AERCO GF-105 User Manual
Instruction
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
GF-105
Installation, Operation
& Maintenance Instructions
KC Series
Gas Fired
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
1,000,000 BTU/HR Input
Applicable to Serial Numbers G-01-026 and above
Patent No. 4,852,524
Printed in U.S.A. REVISED 12/30/04
Telephone Support
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through
Friday)
(800) 526-0288
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
© AERCO International, Inc., 2004
The information contained in this operation
and maintenance manual is subject to
change without notice from AERCO
International, Inc.
AERCO makes no warranty of any kind with
respect to this material, including but not
limited to implied warranties of
merchantability and fitness for a particular
application. AERCO International is not
liable for errors appearing in this manual.
Nor for incidental or consequential damages
occurring in connection with the furnishing,
performance, or use of this material.
CONTENTS
GF-105 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER
Operating & Maintenance Instructions
FOREWORD
Section 1 SAFETY PRECAUTIONS--------------------------------1
Section 2 INSTALLATION PROCEDURES-----------------------2
2.1 Receiving the Unit
2.2 Unpacking
2.3 Installation
2.4 Gas Supply Piping
2.5 Electrical Supply
Section 3 CONTROL PANEL COMPONENTS
3.1 The Control Panel
3.2 The Temperature Contro ller
3.3 The Primary Menu
3.4 The Secondary Menu
3.5 The Annunciator Circuit
3.6 The Combustion Safeguard
Controller
Section 4 INITIAL START-UP--------------------------------------17
4.1 Initial Start-Up req uir ements
4.2 Tools and Instrumentation f or
Combustion Calibration
4.3 Combustion Calibration
4.4 Propane Combustion Calibration
2.6 Field Control Wiring
2.7 Flue Gas Vent Installation
2.8 Combustion Air
2.9 Unit Initial Fill
and OPERATING PROCEDURES------------9
3.7 Water Level T est and Reset Switches
3.8 On\Off Switch
3.9 Starting Sequence
3.10 After Flame
3.11 Flame Test Jacks
3.12 Start\Stop Levels
3.13 Auto Restarts
4.5 Unit Reassembly
4.6 Temperature Control Calibration
4.7 Over Temperature Limit Switch
Adjustments
Section 5 SAFETY DEVICE TESTING
5.1 Testing of Safety Devices
5.2 Gas Pressure Fault Test
5.3 Low Water Level Fault Test
5.4 Water Temperature Fault Test
PROCEDURES-----------------------------------25
5.5 Flame Fault Test
5.6 Air Pressure Fault Test
5.7 Purge Interlocks Fault Test
5.8 Safety Pressure Relief Valve Test
i
CONTENTS
Section 6 MAINTENANCE REQUIREMENTS-------------------29
6.1 Maintenance Schedule
6.2 Spark Ignitor
6.3 Flame Detector
6.4 Combustion Calibration
6.5 Safety Device Testing
Section 7 TROUBLESHOOTING-----------------------------------39
7.1 Gas Pressure Fault
7.2 Exhaust Temperature Fault
7.3 Water Level Fault
7.4 Water Temperature Fault
A. Temperature Controller Menus
B. Temperature Controller Quick
Programming Guide
C. Shell Sensor Resistance Chart
D. Mode of Operation Default
Settings
6.6 BTU Transmitter Pump
Lubrication
6.7 BTU Transmitter Assembly
6.8 Manifold and Exhaust Tubes
6.9 Heat Exchanger Inspection
7.5 Flame Fault
7.6 Air Pressure Fault
7.7 System Fault
APPENDICES
E. Dimensional & Parts Drawings
F. Piping Drawings
G. Wiring Schem atics
H. Control Panel Isometric Drawing
WARRA NTIES
2/27/99
ii
FOREWORD
Foreword
The AERCO KC Hot Water Heating System is a true industry advance that meets the needs of
today’s energy and environmental concerns. Designed for use in any potable water heat ing
system, it provides constant temperature water regardless of flow rate. It’s small space
requirements and venting capabilities allows installations without norm al restrictions yet with
maximum flexibility. The KC Heater’s load tracking controls modulate over a 14:1 turndown ratio
to match the system demand and yield thermal efficiencies in excess of 93%.
Because of its compact design with direct or chimney venting, the KC Water Heating System is
applicable to any installation with excellent results. Eff iciency, reliability and longevity make the
KC Water Heat ing System a true step forward in Water Heating System design.
After prolonged shutdown, it is recom mended that the startup procedures in Section 4 and t est
procedures in Section 5 of this manual be performed, to verify system operating parameters. If
there is an emergency, turn off the electrical power supply to the AERCO Heater or close the
Manual Gas Valve located before the AERCO heater. T he I nstaller is to identify the emergency
shut-off device. FOR SERVI CE OR PARTS, contact your local Sales Representative listed below
or AERCO INTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________
iii
SECTION 1 -- SAFETY PRECAUTIONS
Installing or operating per sonnel MUST, at
all times, observe all safety regulations.
The following warnings are general and
must be given the same attention as
specific precautions included in these
instructions. In addition to the
requirements included in this instruct ion
manual, the installation of units MUST
conform with local building codes, or, in
the absence of local codes, ANZI Z223.1
(National Fuel Gas Code, Publication No.
NFPA-54) for gas-fired heaters and
ANSI/NFPASB for LP gas-fired heaters.
Where applicable, t he equipment shall be
installed in accordance with CGA B149.
SAFETY PRECAUTIONS
WARNING!
DO NOT USE MATCHES, CANDLES,
FLAMES, OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS LEAKS.
WARNING!
THE EXHAUST VENT PIPE OPERATES
UNDER POSITIVE PRESSURE AND
MUST BE COMPLETELY SEALED TO
PREVENT LEAKAGE OF COMBUSTION
PRODUCTS INTO LIVING SPACES
.
WARNINGS!
MUST BE OBSERVED TO PREVENT
SERIOUS INJURY TO PERSONNEL
.
WARNING!
BEFORE PERFORMING ANY
MAINTENANCE ON THE UNIT,
SHUT OFF THE GAS SUPPLY AND THE
ELECTRICAL POWER SUPPLY TO THE
UNIT.
WARNING!
FLUIDS UNDER PRESSURE MAY
CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN
RELEASED.. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING
WATER SHUTOFF VALVES AND
CAREFULLY DECREASE ALL TRAPPED
PRESSURES TO ZERO BEFORE
PERFORMING ANY MAINTENANCE.
CAUTIONS!
Must be observed to prevent equipment
damage or loss of operating
effectiveness.
CAUTION!
Many soaps used for gas pipe leak testing
are corrosive to metals. The piping m ust
be rinsed thoroughly with clean water after
leak checks have been completed.
CAUTION!
Do not use this unit if any part has been
under water. Call a qualified service
technician to inspect and replace any
part that has been under water.
NOTES:
Must be observed for effective operating
procedures & conditions
1
INSTALLATION PROCEDURES
SECTION 2 - INSTALLATION PROCEDURES
2.1 RECEIVING THE UNIT
Each KC unit is shipped as a single crated unit.
The shipping weight is approximately 1500 lb.
and must be moved with the proper rigging
equipment for safety and to avoid damages.
The unit should be completely inspected at the
time of receipt from the carrier before the bill of
lading is signed. Each unit has Tip-N-Tell
indicator on the outside of the crate. This
indicates if the unit has been turned on its side.
If the Tip-N-Tell indicator is tripped, do not sign
for the shipment. Note the information on the
carrier’s paperwork and request a freight claim
and inspection by a claims adjuster before
proceeding. Any other visual damage to the
packaging materials should also be made clear
to the delivering carrier.
2.2 UNPACKING
Carefully unpack the unit by removing the
packaging material. Take care not to damage
the unit jacket when cutting away packaging
materials. A close inspection of the unit should
be made to determine if there has been any
damage during shipment that was not indicated
by the Tip-N-Tell.
The freight carrier should be notified immediately
if any damage is detected. The following
accessories come standard with each unit and
are packed separately within the unit’s packing
container
• Spare Spark Ignitor
• Spare Flame Detector
• Manual 1-1/4" Gas Shutoff Valve
• Drain Valve Assembly
• ASME Pressure/Temperature
Relief Valve
• Ignitor Removal Tool (O ne per Site)
• Regulator Adjustment Tool (One
• per Site)
• 2 Lifting Lugs
• Stainless Steel Condensate Cup
• Flue Clamps (2 Pieces)
Optional accessories are also separately packed
within the unit’s packing container. Standard and
optional accessories shipped with the unit
should be identified and put in a safe place until
installation/use.
Figure 2.1
Heater Clearances
2
INSTALLATION PROCEDURES
2.3 INSTALLATION
The unit must be installed with the prescribed
clearances for service as shown in Fig 2.1
These are the minimum clearance dimensions
required by AERCO. Local building codes may
require more clearance and take precedence.
WARNING !
KEEP UNIT AREA CLEAR AND FREE
FROM COMBUSTIBLE MATERIALS AND
FLAMMABLE VAPORS AND LIQUIDS.
2.3.1 SETTING THE UNIT
Locate the lifting lugs, shipped with the unit, and
attach them to the 5/8” x 11 studs at the top of
the unit. Remove the unit from the wooden skid
and place in position using a block and tackle or
hoist attached to the lifting lugs. (see Fig. 2.2).
USE THE LIFTING LUGS TO MOVE THE
UNIT.
2.3.2 WATER INLET AND O UTLET
PIPING
The locations of the 2" NPT cold water inlet and
hot water outlet piping connections are shown in
Figure 2.4. Flow rates through the unit are
limited to 30 gpm continuous and 40 gpm
intermittent.
Shut-off valves and union conections must be
installed in the inlet and outlet lines for
maintenance. The use of dielectric unions is
recommended. Install the piping and
accessories as per the following drawings,
located in Appendix F of this manual.
• SD-B-424 for single units
• SD-B-425 for multiple units
• SD-B-432 for single units with a stratified
tank
• SD-B-434 for multiple units with a stratified
storage tank
NOTE:
All piping must be arranged so that it does
not interfere with removal of any cover,
inhibit service or maintenance, or prevent
access between the unit and walls, or
another unit.
Figure 2.2
Lifting Lug Location
The KC-1000 is U/L approved for installation on
combustible flooring. A 4” to 6" high
housekeeping concrete pad is recommended
and allows for sufficient drainage of the
condensate.
The unit must be secured using only the holes
provided in the frame base. Do not use piping to
secure the unit in place. See drawing AP-A-576
in Appendix E for the base frame dimensions.
In multiple unit installations it is important to
plan the position of each unit. Sufficient space
for piping connections and maintenance
requirements must be given. All piping must
include ample provision for expansion.
Figure 2.3
Inlet and Outlet Location
2.3.3 TEST HOSE BIB
A Test Hose Bib connection, upstream of the
shut off valve on the hot water outlet, is required
3
INSTALLATION PROCEDURES
for startup and testing. It should be a minimum
of 3/4". It cannot be omitted (See Fig. 2.4a)
maintenance. Recirculation flow rates must be
kept to 8 gpm or less. In a multiple unit
installation, each unit must be tied into the
system recirculation system.
Figure 2.4a
Hose Bibb Location
2.3.4 PRESSURE/TEMPERATURE
RELIEF AND DRAIN
VALVE
INSTALLATION
An ASME rated Pressure/Temperature Relief
Valve is supplied with each unit. The valve
setpoint is 150 psig/210
valve as shown in Fig. 2.4. A suitable pipe
compound should be used on the threaded
connections. Any excess should be wiped off to
avoid getting any into the valve body. The relief
valve should be pipied to within 12 inches of the
floor to prevent injury in the event of a
discharge. The relief piping must be full size, 11/2”, without reduction. No valves, restrictions,
or other blockages are allowed in the discharge
line. In multiple unit installations the discharge
lines must not be manifolded together. Each
must be individually run to a suitable discharge
location.
A 1” drain valve assembly is furnished with each
unit. The assembly should be installed as shown
in Figure 2.4. The drain should be hard piped to
a suitable drain.
0
F. Install the relief
Figure 2.4b
Pressure/Temperature Relief and Drain
Valve Installation Location
2.3.6 CONDENSATE PIPING
The KC Heater is designed to condense and the
installation must have provisions for suitable
drainage. A 1 inch ID silicone hose, supplied
with the unit, directs condensate from the
exhaust manifold to a stainless steel condensate
cup. The condensate cup is shipped loose and
should be installed inside the unit directly under
the manifold’s condensate drainage hole. The
condensate drain fitting is attached to the cup
and should be located at the rear of the unit as
shown in Figure 2.5. A 5/8-inch ID flexible
polypropylene tubing (or suitable equivalent)
should be used to carry the condensate by
gravity to a nearby floor drain. If a floor drain is
not available, a condensate pump can be used
to remove the condensate to a convenient drain.
The maximum condensate flow rate is 5 GPH.
The condensate cup and line must be
removable for routine maintenance. Do not
hard pipe.
2.3.5 SYSTEM RECIRCULATION
The system recirculating line ties into the unit at
the recirculating tee fitting provided in the drain
valve assembly (see Fig. 2.4b). Shut off valves
and union connections are recommended for
4
Figure 2.5
Condensate Drain Assembly Location
2.4 GAS SUPPLY PIPING
AERCO Gas Fired Equipment Gas Components
and Supply Design Guide (GF-1030) should be
consulted before any gas piping is designed or
started.
INSTALLATION PROCEDURES
A suitable piping compound approved for use
with gas should be used sparingly. Any excess
must be wiped off to prevent clogging of
components.
To avoid damage to the unit when pressure
testing gas piping, isolate the unit from the gas
supply piping. At no time should there be more
than 1 psig maximum to the unit. Bubble test all
external piping thoroughly for leaks using a soap
and water solution or suitable equivalent. The
gas piping must meet all applicable codes.
WARNING !
DO NOT USE MATCHES, CANDLES,
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS LEAKS
.
CAUTION !
Many soaps used for gas pipe leak testing
are corrosive to metals. The piping m ust be
rinsed thoroughly with clean water after
leak checks have been completed.
NOTE:
All gas piping must be arranged so that it
does not interfere with removal of any
cover, inhibit service or maintenance, or
prevent access between the unit and walls,
or another unit
The location of the 1-1/4" inlet gas connection
on the right side of the unit is shown in Figure
2.6.
All pipe should be de-burred and internally
cleared of any scale or iron chips before
installation. No flexible connectors or nonapproved gas fittings should be installed. Piping
should be supported from floor or walls only and
must not be secured to the unit.
.
Figure 2.6
Gas Supply Regulator and Manual Shut -
Off Valve Location
2.4.1 GAS SUPPLY PRESSURE REGULATOR
A mandatory external, in line, supply gas
regulator (supplied by others) should be
positioned as shown in Figure 2.6. Union
connections should be placed in the proper
locations to allow maintenance of the regulator if
required.
NOTE:
An individual gas pressure regulator must
be installed upstream of each unit. The
regulator must regulate gas pressure to
8.5” W . C. for FM gas train and 8.9” W.C. for
IRI gas trains at 1,000,000 BTU/H for
natural gas and propane units.
The maximum static inlet pressure to the unit
must be no more than 14” water column.
Minimum gas pressure is 8.5” W.C. for FM gas
trains and 8.9” W.C. IRI gas trains when the unit
is firing at maximum input. Gas pressure should
5
INSTALLATION PROCEDURES
not exceed 10.5” W.C. at any time when the unit
is firing. Proper sizing of the gas supply regulator
in delivering the correct gas flow and outlet
pressure is mandatory. The gas supply pressure
regulator must maintain the gas pressure at a
minimum of 8.5” W.C. (FM) or 8.9” W.C. (IRI)
when the unit is at maximum BTU input
(1,000,000 BTU/HR). The supply gas regulator
must be able to supply sufficient capacity
volume, (1000 cfh), to the unit and should have
no more than 1" droop from minimum to full fire.
The supply gas regulator must also be rated to
handle the maximum incoming gas pressure.
When the gas supply pressure will not exceed
14” W.C. a non-lock up, or flow through style
regulator, may be used. When supply gas
pressure will exceed 14” W.C., a lock up style
regulator must be used. The gas supply
regulator must be propery vented to outdoors.
Consult the local gas utility for exact
requirements concerning venting of supply gas
regulators.
CAUTION!
A lockup style regulator must be used when
gas supply pressure exceeds 14” W. C.
ELECTRICAL WIRING BOX
FRAME
SSOV
ACTUATOR
BLOWER
Figure 2.7
AC Wiring Box Location
2.4.2 MANUAL GAS SHUTOFF VALVE
A 1-1/4” manual gas shutoff valve is furnished
with each unit and should be positioned as
shown in Figure 2.6. The valve must be installed
upstream of the gas supply regulator in a readily
accessible location.
2.4.3 IRI GAS TRAIN KIT
The IRI gas train is an optional gas train required
in some areas by code or for insurance
purposes. The IRI gas train may be ordered preassembled or as separate components. If either
IRI gas train option is ordered a complete
instructional package, detailing field installation
will be included. To obtain a copy of an IRI
instructional package prior to the equipment
shipping contact your local representative or
AERCO.
2.5 ELECTRIC SUPPLY
AERCO Gas Fired Equipment Electrical Power
Wiring Guide (GF-1060) must be consulted in
addition to the following material before wiring to
the unit is started. The location of the electrical
wiring box is on the front right side of the unit as
shown in Figure 2.7.
NOTE:
All electrical conduit and hardware should
be installed so that it does interfere with the
removal of any cover, inhibit service or
maintenance, or prevent access between
the unit and walls or another unit.
2.5.1 ELECTRICAL REQUIREMENTS
Electrical requirements for each unit are 120
VAC, 1 Phase, 60 Hz, 20 Amps from a
dedicated electrical circuit. No other devices
should be on the same electrical circuit as a KC
unit. A disconnecting means such as a service
switch must be installed near the unit for normal
operation and maintenance. All electrical
connections should be made in accordance with
the National Electrical Code and/or with any
applicable local codes.
The electrical wiring diagram is shown in Figure
2.8. Conduit should be run from the knockouts
provided in the side of the electrical box in such
a manner that it does not interfere with the
removal of any sheet metal covers. A flexible
electrical connection may be utilized to allow the
covers to be removed easily.
6
Figure 2.8
Electrical W ir ing Diagram
2.6 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an
internal operating control system. No field control
wiring is required for normal operation. However
a fault relay, for remote fault indication, and
enable/disable interlock circuits are provided.
Wiring for these circuits can be accomplished in
the Field Control Wiring Box behind the left side
panel (see Fig. 2.9).
INSTALLATION PROCEDURES
This interlock must be closed,(jumped), to allow
the unit to fire. When the interlock is open, the
control panel Annunciator will display
'INTERLOCK DISABLED' and the unit will not
fire. The unit comes factory wired with the
interlock closed.
2.6.2 THE FAULT RELAY
The fault relay is a single pole single throw relay,
that is energized upon any fault condition. The
relay will remain energized until the fault is
cleared and the CLEAR button is pushed The
normally open field connections are shown in
Figure 2.10. The relay contacts are rated for 5
amps at 250 VDC and 5 amps at 30 VDC.
AERCO INTERNATIONAL INC.
BLOWER
FIELD WIRING
816
OUTDOOR
START
INDICATION
FAULT
-
BMS
+
SHIELD
AIR
SENSOR
7
15
6
14
4-20 mA
5
13
+
4
12
3
11
2
10
EXH.
TEMP.
SWITCH
1
9
FIELD
CONTROL
WIRING
BOX
GAS SHUT-OFF VALVE
Figure 2.9
Field Control W ir ing Box Location
2.6.1 ENABLE/DISABLE INTERLOCK
Each unit has an enable/disable interlock circuit
located in the field wiring box (see Figure 2.10).
Figure 2.10
Field Control Box Wir ing
2.7 FLUE GAS VENT INSTALLATION
AERCO Gas Fired Venting and Combustion Air
Guide, GF-1050, must be consulted before any
flue or combustion air venting is designed or
installed. Suitable, U/L approved, positive
pressure, watertight vent materials MUST be
used for safety and UL certification. Because
the unit is capable of discharging low
temperature exhaust gases, the flue must be
pitched back towards the unit a minimum of 1/4"
per foot to avoid any condensate pooling and to
allow for proper drainage.
While there is a positive flue pressure during
operation, the combined pressure drop of vent
and combustion air systems must not exceed
140 equivalent feet of 0.81” W.C. Fittings as
well as pipe lengths must be calculated as part
7
INSTALLATION PROCEDURES
of the equivalent length. For a natural draft
installation the draft must not exceed - 0.25”
W.C. These factors must be planned into the
vent installation. If the maximum allowable
equivalent lengths of piping are exceeded, the
unit will not operate properly or reliably.
2.8 COMBUSTION AIR
The AERCO Gas-Fired Heater Venting and
Combustion Air Guide, GF-1050 MUST be
consulted before any flue or inlet air venting is
designed or installed. Air supply is a direct
requirement of ANSI 223.1, NFPA-54, and local
codes. These codes should be consulted before
a permanent design is determined.
The combustion air must be free of chlorine,
halogenated hydrocarbons or other chemicals
that can become hazardous when used in gasfired equipment. Common sources of these
compounds are swimming pools, degreasing
compounds, plastic processing, and refrigerants.
Whenever the environment contains these types
of chemicals, combustion air MUST be supplied
from a clean area outdoors for the protection
and longevity of the equipment and warranty
validation.
The more common methods of combustion air
supply are outlined below. For combustion air
supply from ducting, consult the AERCO GF1050, Gas Fired Venting and Combustion Air
Guide.
2.8.1 COMBUSTION AIR FROM OUTSIDE
THE BUILDING
Air supplied from outside the building must be
provided through two permanent openings. For
each unit these two openings must have a free
area of not less than one square inch for each
4000 BTUs input of the equipment or 250 square
inches of free area. The free area must take into
account restrictions such as louvers and bird
screens.
be deducted from the maximum allowable
discharge piping amounts. Each unit must have a
minimum 6" diameter connection made to the
optional Inlet Air Adapter # GM-18917 available
from AERCO. This Adapter bolts directly on to
the air inlet of the unit blower. See installation
instructions with Adapter. All inlet air ducts must
be sealed air tight.
2.9 UNIT INITIAL FILL
Before filling the shell for the first time, blow out
all the connecting water and gas piping and
check thoroughly for leaks. Rinse all soap suds
from the gas piping with clean water. Do not
allow water to get on the Control Panel or
electrical connections. Check that all installation
procedures have been completed.
The following steps should be followed to fill the
unit:
1. Close the unit’s drain valve.
2. Open the shut-off valves at the water inlet
and outlet.
3. Open the temperature/pressure relief valve
to allow air to escape from the shell. The
shell is full when water flows out of relief
valve discharge piping.
4. Close the temperature/pressure relief valve
and open fixtures in building to free the
system of air.
2.8.2 COMBUSTION AIR FROM INSIDE
THE BUILDING
When combustion air is provided from within the
building, it must be supplied through two
permanent openings in an interior wall. Each
opening must have a free area of not less than
one square inch per 1000 BTUH of total input or
1000 square inches of free area. The free area
must take into account any restrictions such as
louvers.
2.8.3 SEALED COMBUSTION
The unit is UL approved for a 100% sealed
combustion application when installed properly.
When a sealed combustion air application is
installed, the sealed combustion air piping must
8
CONTROL PANEL OPERATING PROCEDURES
SECTION 3- CONTROL PANEL OPERATING PROCEDURES
The following is a guide to the operation of the
unit’s control panel. Initial startup of this unit must
be performed by factory trained startup personnel.
Operation prior to initial startup by factory trained
personnel will void the warranty.
CAUTION:
All initial installation procedures must be
satisfied before attem pt ing to start the unit
WARNING:
DO NOT ATTEMPT TO DRY FIRE THE KC
1000. STARTING THE UNIT WITHO UT A
FULL WATER LEVEL CAN SERIOUSLY
DAMAGE THE UNIT AND MAY RESULT IN
PERSONNEL INJURY OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID
ANY WARRANTY.
3.1 THE CONTROL PANEL
The KC 1000 Control Panel has been designed to
provide the operator with all the necessary
information required for operation and
troubleshooting the unit. There are six separate
accessible controls or displays, available to the
operator (see Figure 3.1). These are:
1. The Temperature Controller
2. The Annunciator & Function Switches
3. The Combustion Safeguard Controller
4. Water Level Test and Reset Switches
5. On/Off Switch
6. Fault Indicator Light
The following sections will describe the above
components in more detail.
WARNING
CONTROL BOX INTERNALS MUST NOT
BE SERVICED OR ACCESSED BY OTHER
THAN FACTORY CERTIFIED SERVICE
TECHNICIANS. ALL CONTROL BOX
INTERNALS HAVE THE CAPABILITY OF
HOLDING AN ELECTRICAL VOLTAGE OF
120 VOLTS AC.
3.2 THE TEMPERATURE CONTROLLER
The temperature controller is a PID
programmable controller that utilizes feed forward
and feedback information to accurately maintain a
desired set point. It is the primary source for
programming and viewing operating parameter
settings. It also plays a part in the start sequence
and includes other features such as:
• 2- eight segment LED displays
• 5 indicator status lights
• 3 menu levels
• RS-485 communications capability,
.
FIGURE 3.1
Front Panel Controls Location
3.2.1 LED DISPLAYS
The upper and lower displays each consist of four
8 segment LED’s’ (see figure 3.2). When an
operating parameter is chosen to be changed or
looked at, the lower led display indicates the
parameter being looked at in the form of a code.
The upper display indicates the parameter’s value.
For a complete listing of the operating parameters
see Appendix A of this manual.
3.2.2 INDICATOR STATUS LIGHTS
The first LED indicator light, “MAN”) indicates
whether the controller is in auto or manual mode,
(see Fig. 3.2). When lit the controller is in manual
mode and the operator is responsible for
operation of the unit. When the LED is not lit the
controller is in auto mode. In auto mode the
controller is operating the unit from signals
generated by sensors located on the unit.
The second LED, “REM”, designates whether the
controller is being controlled locally or remotely.
(see Fig. 3.1). When lit the controller is in remote
mode and can accept commands from an
external source via the RS-485 interface. When
this LED is not lit the controller is in local mode
and will respond to whatever the current internal
settings are. All external commands are ignored.
9
CONTROL PANEL OPERATING PROCEDURES
The third LED, “ON”, indicates the status of the
start relay, (Fig. 3.2). The start relay is internal to
the controller and is part of the start string for the
unit. When this LED is lit there is a demand for
heat and the start relay is closed.
o
The last two LED’s, “
whether the temperature displayed is °F or °C.
F” and “oC”, indicate
NOTE:
When the t em per ature controller is
displaying in oC only the temperature being
displayed is affected. All other set t ings
remain in oF.
Figure 3.2
Temperature Controller Operating Status
Lights
menu parameter are listed within this section. For
more data concerning the minimum and
maximum range, and factory defaults of menu
parameters, see the Appendix D of this manual.
3.3 PRIMARY MENU
The primary menu is the default menu. When in
another menu level and there is no activity for
five minutes the temperature controller will
default back to the primary menu. The Primary
menu allows the operator access to the controller
parameters listed below.
Code Meaning
tout Actual unit outlet water temperature.
pct Current firing rate of the unit in
percent.
Setp The desired set-point of outlet water
temperature.
Auto Automatic controlling mode ON or
OFF.
3.3.1 OUTLET TEMPERATURE (TOUT)
Outlet temperature is the actual outlet water
temperature of the unit. To access outlet
temperature, press the INDEX button until (tout) is
displayed in the lower LED. The variable under
this feature may not be manually changed. Fig 3.3,
below, shows an outlet temperature of 120º F
3.2.3 MENU LEVELS
The temperature controller has two menu levels
that are operator accessible for programming the
unit functions and parameters. These are the
Primary and Secondary menus.
To change from the primary menu to the
secondary menu simultaneously depress the
arrow key and ENTER button. To change from
the secondary to the primary menu
simultaneously press the ⇓ arrow key and the
INDEX button.
To scroll through a menu, depress the INDEX
button. To change a parameter scroll through the
menu until the desired parameter is indicated on
the controller’s lower LED display. Then use the
!
and " arrow keys to change the parameters
value. Once the desired parameters value has
been changed the ENTER key must be pushed
for the change to be recognized by the controller.
Leaving the desired parameter without entering
the new value will result in that parameter value
defaulting back to the previous value. Detailed
descriptions and instructions for accessing each
!
Figure 3.3
Outlet Temperature Display
3.3.2 PERCENTAGE OF FIRING RATE
(Pct)
Percentage of firing rate is a number, in percent,
that is related to the input BTU’s of the unit. For
instance a 50% signal equals approximately
500,000 BTU gas input while a 75 % signal equals
approximately 750,000 BTU gas input.
CAUTION:
Do not leave the unit unattended while in the
manual mode of operation.
10
CONTROL PANEL OPERATING PROCEDURES
To access the percent of firing rate press the
INDEX button while in the primary menu until
(Pct) is displayed in the lower LED. Use the
arrow key to increase or decrease the percentage
of firing rate. Press the ENTER button to accept
the desired change. Figure 3.4 shows the
temperature controller displaying a 100% firing
rate.
!, "
Figure 3.4
Percent of Firing Rate Display
WARNING:
WHEN SWITCHING FROM AUTO TO
MANUAL MODE, THE FIRING RATE DOES
NOT CHANGE. THE UNIT WILL CONTINUE
TO OPERATE AT THE SAME FIRING RATE
PERCENTAGE AS WHEN THE UNIT WAS
IN AUTO MODE.
3.3.3 SETPOINT (SETP)
Setpoint is the desired outlet water temperature
that is to be maintained by the unit when in
automatic mode. Fig 3.5 shows the controller with
a setpoint of 120º F.
NOTE:
Changing the setpoint will only be
recognized when the unit is in the automatic
mode.
3.3.4 AUTOMATIC\MANUAL (AUTO)
When set to automatic mode the controller is
receiving and processing inputs from temperature
sensor(s) located externally or on the unit. The
controller uses these inputs to automatically
decrease or increase the firing rate to match the
load.
In manual mode the controller no longer
automatically controls the firing rate of the unit. It
is up to the operator to control the outlet
temperature and firing rate. Manual mode is
commonly used for service and troubleshooting
the unit. All safety limits remain functional
whether the controller is in automatic or manual
mode.
To place the controller in automatic mode press
the INDEX button until (Auto) is displayed in the
lower LED.
!
Now press the
displayed in the upper LED, (see Fig. 3.6). Press
the enter button to accept the change. The MAN
LED should not be lit.
To place the KC 1000 in manual mode, press the
! "
arrow keys until OFF is displayed in the
upper LED (See Fig. 3.7). Press the enter button
to accept the change. The MAN LED should now
be lit.
" arrow keys until ON is
To access the unit’s setpoint press the INDEX
button until (Setp) is displayed in the lower LED.
To increase or decrease the unit’s setpoint press
! "
the
accept the change.
arrow keys. Press the ENTER button to
Figure 3.5
Setpoint Display
Figure 3.6
Auto/Manual Display with Auto On
11
CONTROL PANEL OPERATING PROCEDURES
Figure 3.7
Auto/Manual Display with Manual ON
3.4 SECONDARY MENU
The secondary menu is primarily related to
temperature control. It is necessary to access this
menu when temperature calibrating the unit.
To access the secondary menu, press the
arrow key and ENTER simultaneously. To scroll
through the menu press the INDEX button. The
secondary menu allows access to the following
temperature control features:
!
For a complete explanation of the secondary
menu parameters see the Appendix A of this
manual.
3.5 THE ANNUNCIATOR CIRCUIT
The annunciator consists of the annunciator
circuit board, the front panel LCD display, and 4
function switches (see Fig. 3.8). The annunciator
circuit board is the interface between the LCD
display and the combustion safeguard system. It
monitors the unit during every phase of operation
and prompts the LCD display with start sequence
and fault messages. The function switches are
used to reset the annunciator and gain access to
the annunciator’s three function displays.
Func
tout
FFt
Pct
SetP
SEnS
OFSt
LLt
HLt
Pb1 Proportional Band
Int Integral Rate
Drt Derivative Time
Fdb Feedback on or off
Addr
LOre
Unit’s mode of
operation
Outlet water
temperature
Water temperature
at the BTU
transmitter sensor
Firing rate of the unit
in percent
The desired set point
of outlet water temp
High flow
temperature
adjustment
Low flow
temperature
adjustment
Low temperature
alarm
High temperature
alarm
Controller address
for external
communication
Local/ remote status
of the control
Figure 3.8
Annunciator Function Switches and LCD
Display
The annunciator circuit board and LCD display
are not an integral part of the start sequence or
combustion safeguard system. If either should fail
the unit will still operate with no adverse effects.
The annunciator start sequence messages, fault
messages, function switches and function displays
are explained below.
3.5.1 ANNUNCIATOR FUNCTION
DISPLAYS AND SWITCHES
The annunciator has three function displays that
are available to the operator. These are the
MAIN, the CYCLES, and the SET DATE displays.
These displays are accessed using the four
membrane switches located directly under the
12
CONTROL PANEL OPERATING PROCEDURES
LCD display on the front of the control panel.
!, "
They are labeled CLEAR,
The MAIN display is used during normal operation
of the unit. In the MAIN display, start sequence
and fault messages can be viewed. To return to
the MAIN display from any other display,
simultaneously press CLEAR and the
key. To reset the MAIN display after a fault has
occurred press the CLEAR button.
The CYCLES display indicates the date and time,
and the number of cycles the unit has started.
When in the CYCLES display only the number of
cycles can be reset. To reset the number of cycles
to zero, simultaneously press the
keys and hold them for approximately four
seconds.
In the SET DATE display, both the time and date
are displayed and can be changed.
To access the SET DATE display, press the
CLEAR button while in the CYCLES display.
Continue pressing the CLEAR button to move
through the SET DATE display fields. Use the
"
arrow keys to set the date and time.
The following table shows the messages
displayed after accessing the CYCLES and SET
DATE DISPLAYS.
The number of times
# CYCLES =
“DATE” “TIME”
SET DATE:
“DATE” “TIME”
completed it’s start
cycle, and the time
Displays and allows
setting of the date
, and AUX.
!
arrow
! "
arrow
the controller has
and date
and time
!
3.5.2 ANNUNCIATOR FAULT MESSAGES
The following table lists the Annunciator fault
messages and their meanings.
LOW WATER
LEVEL
REMOTE
DISABLED
PURGE INTLK
OPEN
LOW AIR FLOW
SYSTEM FAULT
PURGE
INTERLOCKS
SYSTEM FAULT
LOW AIR
PRESSURE
FLAME FAULT
DURING
IGNITION TRIAL
LOCKOUT RUN
AIR FLOW
LOCKOUT RUN
FLAME
LOCKOUT RUN
HI EXHAUST
TEMP
The unit water level is
below the probe level.
The interlock terminals,
in the relay box, are not
closed.
The proof of closure
switch or the purge
switch did not prove
closed during the start
sequence.
The air flow switch did
not proved closed
during the start
sequence.
The proof of closure
switch or purge switch
did not proved closed 45
seconds after the unit
attempted to start.
The air pressure switch
did not prove closed 45
seconds after the unit
attempted to start.
Flame did not prove at
the end of the trial for
ignition period.
The air pressure switch
opened after flame was
proven.
Flame signal was lost
after flame was proven.
The combustion
safeguard is locked out.
The exhaust gas
temperature has
exceeded 500º F
3.5.3 ANNUNCIATOR START SEQUENCE
MESSAGES
The following table lists the annunciator start
sequence messages.
MESSAGE MEANING
AC power has been
RESET MAIN
POWER
HIGH WATER
TEMP
LOW GAS
PRESSURE
interrupted. Power must
be shut off for 20
seconds to reset the
display.
Outlet water
temperature has
exceeded the high
temperature limit
setting.
The unit has tripped due
to low gas pressure.
13
MESSAGE MEANING
The unit is in standby
STANDBY
PURGING The unit is in the 7 sec
IGNITION TRIAL
FLAME PROVEN
mode waiting for a call
for heat
purge.
The unit is in ignition
position attempting to
light the burner
The unit has
established flame and
is running normally.
CONTROL PANEL OPERATING PROCEDURES
3.6 THE COMBUSTION SAFEGUARD
CONTROLLER
The Combustion Safeguard is responsible for
monitoring the safety components during the start
sequence, and after flame is established. It is also
responsible for timing of the purge and ignition
cycles during the start sequence.
The combustion safeguard is located on the left
side of the control panel as shown in Figure 3.9.
There are five status LEDs that indicate the
status of operation. Along with the annunciator,
these are useful as a double check for proper
system operation and troubleshooting. The table
below defines the function of each light. The
reset button located under the LEDs is to reset
the combustion safeguard on lockout.
DESCRIPTION FUNCTION
POWER
PILOT
FLAME
MAIN
ALARM
Lights upon power up of
the unit.
Lights when there is a call
for heat.
Lights once flame has
been detected.
Lights after flame has
been detected and
stabilized
This lights when the
controller is in a LOCKOUT
condition.
3.7 WATER LEVEL TEST and RESET
SWITCHES
The water level switches are located on the left
side of the panel (see Fig. 3.10). When depressed
the TEST switch simulates a low water level
condition by breaking the connection between the
water level probe and the sensing circuitry. To test
the water level circuitry, depress the test switch for
3 seconds. The unit should fault resulting in the
red fault light blinking and the LED display
indicating LOW WATER LEVEL.
Figure 3.10
Water Level Test and Reset Switch Locations
Figure 3.9
Combustion Safeguard Status Indicator LED
Location
Note:
Only water level circuitry is tested during the
above test. To determine if the probe is
functioning properly, the water level must be
reduced below the level of the probe.
To reset the unit, depress the water level reset
switch, the annunciator clear button, and if
necessary, the reset button on the combustion
safeguard.
3.8 ON/OFF SWITCH
The ON/OFF switch is located on the right side of
the control box above the temperature controller
(see Figure 3.1). It is part of the start string and
must be in the ON position to enable the unit to
fire. When the switch is in the ON position and
illuminated, it is indicating that the start limit
string, consisting of water temperature, gas
pressure, water level, and the interlock is
satisfied. The unit, at this point, is in standby
mode and ready to run.
14
CONTROL PANEL OPERATING PROCEDURES
3.9 START SEQUENCE
When the unit is in the standby mode, and there
is a demand for hot water, the following will occur:
1. Upon demand the temperature controller’s ON
status indicator will light.
2. The combustion safeguard’s PILOT LED
lights, and the blower contactor energizes,
starting the blower.
3. The system next checks for proof of closure
from the safety shut-off valve, (see Fig. 3.11),
and the air fuel valve rotates open engaging
the air /fuel valve open switch (see Fig. 3.12).
4. The LCD display shows PURGE INTLK OPEN
until the above conditions are met. Once met
the LCD display will show LOW AIR FLOW.
5. The blower proof switch closes, (See Fig.
3.13), and the LCD display will show
PURGING.
6. Closure of the blower proof switch signals the
combustion safeguard to begin its 7-second
purge cycle.
145
146
147
149
148
FROM
CONNECTOR
9A
Figure 3.12
Air/Fuel Valve Open and Engaging the
Air/Fuel Valve Open Microswitch
7. At the end of the purge cycle the combustion
safeguard initiates a 10 second trial for ignition
and the following simultaneously occurs:
• The LCD displays the message IGNITION
TRIAL.
• The ignition transformer energizes.
• The air/fuel valve rotates to its low fire
position. This engages the air-fuel valve
closed switch, energizing the safety shut-off
valve, (see Fig. 3.14).
PROOF OF
CLOSURE
SWITCH
SAFETY
SHUT-OFF
VALVE
Figure 3.11
Proof of Closure Switch Location
Figure 3.13
Blower Proof Switch Location
8. Once the combustion safeguard detects
flame, its flame LED lights. Power is removed
15
CONTROL PANEL OPERATING PROCEDURES
from the ignition transformer and the MAIN
LED lights of the combustion safeguard.
At this point, the annunciator will display FLAME
PROVEN. The unit, in the automatic mode, is
released to modulate through the PID controls.
3.10 AFTER FLAME
Once the control signal has gone below the stop
level (see section 3.12 for Stop Level explanation),
the temperature controller’s green ON light
extinguishes, indicating there is no longer a call for
heat. This signals the combustion safeguard to
shut down the burner. The POWER LED of the
combustion safeguard remains illuminated and the
annunciator displays the message STANDBY.
3.11 FLAME TEST JACKS
The front of the combustion safeguard has two
test jacks marked + and - for flame monitoring,
(see Fig. 3.15). To access the test jacks remove
the combustion safeguard cover by turning the
center screw counterclockwise. A standard
voltmeter is required to monitor the flame signal
strength. A flame signal of 1.5 to 5VDC is typical
during proper operation of the unit.
Figure 3.15
Flame Test Jack Location
3.12 START STOP LEVELS
The start and stop levels are the firing rate
percentages that represent a call for heat and an
indication that the call for heat has been satisfied.
The start level is preset to 20% and the stop level
is preset to 16%. These are factory preset and
should not require adjustment.
Figure 3.14
Air/Fuel Valve in Ignition Position, Engaging
the Ignition Microswitch
16
SECTION 4 - INITIAL START UP
INITIAL START-UP
4.1 INITIAL START- UP REQUIREMENTS
The Initial Start-Up of the KC-1000 Boiler is
comprised of the following steps:
• installation completed 100%
• combustion calibration
• proper setting of controls and limits
• temperature calibration
• safety device testing (see Section 5)
Installation procedures should be completed
100% before performing initial start-up and the
start-up must be complete prior to putting the
unit into service. Starting a unit without the
proper piping, venting, or electrical systems can
be dangerous and void the product’s warranty.
These start-up instructions should be precisely
followed in order for the unit to operate safely, at
a high thermal efficiency, and with low flue gas
emissions.
Initial unit start-up is to be performed ONLY by
AERCO factory trained start-up and service
personnel. After following the steps in this
section, it will be necessary to perform the mode
of operation settings in section 5, and the safety
control test procedures in section 6 to complete
the initial unit start-up.
An AERCO Gas Fired Startup Sheet included
with each KC-1000 must be completed for each
unit for warranty validation and a copy must be
returned promptly to AERCO at:
AERCO International, Inc.
159 Paris Ave.
Northvale, NJ 07647
WARNING
!
DO NOT ATTEMPT TO FIRE THE UNIT
WITHOUT FULL WATER LEVEL. THI S
CAN SERIOUSLY DAMAGE THE UNIT
AND MAY RESULT IN PERSONAL
INJURY OR PROPERTY DAMAGE. THIS
IS NOT COVERED BY WARRANTY.
CAUTION!
All installation procedures in Section 2 must
be completed before attempting to start the
unit.
4.2 TOOLS AND INSTRUMENTATION
FOR COMBUSTION CALIBRATION
To properly perform combustion calibration, the
proper instruments and tools must be used and
correctly installed on the unit. The following
sections outline the necessary tools and
instrumentation as well as their installation.
4.2.1 REQUIRED TOOLS AND
INSTRUMENTATION
The following tools and instrumentation are
necessary to perform combustion calibration of
the unit:
1. A digital combustion analyzer with oxygen
accuracy to 0.4%, and carbon monoxide in
PPM
2. ** A 16" W.C. manometer and plastic tubing
3. Three, 1/8" NPT to barbed fittings for use
with manometers
4. Aerco differential gas pressure regulator
adjustment tool P/N GM-122643 (one
supplied per installation)
5. Small and large flat blade screwdrivers
6. 7/16" open end wrench and small adjustable
wrenches
7. Tube of silicone adhesive
8. * Digital multimeter with 10 amp and volt
capability
*Although not necessary for actual start-up
procedures, recommended for troubleshooting.
**For propane fired units: an additional 8" W.C.
manometer and 1/2" NPT to barbed fitting is
needed.
4.2.1 INSTALLING THE SUPPLY GAS
MANOMETER
1. Close the manual gas supply valve upstream
of the unit.
2. Remove the 1/8" NPT pipe plug from the gas
train assembly. This pipe plug is located
below the low gas pressure switch before
the safety shut off valve (see Fig. 4.1).
3. Install a barbed fitting into the pipe plug
tapping.
4. Attach one end of a length of plastic tubing
to the barbed fitting and one end to the 16"
W.C. manometer.
17
1/4" NPT PLUG
(INSTALL
MANOMETER
HERE)
SSOV
Figure 4.1
1/8” Gas Plug Location
4.2.2 PREPARING THE FLUE VENT
PROBE HOLE
1. If the unit has been installed using the
recommended AL29-4C vent, there will be a
3/8” hole, 18” to 24” above the exhaust
manifold. The outer vent section, that
covers vent section connections must be
loosened and slid down to uncover the hole
(see Fig. 4.2).
2. If equipped with one, adjust the stop on the
combustion analyzer probe so that it
extends into the flue gas flow without hitting
the opposite wall of the flue. Do not insert
the probe at this time.
INITIAL START-UP
Figure 4.3
Differential Reg ulator Adjustment Tool
Installation
4.2.3 INSTALLING THE DIFFERENTIAL
REGULATOR ADJUSTMENT TOOL
1. Remove the cap from the differential
pressure regulator (see Fig. 4.3).
2. Place the gasket from the regulator cap onto
the regulator adjustment tool.
3. Prior to Installing the tools on the regulator
pull up the tool's screwdriver blade. Then
thread the tool into the regulator.
4. Engage the tool’s screwdriver blade into the
regulator’s adjustment screw slot.
4.3 COMBUSTION CALIBRATION
The KC-1000 ships combustion calibrated from
the factory. Recalibration as part of a start-up is
necessary due to altitude, gas BTU content, gas
supply piping and supply regulators. Factory test
data sheets are shipped with each unit as a
reference.
Figure 4.2
Analyzer Probe Hole Location
The following combustion calibration procedure
closely follows the factory procedure. By
following this procedure readjustment of
combustion will be kept to a minimum.
NOTE:
If the instructions in section 4. 2 have not yet
been performed, go back and do so before
continuing.
1. Open the supply and return valves to the unit
and ensure that the system pumps are
running.
2. Open the gas supply valve(s) to the unit.
18
INITIAL START-UP
3. Using the 16” manometer installed as per
Section 4.2.1, adjust the gas supply
regulator until a reading of 12” W.C. static
pressure is obtained.
4. Place the green ON/OFF switch in the OFF
position. Turn on AC power to the unit. The
temperature controller and annunciator
displays should light.
5. Put the temperature controller in manual
mode
NOTE:
For a review of control panel operating
procedures, see Section 3.
6. Change the firing rate (Pct) to 0.0%.
7. Place the green ON/OFF switch in the ON
position.
8. Change the firing rate (Pct) to 25%. This will
put the unit into the starting sequence.
NOTE:
On initial start-up or return to service from a
fault condition, a warm-up timer of 2
minutes is activated by the controller. This
prevents the BTU input from exceeding
400,000 BTUs/HR even though the control
signal may indicate a greater input.
9. Observing the 2 minute warm-up period
increase the firing rate in 10 % increments
while monitoring the gas pressure after
every increase. If gas pressure dips below
8.5” W.C. for FM gas trains and 8.9” W.C.
for IRI gas trains at any input percentage,
stop and raise the pressure. Once 100% is
reached adjust the gas pressure for 8.5”
W.C. for FM and 8.9” W.C. for IRI.
NOTE:
If 8.5” W.C. (FM) or 8.9” (IRI ) gas pressure
cannot be obtained at the 100% firing rate,
it will be necessary to stop calibration and
contact the local AERCO representative in
your area. Running the unit on insufficient
gas pressure will void the warranty
10. Once 8.5” W.C. is set at the 100% level,
change the firing rate (Pct) to 30%. Insert
the combustion analyzer probe into the
stack.
NOTE:
Always go to a percentage of firing rate
from the same direction, ( i. e. , 100% to 30%
or 30% to 20%). Whenever going to a firing
rate from below (i.e., 20% to 30%), first go
above then back down to the desired firing
rate. This is necessary due to hysteresis in
the air/fuel stepper mot or. Hysteresis
causes the air/fuel valve to stop in a slightly
different position if the firing rat e
percentage is approached from below or
above. This results in a difference in
oxygen readings for the same f iring rate
percentage causing unnecessary
recalibration.
11. Allow enough time for the combustion
analyzer to settle. Compare the measured
oxygen level to the oxygen range for intake
air temperature in Table 1.
Table 1
Inlet Air
Temp Oxygen
20oF 5.7% <50ppm
40oF 5.5% <50ppm
60oF 5.2% <50ppm
80oF 5.0% <50ppm
100oF 4.9% <50ppm
Combustion Oxygen Levels for a 30%
Firing Rate
12. If the measured oxygen level is within the
range, at the current intake air temperature
in Table 1, no adjustment is necessary.
Proceed to step 17.
13. If the measured oxygen level is below the
range in Table 1, rotate the differential
regulator adjustment tool counter clockwise
1/4-1/2 revolution to decrease gas flow.
14. Wait for the combustion analyzer to settle,
then compare the new oxygen reading to
Table 1. Repeat adjustment until oxygen is
within the specified range.
15. If the measured oxygen level is above the
oxygen range in Table 1, rotate the
differential regulator adjustment tool
Carbon
Monoxide
19
INITIAL START-UP
clockwise, 1/4-1/2 turns, to increase gas
flow.
16. Wait for the analyzer reading to settle, then
compare the new reading to Table 1. Repeat
adjustment until oxygen is within the
specified range.
NOTE:
Adjust only the different ial regulator at 30%
control signal, do not adjust the air shutter
17. Once the oxygen level is within the specified
range at 30%, change the firing rate to 20%.
18. Oxygen levels at the 16% firing rate should be
10% or less as shown in Table 2. If the
measured oxygen level is less then 10%, no
adjustment is necessary. If the measured
oxygen levels are greater than 10%, rotate the
regulator adjustment tool clockwise 1/4 to 1/2
revolution to add gas.
19. Wait for the analyzer to settle. Repeat
adjustment until the measured oxygen reading
is 10% or less.
20. If the oxygen level cannot be brought to 10%
or less, check the oxygen level in 1%
increments above the 16% firing rate until an
oxygen level of 10%, or less, is measured.
Reset the unit’ stop level at that firing rate. Go
back and recheck the oxygen level at 30%
before continuing.
Table 2
Inlet Air
Temp
20oF 10% or less <25ppm
40oF 10% or less <25ppm
60oF 10% or less <25ppm
80oF 10% or less <25ppm
100oF 10% or less <25ppm
Combustion Oxygen Levels for a 20%
21. Change the firing rate to 100%. After the
combustion analyzer has settled, compare
the measured oxygen level with the levels in
Table 3.
22. If the measured oxygen reading is below the
oxygen range in Table 3, loosen the two
bolts that secure the inlet air shutter to the
unit using a 7/16” wrench (see Fig. 4.4).
Oxygen Carbon
Monoxide
Firing Rate
Open the shutter 1/4” to 1/2”, to increase the
oxygen level then tighten the nuts.
23. Wait for the analyzer to settle, then compare
the new oxygen reading to Table 3. Repeat
the inlet air shutter adjustment until the
oxygen is within the specified range. Firmly
tighten the inlet air shutter locking nuts when
finished.
Table 3
Inlet Air
Temp
Oxygen Carbon
Monoxide
20oF 5.4% <150ppm
40oF 5.4% <150ppm
60oF 5.2% <150ppm
80oF 4.9% <150ppm
100oF 4.7% <150ppm
Combustion Oxygen Levels for a 100%
Firing Rate
REMINDER:
At 30% firing rate adjust only the differential
pressure regulator. At 100% firing rate,
adjust only the inlet air shutter.
BLOWER INLET
Figure 4.4
Air Shutter Locking Nut Locat ion
24. If the measured oxygen reading is above the
oxygen range in Table 3, loosen the two
7/16" locking nuts securing the inlet air
shutter. Close the air shutter 1/4” to 1/2” to
decrease the oxygen level and tighten the
two nuts.
25. Allow the analyzer to settle, then compare
the new oxygen reading to Table 3.
SCREEN
SHUTTER
SHUTTER LOCKING
NUTS
BLOWER OUTLET
20
INITIAL START-UP
26. Allow the analyzer to settle. Repeat the
adjustment until the oxygen is within the
specified range. Firmly tighten the inlet air
shutter locking nuts when finished.
NOTE:
Adjust the inlet air shutter only at 100%
firing rate. Do not adj ust the differential
pressure regulator.
27. Change the firing rate to 30%. Allow time for
the combustion analyzer to settle. Check the
measured oxygen reading to insure that it is
still within the range as per Table 1.
28. Continue this procedure until all oxygen
levels are within the ranges specified in
Tables 1,2, and 3.
29. Record all readings on the AERCO start-up
sheet provided with each unit. Proceed to
Section 4.5.
4.4 PROPANE COMBUSTION
CALIBRATION
For propane units it will be necessary to install
an additional 8” W.C. manometer as described
below. This is used to measure the pressure
drop across the air/propane mixing orifice.
1. Referring to Fig. 4.5 remove the 1/8” NPT
plug from the gas inlet pipe ahead of the
burner and install an 1/8” NPT barbed fitting.
2. Remove the 1/2” NPT plug from the tee
located after the air pressure regulator and
install a 1/2” barbed fitting (see fig. 4.5).
3. Attach the 8” W.C. manometer to the barbed
fittings installed in steps 1, and 2.
4. While following the combustion calibration
procedure in Section 4.3 measure the
pressure drop across the air/propane mixing
orifice using the 0-8” W.C. manometer.
5. This reading should remain a constant 3.8”
to 4” W.C. throughout the operating range.
6. If the pressure drop is not within this range,
remove the cap from the air pressure
regulator.
7. Using a flat blade screwdriver adjust the
regulator until 3.8”-4.0” W.C. is obtained.
Clockwise will increase the reading and
counter-clockwise will decrease the reading.
8. If adjustments are made to this regulator it
will be necessary to recheck oxygen settings
at 16%, 30%, and 100% firing rates
NOTE:
After an adjustment is m ade to the air
regulator, the cap must be put back on
securely to obtain an accurate reading
Figure 4.5
Propane Air Different ial Pressure Taps
4.5 UNIT REASSEMBLY
Once combustion calibration is set properly, the
unit can be re-assembled for permanent
operation.
1. Put the green ON/OFF switch in the off
position. Disconnect the AC power supply to
the unit.
2. Shut off the gas supply to the unit.
3. Remove the regulator adjustment tool by
first pulling up the screwdriver blade to
disengage it from the regulator adjusting
screw, and then turning the tool out of the
top of the regulator.
4. Remove the gasket from the tool and place it
back onto the regulator cap.
5. Apply a drop of silicone to the regulator
adjusting screw to lock its setting.
6. Reinstall the cap and gasket back on the
regulator. Tighten the cap using a
screwdriver or wrench.
7. Remove all of the manometers and barbed
fittings and reinstall the pipe plugs using a
suitable thread compound.
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