESSAGES.

Fault messages which may appear in the VFD display are listed in Table 4-2.

ay also

and date are also

ed, the time and date are shown in place

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Table 4-2. Fault Messages

FAULT MESSAGE FAULT DESCRIPTION

HIGH WATER TEMP

SWITCH OPEN

LOW WATER

LEVEL

LOW GAS

PRESSURE

HIGH GAS

PRESSURE

INTERLOCK

OPEN

DELAYED

INTERLOCK OPEN

AIRFLOW FAULT

DURING PURGE

PRG SWTCH OPEN

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

IGN SWTCH CLOSED

DURING PURGE

PRG SWTCH CLOSED

DURING IGNITION

AIRFLOW FAULT

DURING IGN

AIRFLOW FAULT

DURING RUN

SSOV

SWITCH OPEN

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING IGN

SSOV FAULT DURING RUN SSOV RELAY

FAILURE

FLAME LOSS

DURING IGN FLAME LOSS DURING RUN

HIGH EXHAUST TEMPERATURE

The High Water Temperature Limit Switch is open.

The Water Level Control board is indicating low water level.

The Low Gas Pressure Limit Switch is open.

The High Gas Pressure Limit Switch is open.

The Remote Interlock is open.

The Delayed Interlock is open.

The Blower Proof Switch opened during purge.

The Purge Position Limit switch on the air/fuel valve opened during purge. The Ignition Position Limit switch on the air/fuel valve opened during ignition. The Ignition Position Limit switch on the air/fuel valve closed during purge. The Purge Position Limit switch on the air/fuel valve closed during ignition. The Blower Proof Switch opened during ignition.

The Blower Proof Switch opened during run.

The SSOV switch opened during standby.

The SSOV switch opened during purge.

The SSOV switch closed or failed to open during ignition.

The SSOV switch closed for more than 15 seconds during run. A failure has been detected in one of the relays that control the SSOV. The Flame signal was not seen during ignition or lost within 5 seconds after ignition. The Flame signal was lost during run.

The High Exhaust Temperature Limit Switch is closed.

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Table 4-2. Fault Messages - Continued

FAULT MESSAGE

RESIDUAL

FLAME

HEAT DEMAND

FAILURE

IGN BOARD

COMM FAULT

DIRECT DRIVE SIGNAL FAULT

REMOTE SETPT

SIGNAL FAULT

OUTDOOR TEMP

SENSOR FAULT

OUTLET TEMP

SENSOR FAULT

FFWD TEMP

SENSOR FAULT

HIGH WATER

TEMPERATURE

LINE VOLTAGE

OUT OF PHASE

STEPPER MOTOR

FAILURE

MODBUS COMM

FAULT

The Flame signal was seen for more than 30 seconds during standby. The Heat Demand Relay on the Ignition/Stepper (IGST) board failed to activate when commanded. A communication fault has occurred between the Primary Micro-Controller (PMC) board and Ignition/Stepper (IGST) board. The direct drive signal is not present or is out of range.

The remote setpoint signal is not present or is out of range.

The temperature measured by the Outdoor Air Sensor is out of range. The temperature measured by the Outlet Sensor is out of range. The temperature measured by the Feed-Forward (FFWD) Sensor is out of range. The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting. The High AC voltage is out of phase from the low AC voltage.

The stepper motor failed to move the valve to the desired position. The RS485 (MODBUS) network information is not present or is corrupted.

FAULT DESCRIPTION

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SECTION 5 - INPUT/OUTPUT INTERFACES & OPERATING MODES

5.1 INTRODUCTION

This Section provides descriptions of the Input/Output (I/O) wiring connections which can be made at the Input/Output (I/O) Box included with the C-More Control Panel. For KC Series units, the I/O Box is located on the left side of the unit. For Benchmark Series units, the I/O Box is located on the front of the unit behind the door.

Also included in this Section are descriptions of the available operating modes which can be set up for Water Heaters and Boilers utilizing the CMore menus.

5.2 I/O INTERFACES

All wiring connections are made at the terminal strips contained in the I/O Box. The I/O Box cover contains a connection diagram as shown in Figure 5-1. Refer to this diagram when making all field wiring connections to the I/O Box. The connections shown in Figure 5-1 are described in the following paragraphs.

CAUTION!

DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage.

5.2.1 OUTDOOR SENSOR IN

An outdoor air temperature sensor (AERCO Part No. 122790) will be required mainly for the Indoor/Outdoor Reset Mode of operation for boilers. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature. This feature allows the boiler to be enabled or disabled based on the outdoor air temperature. The factory default for the outdoor sensor is DISABLED. To enable the sensor or choose a system start temperature, see the Configuration Menu in Table 2-3.

The outdoor sensor may be wired up to 200 feet from the boiler. It is connected to the OUTDOOR SENSOR IN and SENSOR COMMON terminals in the I/O Box (see Figure. 5-1). Wire the sensor using a twisted shielded pair cable of 18-22 AWG wire. There is no polarity to observe when

terminating the wires. The 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 ungrounded.

When mounting the sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be shielded from direct sunlight as well as impingement by the elements. If a shield is used, it must allow for free air

circulation

5.2.2 AUX SENSOR IN

The AUX SENSOR IN terminals can be used to add an additional temperature sensor for monitoring purposes. This input is always enabled and is a view only input that can be seen in the operating menu. The sensor must be wired to the AUX SENSOR IN and SENSOR COMMON terminals. It must be similar to AERCO BALCO wire sensor P/N 123449. A resistance chart for this sensor is provided in Appendix D.

5.2.3 ANALOG IN

The ANALOG IN + and – terminals are used when an external signal is used to drive the firing rate (Direct Drive Mode- Boiler Only) or change the setpoint (Remote Setpoint Mode) of the unit.

Either a 4 to 20 mA / 1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the setpoint or firing rate. The factory default setting is for 4 to 20 mA / 1 to 5 VDC, however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu described in Sections 2 and

3. If voltage rather than current is selected as the drive signal, a DIP switch must be set on the PMC Board located inside the Control Box. Refer to Appendix F for information on setting DIP switches.

All supplied signals must be floating (ungrounded) signals. Connections between the source and the unit’s I/O Box must be made using twisted shielded pair wire of 18 – 22 AWG, such as Belden 9841(see Fig. 5-1). Polarity must be maintained and the shield must be connected

C-MORE CONTROL PANEL OPERATION

only at the source end and must be left floating (not connected) at the unit’s I/O Box.

Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F setpoint or a 0% to 100% firing rate. No scaling for

these signals is provided.

5.2.4 B.M.S. (PWM) IN

interlocks which are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. Both interlocks, described below, are factory wired in the closed position.

NOTE:

Both the Delayed Interlock and the Remote Interlock must be in the closed position to allow the unit to fire.

NOTE

Only BMS Model 168 can utilize pulse width

modulation, not

These terminals are used to connect the AERCO Boiler Management System (BMS Model 168) to the unit. The BMS Model 168 utilizes a 12 millisecond, ON/OFF duty cycle. This duty cycle is Pulse Width Modulated (PWM) to control firing rate. A 0% firing rate = a 5% ON pulse and a 100% firing rate = a 95% ON pulse.

the BMS II Model 5R5-384.

5.2.5 SHIELD

The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit. Shields must only be connected to these terminals.

5.2.6 mA OUT

These terminals provide a 4 to 20 mA output that can be used to monitor setpoint ( 40°F to 240°F), outlet temperature (30°F to 245°F), or fire rate (0% to 100%). This function is enabled in the Configuration Menu (Table 2-3).

5.2.9.1 REMOTE INTERLOCK IN

The remote interlock circuit (REMOTE INTL’K IN) is provided to remotely start (enable) and stop (disable) the Boiler if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumpered).

5.2.9.2 DELAYED INTERLOCK IN

The delayed interlock circuit (DELAYED INTL’K IN) is typically used in conjunction with the auxiliary relay described in paragraph 5.2.11. This interlock circuit is located in the purge section of the start string. It can be connected to the proving device (end switch, flow switch etc.) of an auxiliary piece of equipment started by the unit’s auxiliary relay. The delayed interlock must be closed for the unit to fire. If the delayed interlock is connected to a proving device that requires time to close (make), a time delay (Aux Start On Dly) that holds the start sequence of the unit long enough for a proving switch to make can be programmed. Should the proving switch not prove within the programmed time frame, the unit will shut down. The Aux Start On Dly can be programmed from 0 to 120 seconds. This option is locate in the Configuration Menu.

5.2.7 RS485 COMM

These terminals are used for RS485 MODBUS serial communication between the unit and an external “Master”, such as a Boiler Management System or other suitable device.

5.2.8 EXHAUST SWITCH IN

These terminals permit an external exhaust switch to be connected to the exhaust manifold of the unit. The exhaust sensor should be a normally open type switch (such as AERCO Part No.

123463) that closes (trips) at 500°F.

5.2.9 INTERLOCKS

The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers. These interlocks are called the Remote Interlock and Delayed Interlock. The wiring terminals for these interlocks are located inside the I/O Box. The I/O Box cover contains a wiring diagram (Figure 5-1) which shows the terminal strip locations for these

5.2.10 FAULT RELAY

The fault relay is a single pole double throw (SPDT) relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC, resistive. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed.

5.2.11 AUXILIARY RELAY CONTACTS

Each unit is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and de-energized after the demand for heat is satisfied. The relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be used as a unit status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 amps resistive. Refer to Figure 5-1 to locate the AUX RELAY terminals for wiring connections.

C-MORE CONTROL PANEL OPERATION

Figure 5-1. I/O Box Terminal Strip Connections

5.3 MODES OF OPERATION

KC Series Water Heaters are capable of being operated in either the Constant Setpoint Mode or Remote Setpoint Mode. In addition to the Constant and Remote Setpoint Modes, KC and Benchmark Series Boilers can also be operated in the Direct Drive Mode, Boiler Management System (BMS) Mode, Indoor/Outdoor Reset Mode or Combination Mode.

The following paragraphs briefly describe the required connections and menu settings to place the unit in each of these modes.

5.3.1 Constant Setpoint Mode

The Constant Setpoint mode is used when a fixed header temperature is desired. Common uses of this mode of operation include water source heat pump loops, and indirect heat exchangers for potable hot water systems or processes.

There are no external sensors necessary to operate in this mode. While it is necessary to set the desired setpoint temperature, it is not necessary to change any other temperaturerelated functions. The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be

contacted. See Sections 2 and 3 for complete listings of temperature related menu functions and factory defaults.

5.3.1.1 Setting The Setpoint

The setpoint temperature of the unit is adjustable from 40°F to 240°F.. To set the unit for operation in the Constant Setpoint Mode, the following menu settings must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler (or Heater)

Constant Setpoint Mode Internal Setpt Select desired setpoint

using ▲ and ▼ arrow

keys (40° to 240°F)

Refer to paragraph 2.2 for detailed instructions on changing menu options.

5.3.2 Remote Setpoint Modes

The unit’s setpoint can be remotely controlled by an Energy Management System utilizing either a current or voltage signal level.

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The current/ voltage signal can be at either of the following levels:

4 - 20 mA/1 - 5 Vdc 0 - 20 mA/0 - 5 Vdc

The factory default setting for the Remote Setpoint mode is 4 - 20 mA/1 - 5 Vdc. With this setting, a 4 to 20 mA/1 to 5 Vdc signal, sent by an EMS or BAS, is used to change the unit's setpoint. The 4 mA/1V signal is equal to a 40°F setpoint while a 20 mA /5V signal is equal to a 240°F setpoint. When a 0 to 20 mA/0 to 5 Vdc signal is used, 0 mA is equal to a 40°F setpoint.

In addition to the current and voltage signals described above, the Remote Setpoint mode can also be driven by a RS485 Modbus Network signal from an EMS or BAS.

The Remote Setpoint modes of operation can be used to drive single as well as multiple units.

NOTE

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the PMC Board located in the Control Panel Assembly. Refer to Appendix F for details.

In order to enable the Remote Setpoint Mode, the following menu setting must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Remote Setpoint

Remote Signal 4-20mA/1-5V,

0-20mA/0-5V, or Network

Refer to paragraph 2.2 for detailed instructions on changing menu options.

If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information.

While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions

and their factory defaults, refer to Tables 3-1 and 3-2.

5.3.2.1 Remote Setpoint Field Wiring

The only wiring necessary for the Remote Setpoint modes is the external control wiring from the source, to the ANALOG IN terminals on the terminal strip inside the I/O Box. The I/O Box is located on the left side of the KC Series units and on the front of Benchmark Series units. Refer to the wiring diagram (Figure 5-1) provided on the cover of the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating (ungrounded), and the wire used must be a two wire shielded cable of 18 to 22 AWG. Polarity must be observed and the source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.3.2.2 Remote Setpoint Startup

Since this mode of operation is factory preset and the setpoint is being externally controlled,

no startup instructions are necessary. In this

mode, the REMOTE LED will light when the external signal is present.

To operate the unit in manual mode, press the AUTO/MAN switch. The REMOTE LED will go off and the MANUAL LED will light

To change back to the Remote Setpoint mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.

NOTE:

The modes of operation described in paragraphs 5.3.3 through 5.3.6 apply ONLY to KC and Benchmark Series Boilers. External wiring connections for these modes are made at the Input/Output (I/O) Box which is located on the left side of KC Series units and on the front of Benchmark Series units.

5.3.3 Indoor/Outdoor Reset Mode

This mode of operation is based on outside air temperatures. As the outside air temperature decreases, the supply header temperature will increase and vice versa. For this mode, it is necessary to install an outside air sensor as well as select a building reference temperature and a reset ratio.

C-MORE CONTROL PANEL OPERATION

5.3.3.1 Reset Ratio

Reset ratio is an adjustable number from 0.1 to

9.9. Once adjusted, the supply header temperature will increase by that number for each degree that the outside air temperature decreases. For instance, if a reset ratio of 1.6 is used, for each degree that outside air temperature decreases, the supply header temperature will increase by 1.6 degrees.

5.3.3.2 Building Reference Temperature

This is a temperature from 40°F to 230°F. Once selected, it is the temperature that the system references to begin increasing its temperature. For instance, if a reset ratio of 1.6 is used, and we select a building reference temperature of 70°F, then at an outside temperature of 69°F, the supply header temperature will increase by

1.6° to 71.6°F.

5.3.3.3 Outdoor Air Temperature Sensor Installation

The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected. The sensor must be shielded from the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used, it must allow free air circulation. The sensor may be mounted up to two hundred feet from the unit. Sensor connections are made inside the Input/Output (I/O) Box at the terminals labeled OUTDOOR SENSOR IN and SENSOR COMMON using shielded 18 to 22 AWG wire. A wiring diagram is provided on the cover of the I/O Box. Refer to Section 2 of Operation & Maintenance Manual GF-109 (KC Series) or GF-110 (Benchmark Series) for additional wiring information.

5.3.3.4 Indoor/Outdoor Startup

1. Refer to the indoor/outdoor reset ratio charts in Appendix C.

2. Choose the chart corresponding to the desired building reference temperature.

3. Go down the left column of the chart to the coldest design outdoor air temperature expected for your area.

NOTE:

A design engineer typically provides design outdoor air temperature and supply header temperature data

4. Once the design outdoor air temperature is

5. Next, go up that column to the Reset Ratio

6. Access the Configuration Menu and scroll

7. Press the CHANGE key. The display will

8. Use the ▲ and ▼ arrow keys to select the

9. Press ENTER to save any changes.

10. Next, scroll through the Configuration Menu

11. Press the CHANGE key. The display will

12. Use the ▲ and ▼ arrow keys to select the

13. Press ENTER to save the change.

Refer to paragraph 2.2 for detailed instructions on menu changing.

5.3.4 Direct Drive Modes

The boiler’s fire rate can be changed by a remote signal typically sent from an energy management system. The Direct Drive modes are driven by current or voltage signals in the following ranges:

4 - 20 mA/1 - 5 Vdc 0 - 20 mA/0 - 5 Vdc

The factory default setting is 4 - 20 mA/1 - 5 Vdc. In this mode of operation, a 4 to 20mA signal, sent by an energy management system, is used to change the boiler’s fire rate from 0% to 100%. The 4 mA/1Vdc signal is equal to a 0% fire rate while a 20 mA /5Vdc signal is equal to a 100% fire rate. When a 0-20 mA/0-5 Vdc signal is used, zero is equal to a 0% fire rate.

In addition to the current and voltage signals described above, the Direct Drive mode can also be driven by a RS-485 Modbus Network signal from an EMS or BAS.

chosen, go across the chart to the desired supply header temperature (setpoint) for the design temperature chosen in step 3.

row to find the corresponding reset ratio.

through it until the display shows Bldg Ref Temp (Building Reference Temperature).

begin to flash.

desired building reference temperature.

until the display shows Reset Ratio.

begin to flash.

reset ratio determined in step 5.

C-MORE CONTROL PANEL OPERATION

When in a Direct Drive mode, the boiler is a slave to the energy management system and does not have a role in temperature control. Direct Drive can be used to drive single as well as multiple boilers.

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the PMC Board in the Control Box. Refer to Appendix F for details.

To enable the Direct Drive Mode, the following menu setting must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Direct Drive Remote Signal 4-20mA/1-5V,

0-20mA/0-5V, or Network

Refer to paragraph 2.2 for instructions on changing menu options

If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information.

5.3.4.1 Direct Drive Field Wiring

The only wiring necessary for Direct Drive mode is connection of the remote signal leads from the source to the ANALOG IN terminals at the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded), and the wire used must be a two wire shielded cable of 18 to 22 AWG. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.3.4.2 Direct Drive Startup

Since this mode of operation is factory preset and the fire rate is being externally controlled,

no startup instructions are necessary. In this

mode, the REMOTE LED will light when the signal is present.

To operate the boiler in manual mode, press the MAN switch. The REMOTE LED will go off and the MANUAL LED will light.

To change back to the Direct Drive mode, simply press the AUTO switch. The REMOTE LED will again light and the MANUAL LED will go off.

5.3.5 Boiler Management System (BMS)

NOTE

BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signaling to the Boiler. BMS II Model 5R5-384 can utilize only RS485 signaling to the Boiler.

The BMS mode of operation is used in conjunction with an AERCO Boiler Management System. The BMS mode is used when it is desired to operate multiple units in the most efficient manner possible. The BMS can control up to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS485) network communication. For BMS programming and operation, see GF-108M (BMS Model 168) and GF-124 (BMS II Model 5R5-384), BMS Operations Guides. For operation via an RS485 Modbus network, refer to Modbus Communication Manual GF-114. The AERCO BMS monitors all system-related parameters and modulates the firing rates of the units.

To enable the BMS Mode, the following menu settings must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Direct Drive Remote Signal BMS (PWM Input)

Network (RS485)

Refer to paragraph 2.2 for instructions on changing menu options.

5.3.5.1 Boiler Management System External Field Wiring

Wiring for this system configuration is connected between the BMS panel Model 168, boilers 1 through 8, to the B.M.S. (PWM) IN terminals in the I/O Box on the Boiler. Refer to the wiring diagram provided on the cover of the I/O Box.

Wiring connections for RS485 Modbus control are made between connector JP11 on the BMS Model 168 (boilers 9 to 40)/or JP6 on BMS II Model 5R5-384 (boilers 1 to 32 and the RS485 COMM terminals in the I/O Box.

C-MORE CONTROL PANEL OPERATION

Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the polarity shown for the B.M.S. (PWM) IN connections. The shield is connected at the BMS to any minus (-) boiler terminal and the boiler end of the shield must be left floating. Each unit’s wiring must conform to the above.

5.3.5.2 Boiler Management System Setup

and Startup

This mode of operation is factory preset and the AERCO BMS Model 168 controls the firing rate. There are no setup instructions for each individual unit.

To operate the unit in manual mode, press the AUTO/MAN switch. The REMOTE LED will go off and the MANUAL LED will light

To change back to the BMS mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.

5.3.6 Combination Control System

(CCS)

NOTE

Only BMS Model 168 can be utilized for the Combination Mode, not (Model 5R5-384).

A Combination Control System is one that uses multiple boilers to cover both space-heating and domestic hot water needs. An AERCO Boiler Management System (BMS Model 168) and a Combination Control Panel (CCP) are necessary to configure this system. Typically, enough boilers are installed to cover the space-heating load on the design day, however one or more units are used for the domestic load.

The theory behind this type of system is that the maximum space-heating load and the maximum domestic hot water load do not occur simultaneously. Therefore, boilers used for the domestic hot water are capable of switching between constant setpoint and BMS modes of operation. These boilers are the combination units and are referred to as the combo boilers. The combo boilers heat water to a constant setpoint temperature. That water is then circulated through a heat exchanger in a domestic hot water storage tank.

When the space-heating load is such that all the space-heating boilers are at 100% firing rate, the BMS will then ask the Combination Control

the BMS II

Panel for the domestic boilers to become spaceheating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become space-heating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the CCP switches the combo units back to the domestic load.

When the combo units are satisfying the domestic load they are in constant setpoint mode of operation. When the combo units switch over to space heating, their mode of operation changes to the BMS mode. For more information concerning the operation of the Combination Control Panel see the AERCO CCP-1 literature.

5.3.6.1 Combination Control System Field Wiring

Wiring for this system is between the BMS panel, the CCP and the B.M.S. (PWM) IN terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above. For a complete CCP system-wiring diagram see the AERCO CCP-1 literature.

5.3.6.2 Combination Control System Setup and Startup

Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode, remote signal type and setpoint. The setpoint is adjustable from 40°F to 220°F.

Enter the following settings in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Combination Remote Signal BMS (PWM) Input Internal Setpt 40°F to 240°F

Refer to paragraph 2.2 for instructions on changing menu options.

While it is possible to change other temperaturerelated functions for combination mode, the unit is factory preset. These preset settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint.

C-MORE CONTROL PANEL OPERATION

5.4 START SEQUENCE

When the unit is in the Standby mode and all pre-purge safety switches are closed, the READY light above the ON/OFF switch will be lit. When there is a demand for heat, the following events will occur:

NOTE:

If any of the Pre-Purge safety switches (low water level, high water temperature, high or low gas pressure) are open, the appropriate fault message will be displayed. Also, the appropriate fault messages will be displayed throughout the start sequence, if the required conditions are not observed.

1. The DEMAND LED status indicator will light.

2. The unit checks the proof of closure switch

on the Safety Shut-Off Valve (SSOV) shown in Figure 5-2.

switch. The dial on the Air/Fuel Valve (Figure 5-3) will read 100 to indicate that the valve is full-open (100%).

100%.

NOTE:

The Air/Fuel Valves shown in Figures 5-3 and 5-5 are used on KC Series units. Although slight physical differences exist between the Air/Fuel Valves used on Benchmark Series units, the valves are functionally identical.

STEPPER

MOTOR

Figure 5-2. Proof of Closure Switch

3. With all required safety switches closed, a

purge cycle will be initiated and the following events will occur:

(a) Blower relay energizes and turns on

blower.

(b) Air/Fuel Valve rotates to the full-open

purge position and closes purge position

DIAL (DETAIL “A”)

100

DETAIL "A"

Figure 5-3.

KC1000 Air/Fuel Valve In Purge Position

4. Next, the blower proof switch (Figure 5-4)

closes and the display will show Purging and

indicate the elapsed time of the purge cycle in seconds. The normal (default) time for the purge cycle is 7 seconds.

C-MORE CONTROL PANEL OPERATION

7. With the unit firing properly, it will be controlled by the temperature controller circuitry. The FIRE RATE will be continuously displayed on the front panel bargraph.

8. Once the demand for heat has been satisfied, the Control Box will turn off the gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed.

Standby will be displayed.

Figure 5-4.

Blower Proof Switch

5. Upon completion of the purge cycle, the Control Box initiates an ignition cycle and the following events occur:

(a) The Air/Fuel Valve rotates to the low-fire

ignition position and closes the ignition switch. The dial on the Air/Fuel Valve (Figure 5-5) will read between 25 and 35 to indicate that the valve is in the lowfire position.

(b) The igniter relay is activated and

provides ignition spark.

STEPPER

MOTOR

DIAL (DETAIL “A”)

is energized (opened) allowing gas to flow into the Air/Fuel Valve. Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected.

6. After 2 seconds of continuous flame, Flame Proven will be displayed and the flame

strength will be indicated. After 5 seconds, the current date and time will be displayed in place of the flame strength.

DETAIL "A"

Figure 5-5.

KC1000 Air/Fuel Valve In Ignition Position

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SECTION 6 - CALIBRATION AND DIAGNOSTIC MENUS

6.1 INTRODUCTION

The Level 2 Password (6817) must be entered to access the Calibration and Diagnostic procedures describe in this Section.

6.2 CALIBRATION PROCEDURES

The items contained in the Calibration Menu shown in Table 2-5 permit the user to set or adjust a number of functions in the KC and Benchmark Series units. The descriptions and procedures necessary to implement each of these Calibration Items are provided in the following paragraphs.

6.2.1 Stepper Feedback Calibration.

The Stepper Feedback (Fbk) function checks the calibration of the Air/Fuel Valve Stepper Motor feedback current. This is accomplished by positioning the Air/Fuel Valve stepper motor at the 0% (fully closed) and 100% (fully open) positions and storing the feedback potentiometer readings at these settings. It also permits verification of the Stepper Motor Feedback at the 50% position. The position of the Stepper Motor is verified by visually checking the dial on the Air/Fuel Valve. In addition, the FIRE RATE bargraph segments will light to indicate motor position. To initiate this calibration procedure, proceed as follows:

1. Press the ▲ or ▼ arrow key until Stepper Fbk Cal 0% is displayed.

2. Press the CHANGE key. Stepper Fbk will

begin to flash.

3. Press and hold the ▼ arrow key and monitor the dial on the Air/Fuel Valve.

4. Release the ▼ arrow key when the Air/Fuel Valve reaches the 0% (fully closed) position, but is not pressing against the stop. Momentarily tap the ▲ arrow key a few times to ensure it is not contacting the stop.

5. Press the ENTER key. Cal 100% will be

displayed.

6. Press and hold the ▲ arrow key and monitor the dial on the Air/Fuel Valve.

7. Release the ▲ arrow key when the Air/Fuel Valve reaches the 100% (fully open) position, but is not pressing against the stop. Momentarily tap the ▼ arrow key a few times to ensure it is not contacting the stop.

8. Press the ENTER key. Verify 50% will be

displayed and the Air/Fuel Valve will rotate to the 50% position.

9. Verify that the dial on the Air/Fuel Valve indicates approximately 50%. Press ENTER to confirm.

10. Press BACK to exit the Stepper Fbk Calibration.

6.2.2 PWM In Adjustment.

The Pulse Width Modulation (PWM) Input Adjustment is used when the unit is being controlled by a Boiler Management System (BMS). This Calibration procedure allows the PWM duty cycle to be varied ±5.0% in 0.1% increments. The nominal PWM duty cycle is 12 milliseconds where: a 5% pulse ON time = a 0% firing rate and a 95% pulse ON time represents a 100% firing rate. To adjust the overall PWM duty cycle, proceed as follows:

1. Press the ▲ or ▼ arrow key until PWM In Adj is displayed along with the currently

entered adjustment percentage.

2. If the desired percentage is not displayed,

press the CHANGE key. PWM In Adj will

begin to flash.

3. Press the ▲ or ▼ arrow key to increment or decrement the display until the desired adjustment percentage is displayed.

4. Press ENTER to store the selection.

5. Pres BACK to exit the adjustment procedure.

6.2.3 Analog In Adjustment

The Analog Input Adjustment may be utilized when an external signal is used to change the setpoint (Remote Setpoint Mode – Boiler or Heater), or drive the firing rate Direct Drive Mode – Boiler Only). This adjustment allows the 0 to 20 mA or 1 to 5 Vdc input to be changed ±5.0% in 0.1 % increments. The default setting is 0.0%. To view or change this adjustment, proceed as follows:

C-MORE CONTROL PANEL OPERATION

1. Press the ▲ or ▼ arrow key until Analog In Adj is displayed along with the current

adjustment percentage

2. If the desired percentage is not displayed,

press the CHANGE key. Analog In Adj will

begin to flash.

3. Press the ▲ or ▼ arrow key to increment or decrement the display until the desired adjustment percentage is displayed.

4. Press ENTER to store the selection.

5. Pres BACK to exit the adjustment procedure.

6.2.8 A/F Sensitivity

The Air/Fuel (A/F) Valve Sensitivity is used to set the allowable error on the Air/Fuel Valve Stepper Motor position. The sensitivity is adjustable from 1% to 5% in 1% increments. The default value for this setting is 2%. The sensitivity setting represents the maximum percentage that the output fire rate can change without the valve having to move. For example; if the sensitivity is set for 2% and the output fire rate changes 1%, no movement is required. To view or change the A/F Sensitivity, proceed as follows:

6.2.4 Flow In Adjustment.

The Flow Input Adjustment is not currently implemented in the C-More Control Panel. When implemented, it will allow the water flow rate measured by a flow sensor to be adjusted ± 5%.

6.2.5 CO In Adjustment.

The Carbon Monoxide (CO) Input Adjustment is not currently implemented in the C-More Control Panel. When implemented, it will allow input flow rate to be adjusted ±5%.

6.2.6 O2 In Adjustment

The Oxygen (O2) Input Adjustment is not currently implemented in the C-More Control Panel. When implemented, it will allow the input oxygen level to be adjusted ±5%.

6.2.7 mA Out Adjustment

The Milliamp (mA) Output Adjustment permits the output current to be adjusted from -1.0 mA to +1.0 mA in 0.1 mA increments. The default setting is 0.0 mA. This function is associated with the mA OUT terminals in the I/O Box. These terminals provide an output that can be used to monitor setpoint, outlet temperature or fire rate. The function to be monitored is selected in the Configuration Menu. To view or adjust this setting, proceed as follows:

1. Press the ▲ or ▼ arrow key until mA Out Adj

is displayed along with the current adjustment setting in mA.

2. If the desired setting is not displayed, press

the CHANGE key. mA Out Adj will begin to

flash.

3. Press the ▲ or ▼ arrow key to increment or decrement the display until the desire value appears.

4. Press ENTER to store the displayed setting.

1. Press the ▲ or ▼ arrow key until A/F Sensitivity is displayed. The currently set

sensitivity percentage will also appear in the display.

2. If the desired percentage is not displayed,

press the CHANGE key. A/F Sensitivity will

begin to flash.

3. Press the ▲ or ▼ arrow key to increment or decrement the displayed sensitivity percentage to the desired value.

4. Press ENTER to store the new setting.

5. Press BACK to exit the A/F Sensitivity Calibration.

6.2.9 Power Reset

The Power Reset function can be set to Automatic or Manual. However, AERCO strongly recommends that this function always be set to the Automatic (Default) setting.

6.2.10 Water Temp Reset

The Water Temperature Reset function can be set to Automatic or Manual to indicate whether the unit can be restarted or must wait for manual acknowledgement following a high water temperature fault and fault correction. Regardless which setting is used, the High Temperature fault message will be latched. The default for this function is Automatic. To view or change the setting, proceed as follows:

1. Press the ▲ or ▼ arrow key until Water

Temp Reset is displayed. Automatic or Manual will be displayed to indicate the

present setting.

2. If the desired setting is not displayed, press

the CHANGE key. Water Temp Reset will

begin to flash.

3. Press ENTER to toggle the display.

5. Press BACK to exit the mA Out Adj function.

C-MORE CONTROL PANEL OPERATION

4. Press BACK to exit the Water Temp Reset function.

6.2.11 Gas Press Reset

The Gas Pressure Reset function can be set to Automatic or Manual to indicate whether the unit can be restarted or must wait for manual acknowledgement following a high or low gas pressure fault and fault correction. The default setting for this function is Manual. Regardless which setting is used, the High or Low Gas Pressure fault message will be latched. The default for this function is Manual. To view or change the setting, proceed as follows:

IMPORTANT:

DO NOT change this setting to Automatic without written permission from AERCO.

1. Press the ▲ or ▼ arrow key until Gas Pres Reset is displayed. Automatic or Manual will

be displayed to indicate the present setting.

2. If the desired setting is not displayed, press

the CHANGE key. Gas Press Reset will

begin to flash.

3. Press ENTER to toggle the display.

4. Press BACK to exit the Gas Press Reset function.

6.2.12 Min Off Time

The Minimum Off Time specifies the minimum amount of time that the unit must remain off when operating under automatic control. This time is adjustable from 0 to 10 minutes in 1 minute increments. The default value is 1 minute. To view or change this setting, proceed as follows:

1. Press the ▲ or ▼ arrow key until Min Off Time is displayed. The present setting will

also appear in the display.

2. If the desired minimum off time is not

displayed, press the CHANGE key. Min Off Time will begin to flash.

3. Press the ▲ or ▼ arrow key to increment or decrement the displayed until the desired value is shown.

Heater Tuning Display

The Heater Tuning Display function can be set to Enable or Disable (Default = Disable). When Enabled, it permits the Prop Band, Integral Gain and Derivative Time functions in the Tuning Menu to be set. See Table 2-4 for entry ranges.

6.2.14 Heater Breakpoint Display

This menu option is applicable only to Water Heaters and can be set to Enable or Disable (Default = Disable). When Enabled, it permits the Heater Breakpoints listed in the Tuning Menu (Table 2-4) to be viewed or changed.

6.3 DIAGNOSTICS PROCEDURES

The Diagnostics Menu Items listed in Table 2-6 permit the user to check the operational status of the front panel controls indicators and displays and the control system relays and switches. To perform each of the following Diagnostic procedures, first scroll to the Diagnostics Menu using the MENU key and press the ▲ or ▼ arrow key. Proceed to the desired Diagnostic procedure specified in the following paragraphs.

6.3.1 Display Test

The Display Test checks the front panel LED indicators, 7-segment display and LED FIRE Rate bargraph.

1. Press the ▲ or ▼ arrow key until Display Test Off is displayed.

2. Press the CHANGE key. Display Test will

begin to flash.

3. Press the ▲ key. LEDs will be displayed and

the seven panel LEDs will light. These LEDs are: COMM, MANUAL, REMOTE, DEMAND, °F, °C and FAULT.

4. Press the ▲ key. 7-SEG will be displayed and all segments of the three-digit 7-segment display will light.

5. Press the ▲ key. Bar-graph will be displayed

and the 20 segment FIRE RATE bargraph will light.

6. This completes the Display Test. Press the

BACK key to exit the test.

6.3.2

4. Press ENTER to store the new setting.

5. Press BACK to exit the Min Off Time function.

6.2.13

C-MORE CONTROL PANEL OPERATION

Keypad Test

The Keypad Test checks the status of the eight keypad keys on the front panel. The test is initiated as follows:

1. Press the ▲ or ▼ arrow key until Keypad Test Off is displayed.

2. Press the CHANGE key. Keypad Test will

begin to flash.

(a) Aux

(b) Pump

(d) Igniter

6. Pressing the ▼ arrow key will display the previous relay.

7. Press the BACK key to exit the Relay Test.

3. Press each of the keys in the following sequence and verify that the name of each key appears in the panel display:

(a) AUTO/MAN (Manual is displayed).

(b) MENU

(d) ▼ (Down is displayed)

(e) CHANGE

(f) ENTER

(g) CLEAR

4. Press the BACK key to exit the Keypad Test.

6.3.3 Relay Test

The Relay Test allows the user to switch relays ON or OFF. The relays which are tested are: Igniter, Blower, Pump, Aux and Fault relays. The Aux and Fault relays are located in the I/O Box on the left side of the unit. Removing the cover on the I/O Box will permit the ON/OFF status of these relays to be observed. The remaining relays are located in the C-More Control Panel. A “click” can be heard as each relay is turned ON and OFF.

1. Press the ▲ or ▼ arrow key until Relay Test

Off is displayed.

2. Press the CHANGE key. Relay Test will

begin to flash.

3. Press the ▲ arrow key. Fault OFF will be

displayed.

4. To switch relay to ON, press ENTER. Fault ON will be displayed. Press ENTER again to

toggle relay back to OFF. The ON/OFF status of this relay can be observed with the I/O Box cover removed.

5. To change the ON/OFF status of the remaining relays, repeat steps 3 and 4. The display will show the relays in the following order:

6.3.4 Switch Test

The Switch Test allows the user to observe the ON/OFF status of all control system switches in “Real Time”. However, the displayed status can not be changed. This test is useful in determining that all required switches in the “Start String” on in the required positions to permit system startup.

1. Press the ▲ or ▼ arrow key until Switch Test

Off is displayed.

2. Press the CHANGE key. Switch Test will

begin to flash.

3. Press the ▲ arrow key. Exhaust sw will be

displayed along with the present ON/OFF switch status.

4. To check the status of the remaining switches, continue to press the ▲ arrow key. The switch status will be displayed in the following order:

(a) SSOV sw (b) Blower Proof sw (c) Ignition sw (d) Over Temp sw (e) Low Gas Pres (f) Hi Gas Pres (g) Water Lev sw (h) Rem Int sw (i) Front Pnl sw (j) Delayed Int (k) Purge sw

5. Press the BACK key to exit the Switch Test.

6.3.5

C-MORE CONTROL PANEL OPERATION

Stepper Test

The Stepper Test allows e Stepper Motor to be rotated between virtually any position between 0% (fully closed) and 100% (fully open).

1. Press the ▲ or Test 0% is displayed.

2. Press the CHANGE ill begin to flash.

3. Press and hold the Stepper Motor position. The FIRE RATE bargraph will increase to show the valve position and the dial on the Air/Fuel valve will also rotate to track the current position.

4. Press and hold the ▼ arrow ke decrement the Stepper Motor position and verify that bargraph display and Air/Fuel Valve dial track the change.

▼ arrow key until Stepper

the ▲ arrow key to increment

6.3.6 Sensor Log Int

The Sensor Log Interval func user to set the interval at which sensor readings are recorded and stored in memory. By default, this option is set to OFF. However, if desired, the Sensor Log Interval can be enabled and set to values ranging from 1 minute to 24 hours.

the Air/Fuel Valv

key. Stepper Test w

y to

tion permits the

. Press the ▲ or ▼ arrow key until Sensor L

Int Off is displayed.

2. Press the CHANGE key. Sensor Log Int will

begin to flash.

Press the ▲ arrow key until the desired

interval is disp are:

(a) 1 Min

(b) 5 Min

(d) 30 Min

(e) 1 hr

(f) 6 hrs

(g) 12 hrs

(h) 24 hrs

4. With the des ENTER to sto

5. Press BACK to exit the Sensor Log Int function.

layed. The available choices

ired interval displayed, press

re the selection in memory.

C-MORE CONTROL PANEL OPERATION

SECTION 7 - RS232 COMMUNICATION

7.1 INTRODUCTION

The RS232 port on the front panel can be interfaced to a laptop computer or other suitable terminal using a RS232 adapter cable. RS232 communication can be accomplished using any “Dumb Terminal” emulation, such as “Hyper Terminal” which is included with Microsoft Windows. The RS232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays.

7.2 RS232 COMMUNICATION SETUP

Regardless of the terminal emulation utilized, the following guidelines must be adhered to when setting up the RS232 communication link:

1. Baud Rate – The baud rates which can be used with the C-More Control Panel are:

(a) 2400

(b) 4800

(d) 19.2K

2. Data Format – The program must be set for: 8 data bits, 1 stop bit, no parity and either Xon/Xoff or No flow control.

7.3 MENU PROCESSING UTILIZING

RS232 COMMUNICATION.

Viewing data logs and viewing or changing Control Panel menu options using RS232 communication is accomplished as follows:

1. Start the emulator software program and ensure that the specified baud rate and data formats have been entered.

2. Press the Enter key on the laptop. An asterisk (*) prompt should appear.

3. At the prompt, enter the valid RS232 password (jaguar) in lower case letters and press Enter.

4. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices:

M = Display next Menu D = Display menu items N = Display next menu items Cxx = Change item xx F = Fault log display S = Sensor log display T = Time line display L = Log off

NOTE:

The Level 1 password must be entered to change options in the Setup, Configuration and Tuning Menus. The Level 2 password must be entered to view or change options in the Calibration and Diagnostics Menus.

With the exception of the password entry, all other keyboard entries can be made using either upper or lower case.

5. To view the available menus in the top-down

sequence shown in Figure 2-1, enter M <Rtn>. The Menu title and first 10 options will

be displayed.

6. When viewing menus containing more than

10 options, enter N <Rtn> to display the

remaining options.

7. Shortcut keys are also available to go directly to a specific menu. These shortcut keys are:

m0 Default (Operating) Menu m1 Setup Menu m2 Configuration Menu m3 Tuning Menu m4 Calibration Menu m5 Diagnostic Menu

8. To change a value or setting for a displayed menu option, proceed as follows:

(a) Enter C, followed by the number to the

right of the displayed option to be

changed, and then press <Rtn>.

(b) Enter the desired value or setting for the

option and press <Rtn>. Refer to Tables

2-1 through 2-6 for allowable entry ranges and settings.

memory.

C-MORE CONTROL PANEL OPERATION

9. To redisplay the menu and view the option which was just changed in step 5, enter D

and press <Rtn>.

10. To display the Fault (F) Log, Sensor (S) Log or Time (T) Line Log, press F, S or T

followed by <Rtn>. Refer to paragraph 7.4 for

descriptions and samples of these data logs.

11. To log off and terminate the RS232 com-

munication link, press L followed by <Rtn>.

7.4 DATA LOGGING

During operation, the C-More Control Panel continuously monitors and logs data associated with operational events, faults and sensor readings associated with the boiler or water heater system. Descriptions of these data logs are provided in the following paragraphs. The basic procedure for accessing each data log is described in paragraph 7.3, step 7.

7.4.1 Fault Log

The C-More Control Panel logs the last 10 faults (0 – 9) starting with the most recent (#0). They can be viewed in the front panel display or via the RS232 port. The Fault Log cannot be cleared. If the Fault Log already contains 10 faults, the earliest fault is overwritten when a new fault occurs. A sample Fault Log display is shown in Table 7-1.

NOTE:

The Operation Time (T) Log can store thousands of records. Therefore, to view the most recently logged record, enter “T” followed by 0 (zero) and press Enter (i.e. T0 <Enter>). To view earlier records in reverse chronological order, enter T and press Enter. To go back 200 or 1000 records, enter T200 or T1000, etc. and press Enter.

7.4.2 Operation Time Log

The Operation Time Log consists of a string of ASCII records stored in non-volatile memory

within the C-More Control Panel. Events such as power-up, ignition and turn-off are time stamped. Data logged while the unit is running are run-length encoded. Data is logged or the run-length incremented every 30 seconds. For a new run record to be logged, the fire rate or

flame strength must change by more than 5%, or the run mode must change. At steady-state, the run-length is allowed to reach a maximum of 30 minutes before the record is logged. This means that no more than 30 minutes of data can be lost if the unit loses power. Table 7-2 shows a sample Operation Time Log for a boiler:

The Operation Time Log can only be accessed through the RS232 interface using a laptop or other terminal device. Ten operation time records are displayed for each T command entry. The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu.

NOTE:

The Sensor (S) Log can store up to 1200 records. Therefore, to view the most recently logged record, enter “S” followed by 0 (zero) and then press Enter (i.e. S0 <Enter>). To view earlier records in reverse chronological order, enter S and press Enter. To go back 200 or 700 records, enter S200 or S700, etc. and press Enter.

7.4.3 Sensor Log

The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu. The log interval can vary from once every minute to once every day. Table 7-3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode.

C-MORE CONTROL PANEL OPERATION

Table 7-1. Sample Fault Log Display

No. Fault Message Cycle Date Time 0 Direct Drive Signal Fault 609 1/10/02 8:42am 1 Low Gas Pressure 366 7/04/01 5:29pm 2 Loss of Power 0 1/01/01 11:50am

Table 7-2. Sample Operation Time Log Display

Status Fire Rate Flame Run Length Date Time Off, Direct Drive 0 0 8 1/15/02 2:35pm Run, Direct Drive 38 100 34 1/15/02 2:27pm Run, Direct Drive 31 100 30 1/15/02 1:53am Run, Direct Drive 35 100 2 1/15/02 1:23pm Run, Direct Drive 29 100 0 1/15/02 1:21pm Ignition 0 0 0 1/15/02 1:20pm Off, Switch 0 0 35 1/15/02 12:30pm Run, Manual 40 100 0 1/15/02 11:55am Ignition 0 0 0 1/15/02 11:55am Power-up 0 0 0 1/15/02 11:50am

Table 7-3. Sample Sensor Log Display

Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:51pm 130 180 OPEN OPEN 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:16pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:11pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:06pm

OPEN OPEN OPEN 0 .0 0 1/15/02 5:46pm

APPENDIX A

C-MORE CONTROL PANEL VIEWS

A-1

APPENDIX A

A-2

CONTROL PANEL EXPLODED VIEW – KC SERIES SYSTEMS

APPENDIX A

CONTROL PANEL REAR VIEW – KC SERIES SYSTEMS

A-3

APPENDIX A

A-4

CONTROL PANEL EXPLODED VIEW – BENCHMARK SERIES SYSTEMS

APPENDIX A

CONTROL PANEL REAR VIEW – BENCHMARK SERIES SYSTEMS

A-5

APPENDIX B

TROUBLESHOOTING GUIDE

B-1

APPENDIX B

APPENDIX B- TROUBLESHOOTING GUIDE

7.5 B-1. INTRODUCTION

This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark Series Boiler, KC1000 Boiler or KC1000 Water Heater. The troubleshooting procedures contained herein are presented in tabular form in Table B-1 and B-2. Table B-1 pertains to Benchmark and KC1000 Boilers and Table B-2 pertains to KC1000 Water Heaters. Each table is comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action. The numbered items in the Probable Cause and Corrective Action columns correspond to each other. For example, Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.

When a fault occurs in the Boiler or Water Heater, proceed as follows to isolate and correct the fault:

1. Observe the fault messages displayed in the

Control Box display.

2. Refer to the Fault Indication column in the following troubleshooting tables and locate the Fault that best describes the existing conditions.

3. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault Indication.

4. Perform the checks and procedures listed in the Corrective Action column for the first Probable Cause candidate.

5. Continue checking each additional Probable Cause for the existing fault until the fault is corrected.

6. If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative.

B-2

APPENDI

X B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

AIRFLOW FAULT

DURING IGNITION

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING RUN

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

1. Blower not running or running too slow

2. Defective Air Flow Switch

3. Blocked Air flow Switch

4. Blocked Blower inlet or inlet ductwork.

5. No voltage to switch from control box.

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

5. Combustion oscillations

1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices.

2. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

3. Remove the airflow switch and inspect for signs of blockage, clean or replace as necessary.

4. Measure the airflow switch for continuity with the combustion blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

1. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage. If the relay is okay, check the blower.

2. Start the unit. If the blower runs, check the airflow switch for continuity. Replace the switch if there is no continuity.

3. Remove the air flow switch and inspect for signs of blockage, clean or replace as necessary.

4. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

5. Measure for 24 VAC during start sequence from each side of the switch to ground. If 24VAC is not present refer to qualified service personnel.

1. Check combustion blower for signs of excessive heat or high current draw that may trip thermal or current overload devices.

2. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

3. Remove the airflow switch and inspect for signs of blockage, clean or replace as necessary.

4. Measure the airflow switch for continuity with the combustion blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

5. Run unit to full fire. If the unit rumbles or runs rough, perform combustion calibration.

B-3

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

DELAYED

INTERLOCK OPEN

DIRECT DRIVE SIGNAL FAULT

FLAME LOSS

DURING IGN

1. Delayed Interlock Jumper not installed or removed.

2. Device proving switch hooked to interlocks is not closed

1. Direct drive signal is not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

2. Signal is not isolated (floating).

3. Control Box signal type selection switches not set for correct signal type (voltage or current).

1. Worn flame detector

2. No spark from Spark Plug

3. Defective Ignition Transformer

4. Defective Ignition/Stepper (IGST) Board

5. Defective SSOV

6. Defective Differential Pressure Regulator

1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box.

2. If there are 2 external wires on these terminals, check to see if an end switch for a device such as a pump, louver, etc. is tied these interlocks. Ensure that the device and or its end switch are functional. (jumper may be temporarily installed to test interlock)

1. Check I/O Box to ensure signal is hooked up. Hook up if not installed. If installed, check polarity. Measure signal level. Check continuity of wiring between source and boiler.

2. Check signal at source to ensure it is isolated.

3. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Check control signal type set in Configuration Menu.

1. Remove and inspect the flame detector for signs of wear. Replace if necessary.

2. Close the internal gas valve in the boiler. Install and arc a spark ignitor outside the unit.

3. If there is no spark, check for 120VAC at the primary side to the ignition transformer during the ignition cycle.

4. If 120VAC is not present, the IGST Board in the Control Box may be defective. Refer fault to qualified service personnel.

5. While externally arcing the spark ignitor, observe the open/close indicator in the Safety Shut-Off Valve to ensure it is opening. If the valve does not open, check for 120VAC at the valves input terminals. If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel.

6. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure gas is getting to the burner

B-4

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 7. Carbon or other debris on Burner

FLAME LOSS

DURING RUN

HEAT DEMAND

FAILURE

HIGH EXHAUST

TEMPERATURE

HIGH GAS

PRESSURE

1. Worn Flame Detector or cracked ceramic.

2. Defective Differential Regulator.

3. Poor combustion calibration.

4. Debris on burner.

5. Blocked condensate drain.

1. The Heat Demand Relays on the Ignition/Stepper board failed to activate when commanded

2. Relay is activated when not in Demand

1. Defective exhaust sensor.

2. Carboned heat exchanger due to incorrect combustion calibration

1. Incorrect supply gas pressure.

2. Defective Supply Regulator or Wrong Style Regulator

3. Defective High Gas Pressure Switch

7. Remove the burner and inspect for any carbon or debris. Clean and reinstall

1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary.

2. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure that the gas pressure into and out of the valve is correct.

3. Check combustion calibration. Adjust as necessary.

4. Remove the burner and inspect for any carbon or debris. Clean and reinstall.

5. Remove blockage in condensate drain.

1. Press CLEAR button and restart the unit. If the fault persists, replace Ignition/Stepper (IGST) Board.

2. Defective relay. Replace IGST Board.

1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 475 and the exhaust sensor shows continuity replace the sensor.

2. If exhaust temperature is greater than 500 combustion calibration. Calibrate or repair as necessary.

1. If using a non-lock up style regulator for the gas supply, measure static gas pressure downstream, it should be 14”WC or less. Adjust as necessary.

2. If gas supply pressure cannot be lowered, a lock-up style regulator may be required or the supply regulator may be defective.

3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity.

F, check

B-5

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

HIGH WATER TEMP

SWITCH OPEN

HIGH WATER

TEMPERATURE

IGN BOARD

COMM FAULT

IGN SWTCH CLOSED

DURING PURGE

1. Faulty Water temperature switch.

2. Incorrect PID settings.

3. Faulty shell temperature sensor.

4. Unit in Manual mode

5. Unit setpoint is greater than Over Temperature Switch setpoint.

6. Boiler Management System PID or other settings not correctly setup.

7. No interlock to boiler or BMS to disable boiler(s) in event that system pumps have failed.

8. System flow rate changes are occurring faster than boilers can respond.

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Temp HI Limit setting is too low.

1. Communication fault has occurred between the PMC board and Ignition/Stepper (IGST) board

1. Air/Fuel Valve not rotating

1. Test the temperature switch to insure it trips at its actual water temperature setting.

2. Check PID settings against Menu Default settings in the Appendix. If the settings have been changed, record the current readings then reset them to the default values.

3. Using the resistance charts in the Appendix C, Measure the resistance of Shell sensor and BTU sensor at a known water temperature.

4. If unit is in Manual Mode switch to Auto Mode.

5. Check setpoint of unit and setpoint of Temperature Switch; Ensure that the temperature switch is set higher than the unit’s setpoint.

6. Check the BMS for changes to PID default values, correct as necessary.

7. If system pump is controlled by Energy Management System other than BMS or pumps are individually controlled by boiler, check to see if there are flow switches interlocked to the BMS or boiler.

8. If the system is a variable flow system, monitor system flow changes to ensure that the rate of flow change is not faster than what the boilers can respond to.

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Check Temp HI Limit setting.

1. Press CLEAR button and restart unit. If fault persists, contact qualified Service Personnel.

1. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air-Fuel Valve or the Control Box. Refer to qualified service personnel.

B-6

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued)

IGN SWTCH OPEN

DURING IGNITION

INTERLOCK

OPEN

LINE VOLTAGE

OUT OF PHASE

2. Defective or shorted switch

3. Switch wired incorrectly

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Air/Fuel Valve not rotating to ignition position.

2. Defective ignition switch

3. Defective Power Supply Board or fuse

4. Defective IGST Board

1. Interlock jumper not installed or removed

2. Energy Management System does not have boiler enabled.

3. Device proving switch hooked to interlocks is not closed.

1. Line and Neutral switched in AC Power Box.

2. Incorrect power supply transformer wiring.

2. If the Air/Fuel Valve does rotate to purge, check the ignition switch for continuity between the N.O. and COM terminals. If the switch shows continuity when not in contact with the cam replace the switch.

3. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). If the switch is wired correctly, replace the switch

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

1. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position, then back to ignition position (towards closed) during the ignition cycle. If the valve does not rotate back to the ignition position, check the Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air/Fuel Valve or the Control Box. Refer fault to qualified service personnel.

2. If the Air/Fuel Valve does rotate to the ignition position, check the ignition position switch for continuity between the N.O. and COM terminals when in contact with the cam.

3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

1. Check for a jumper properly installed across the interlock terminals in the I/O Box.

2. If there are two external wires on these terminals check any Energy Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning).

3. Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational.

1. Check hot and neutral in AC Power Box to ensure they are not reversed

2. Check transformer wiring, in AC Power Box, against the power box transformer wiring diagram to ensure it is wired correctly

B-7

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

LOW GAS

PRESSURE

LOW WATER

LEVEL

MODBUS COMM

FAULT

PRG SWTCH CLOSED

DURING IGNITION

1. Incorrect supply gas pressure.

2. Defective or incorrectly sized Gas Supply Regulator.

3. Defective Low Pressure Gas Switch

1. Insufficient water level in system

2. Defective water level circuitry.

3. Defective water level probe.

1. Boiler not seeing information from modbus network

1. A/F Valve rotated open to purge and did not rotate to ignition position

2. Defective or shorted switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Measure gas pressure upstream of the supply gas regulator with the unit firing ensure it is 14” WC or greater.

2. Measure gas pressure downstream of the supply regulator with unit firing and adjust the gas supply regulator to increase the outlet gas pressure; if outlet gas pressure cannot be increased, check the sizing of the Supply regulator.

3. Measure gas pressure at the low gas pressure switch, if it is greater than 5” WC measure continuity across the switch and replace if necessary.

1. Check system for sufficient water level.

2. Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. Replace water level circuitry if it does not respond.

3. Check continuity of probe end to the shell, change probe if there is no continuity.

1. Check network connections. If fault persists, contact qualified Service Personnel.

2. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O. and COM terminals. If the switch shows continuity when not in contact with the cam, check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals).

3. If the switch is wired correctly, replace the switch.

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

B-8

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

PRG SWTCH OPEN

DURING PURGE

OUTDOOR TEMP

SENSOR FAULT

REMOTE SETPT

SIGNAL FAULT

RESIDUAL

FLAME

1. Defective purge switch.

2. No voltage present at switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Loose or broken wiring.

2. Defective Sensor.

3. Incorrect Sensor.

1. Remote setpoint signal not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

2. Signal is not isolated (floating) if 4 to 20 mA.

3. Control Box signal type selection switches not set for correct signal type (voltage or current).

1. SSOV not fully closed. 1. Check open/close indicator window of Safety Shut-Off Valve

1. If the air-fuel valve does rotate, check the purge switch for continuity when closing. Replace switch if continuity does not exist.

2. Measure for 24 VAC from each side of the switch to ground. If 24VAC is not present, refer fault to qualified service personnel.

3. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals).

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

1. Inspect Outdoor Temperature sensor for loose or broken wiring.

2. Check resistance of sensor to determine if it is within specification.

3. Ensure that the correct sensor is installed.

1. Check I/O Box to ensure signal is hooked up. Hook up if not installed. If installed, check polarity. Measure signal level. Check continuity of wiring between source and boiler.

2. Check signal at source to ensure it is isolated.

3. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Check control signal type set in Configuration Menu.

(SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.

Close gas shut-off valve downstream of SSOV. Install a manometer or gauge in a gas test port between the SSOV and the gas shut off valve. If a gas pressure reading is observed replace the SSOV valve and or actuator.

B-9

APPENDIX B

TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 2. Defective Flame Detector

SSOV FAULT

DURING PURGE

SSOV FAULT DURING RUN

SSOV RELAY

FAILURE

SSOV

SWITCH OPEN

STEPPER MOTOR

FAILURE

See SSOV SWITCH OPEN

1. SSOV switch closed for 15 seconds during run.

1. SSOV relay failed on board. 1. Press CLEAR button and restart unit. If fault persists, replace

1. Actuator not allowing for full closure of gas valve

2. SSOV powered when it should not be

3. Defective Switch or Actuator

4. Incorrectly wired switch.

1. Air/Fuel Valve out of calibration.

2. Air/Fuel Valve unplugged.

3. Loose wiring connection to the stepper motor.

4. Defective Air/Fuel Valve stepper motor.

5. Defective Power Supply Board or fuse

6. Defective IGST Board

2. Replace Flame Detector.

1. Replace or adjust microswitch in SSOV actuator. If fault persists, replace actuator.

Ignition/Stepper (IGST) Board.

1. Observe operation of the Safety Shut-Off Valve (SSOV) through indicator on the Valve actuator and ensure that the valve is fully and not partially closing.

2. If the SSOV never closes, it may be powered continuously. Close the gas supply and remove power from the unit. Refer fault to qualified service personnel.

3. Remove the electrical cover from the SSOV and check switch continuity. If the switch does not show continuity with the gas valve closed, either adjust or replace the switch or actuator.

4. Ensure that the SSOV Proof of Closure switch is correctly wired.

1. Perform Stepper Test (para. 6.3.5) to ensure stepper motor rotates properly between the 0% (fully closed) and 100% (fully open) positions. Verify that the FIRE RATE bargraph and the dial on the Air/Fuel Valve track each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (para. 6.2.1).

2. Check to ensure that the Air/Fuel Valve is connected to the Control Box.

3. .Inspect for loose connections between the Air/Fuel Valve motor and the wiring harness.

4. Replace stepper motor.

5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

B-10

APPENDIX B

FAULT INDICATION

AIRFLOW FAULT

DURING IGNITION

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING RUN

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE

PROBABLE CAUSES CORRECTIVE ACTION

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

1. Blower not running

2. Defective Air Flow Switch

3. Blocked Air flow Switch

4. Blocked Blower inlet or inlet ductwork.

5. No voltage to switch from control box.

1. Blower stopped running due to thermal

or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

5. Combustion oscillations

1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices.

2. Inspect the inlet to the combustion blower including any duct work leading up to the combustion blower for signs of blockage.

3. Remove the airflow switch and inspect for signs of blockage, clean or replace as necessary.

4. Measure the airflow switch for continuity with the combustion blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace switch.

1. Start the unit. If the blower does not run check the blower solid

state relay for input and output voltage. If the relay is okay, check the blower.

2. Start the unit. If the blower runs, check the airflow switch for

continuity. Replace the switch if there is no continuity.

3. Remove the air flow switch and inspect for signs of blockage,

clean or replace as necessary.

4. Inspect the inlet to the combustion blower including any

ductwork leading up to the combustion blower for signs of blockage.

5. Measure for 24 VAC during start sequence from each side of the

switch to ground. If 24VAC is not present refer to qualified service personnel.

1. Check combustion blower for signs of excessive heat or high

current draw that may trip thermal or current overload devices.

2. Inspect the inlet to the combustion blower including any

ductwork leading up to the combustion blower for signs of blockage.

3. Remove the airflow switch and inspect for signs of blockage,

clean or replace as necessary.

4. Measure the airflow switch for continuity with the combustion

blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

5. Run unit to full fire. If the unit rumbles or runs rough, perform

combustion calibration.

B-11

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

DELAYED

INTERLOCK OPEN

DIRECT DRIVE SIGNAL FAULT

FLAME LOSS

DURING IGN

1. Delayed Interlock Jumper not installed or removed.

2. Device proving switch hooked to interlocks is not closed

1. Unit “Type” is improperly set up as

Boiler instead of Water Heater.

1. Worn flame detector

2. No spark from Spark Plug

3. Defective Ignition Transformer

4. Defective Ignition/Stepper (IGST) Board

5. Defective SSOV

6. Defective Differential Pressure Regulator

7. Carbon or other debris on Burner

1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box.

1. Check the “Unit Type” menu option in the Configuration Menu to ensure that the Unit Type is set to Water Heater. Change menu option if necessary.

1. Remove and inspect the flame detector for signs of wear. Replace if necessary.

2. Close the internal gas valve in the boiler. Install and arc a spark ignitor outside the unit.

3. If there is no spark, check for 120VAC at the primary side to the ignition transformer during the ignition cycle.

4. If 120VAC is not present, the IGST Board in the Control Box may be defective. Refer fault to qualified service personnel.

6. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure gas is getting to the burner.

7. Remove the burner and inspect for any carbon or debris. Clean and reinstall

B-12

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

FFWD TEMP

SENSOR FAULT

FLAME LOSS

DURING RUN

HEAT DEMAND

FAILURE

HIGH EXHAUST

TEMPERATURE

HIGH GAS

PRESSURE

1. Loose or broken wiring.

2. Defective Sensor.

3. Incorrect Sensor.

1. Worn Flame Detector or cracked ceramic.

2. Defective Differential Regulator.

3. Poor combustion calibration.

4. Debris on burner.

5. Blocked condensate drain.

1. The Heat Demand Relays on the

Ignition/Stepper (IGST) board failed to activate when commanded

2. Relay is activated when not in

Demand

1. Defective exhaust sensor.

2. Carboned heat exchanger due to

incorrect combustion calibration

1. Incorrect supply gas pressure.

2. Defective Supply Regulator or

Wrong Style Regulator

1. Inspect feed forward (BTU transmitter) sensor for loose or broken wiring.

2. Check resistance of sensor to determine if it is within specification.

3. Ensure that the correct sensor is installed.

1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary.

2. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure that the gas pressure into and out of the valve is correct.

3. Check combustion calibration. Adjust as necessary.

4. Remove the burner and inspect for any carbon or debris. Clean and reinstall.

5. Remove blockage from condensate drain.

1. Press CLEAR button and restart the unit. If the fault persists, replace IGST Board.

2. Defective relay. Replace IGST Board.

1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 500 and the exhaust sensor shows continuity replace the sensor.

2. If exhaust temperature is greater than 500 combustion calibration. Calibrate or repair as necessary.

1. If using a non-lock up style regulator for the gas supply, measure static gas pressure downstream, it should be 14”WC or less. Adjust as necessary.

2. If gas supply pressure cannot be lowered, a lock-up style regulator may be required or the supply regulator may be defective.

F, check

B-13

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued)

HIGH WATER TEMP

SWITCH OPEN

HIGH WATER

TEMPERATURE

IGN BOARD

COMM FAULT

3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity.

1. Scaled BTU Transmitter.

2. Faulty Water Temperature Switch.

3. Faulty Temperature Sensor

4. Unit in MANUAL Mode

5. Unit setpoint is greater than Over

Temperature Switch setpoint

1. See HIGH WATER TEMP SWITCH

OPEN.

2. Temp HI Limit setting is too low.

1. Communication fault has occurred

between the PMC board and Ignition/Stepper (IGST) board

1. Inspect and clean the BTU transmitter per Maintenance Section.

2. Test the temperature switch to insure it trips at its actual water temperature setting.

3. Using the resistance charts in Appendix C, measure the resistance of Shell sensor and BTU sensor at a known water temperature.

4. If unit is in Manual Mode, switch to Auto Mode.

5. Check setpoint of unit and setpoint of Temperature Switch. Ensure that the temperature switch is set 20 degrees higher than the unit’s setpoint.

1. See HIGH WATER TEMP SWITCH OPEN

2. Check Temp HI Limit Setting.

1. Press CLEAR button and restart unit. If fault persists, contact qualified Service Personnel.

B-14

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

IGN SWTCH CLOSED

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

INTERLOCK

OPEN

1. Air/Fuel Valve not rotating

2. Defective or shorted switch

3. Switch wired incorrectly

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Air/Fuel Valve not rotating to ignition position.

2. Defective ignition switch

3. Defective Power Supply Board or fuse

4. Defective IGST Board

1. Interlock jumper not installed or removed

2. Energy Management System does not have boiler enabled.

3. Device proving switch hooked to interlocks is not closed.

3. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). If the switch is wired correctly, replace the switch

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

2. If the Air/Fuel Valve does rotate to the ignition position, check the ignition position switch for continuity between the N.O. and COM terminals when in contact with the cam.

3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

1. Check for a jumper properly installed across the interlock terminals in the I/O box

3. Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational.

B-15

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

LINE VOLTAGE

OUT OF PHASE

LOW GAS

PRESSURE

LOW WATER

LEVEL

MODBUS COMM

FAULT

PRG SWTCH CLOSED

DURING IGNITION

1. Line and Neutral switched in AC Power Box.

2. Incorrect power supply transformer wiring.

1. Incorrect supply gas pressure.

2. Defective or incorrectly sized Gas Supply Regulator.

3. Defective Low Pressure Gas Switch

1. Insufficient water level in system

2. Defective water level circuitry.

3. Defective water level probe.

1. Water Heater not seeing information from modbus network

1. A/F Valve rotated open to purge and did not rotate to ignition position

2. Defective or shorted switch.

1. Check hot and neutral in AC Power Box to ensure they are not reversed

2. Check transformer wiring, in AC Power Box, against the power box transformer wiring diagram to ensure it is wired correctly

1. Measure gas pressure upstream of the supply gas regulator with the unit firing ensure it is 14” WC or greater.

3. Measure gas pressure at the low gas pressure switch, if it is greater than 5” WC measure continuity across the switch and replace if necessary.

1. Check system for sufficient water level.

2. Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. Replace water level circuitry if it does not respond.

3. Check continuity of probe end to the shell, change probe if there is no continuity.

1. Check network connections. If fault persists, contact qualified Service Personnel.

B-16

APPENDIX B

TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued)

PRG SWTCH OPEN

DURING PURGE

REMOTE SETPT

SIGNAL FAULT

RESIDUAL

FLAME

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Defective purge switch.

2. No voltage present at switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Remote setpoint signal not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

2. Signal is not isolated (floating) if 4 to 20 mA.

3. Control Box signal type selection switches not set for correct signal type (voltage or current).

1. SSOV not fully closed.

2. Defective Flame Detector.