AERCO GF-105 User Manual

Download

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

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

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

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

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

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

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.

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

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

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.

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

4-20 mA

EXH. TEMP. SWITCH

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

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

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.

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.

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.

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

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

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.

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.

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

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

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.

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.

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

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

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.

INITIAL START-UP

8. Replace the unit’s panels and hood.

9. Remove the combustion analyzer probe from the vent hole. Seal the probe hole and replace the vent connection cover.

4.6 TEMPERATURE CONTROL

CALIBRATION

Although the unit comes factory set and calibrated for a 130 necessary to recalibrate temperature control. There are two main adjustments for performing temperature calibration. These are OfSt (offset), and SENS (sensitivity).

Adjustments to OfSt and SENS are made at minimum and maximum load conditions and should be made in increments of 1 to 3. After making an adjustment, outlet water temperature must be allowed to settle for several minutes prior to making further adjustments.

When calibrating temperature control observe the following:

A) The unit must be in operation and in AUTO

mode.

B) Use the outlet temperature and percent input

displays to set load conditions and see the effect of adjustments.

C) Perform the calibration in the SECONDARY

menu of the temperature controller.

D) Make small adjustments and allow time

between adjustments for the outlet temperature to stabilize.

E) Maintain water flow as constant as possible

during these adjustments.

F) Ensure that recirculation loops are operational

while the calibration is being performed.

F setpoint it is usually

4.6.1 SETTING TH E OUTLET WATER

TEMPERATURE SETPOINT

The setpoint of the unit may be changed by following the procedure below. Once a setpoint has been changed recalibration may be necessary. The temperature calibration procedure is outlined in step Sections 4.6.2 and

4.6.3

1. Enter the SECONDARY menu of the temperature controller by simultaneously

pressing

2. Press INDEX until SEtP is displayed. This is the unit’s desired outlet temperature.

and ENTER.

4.6.2 MINIMUM LOAD ADJUSTMENT

1. Place the control in the secondary menu by

simultaneously pressing

2. Press INDEX until Pct is displayed. This is the unit’s percentage of firing rate.

3. Create a minimum load on the system that will yield a steady percentage of firing rate between 25% to 35%.

and ENTER.

NOTE:

It may be desirable to shut off the outlet

valve and use the hose bib to simulate a

minimum flow load condition.

4. Press the INDEX button until tout appears in the lower display. The upper display will be indicating the outlet water temperature.

5. Wait a few minutes to allow the outlet temperature to stabilize.

NOTE:

Keep toggling between the outlet

temperature and input percentage to ensure

that both have stabilized.

6. Once stabilized the outlet temperature should be 2 to 3 degrees above the unit’s set point. If it does not stabilize to 2 or 3 degrees above the setpoint, Offset (OfSt) must be adjusted.

7. To adjust OfSt press INDEX until OfSt appears in the lower display (see figure 4.6).

8. Raise or lower OfSt as needed using the

!&"

buttons. Increasing this value will increase water temperature, decreasing it will decrease water temperature.

9. Press ENTER to accept new values and allow time for the system to settle between adjustments.

3. Adjust this value to the desired set point

! "

using value.

then press ENTER to accept the

FIigure 4.6

Secondary Menu Displaying Offset

INITIAL START-UP

4.6.3 MAXIMUM LOAD ADJUSTM ENT

1. Enter the SECONDARY menu of the temperature controller by simultaneously

pressing

2. Press INDEX until Pct is displayed. This is the unit’s percentage of firing rate.

3. Create a maximum load on the system that will yield a steady percentage of firing rate between 80% to 90%.

and ENTER.

NOTE:

It may be necessary to open the outlet valve

if it was closed during minimum load

adjustment to obtain a sufficient flow rate for

maximum adjustment.

4. Press the INDEX button until tout appears in the lower display. The upper display will be indicating the outlet water temperature.

5. Wait a few minutes to allow the outlet temperature to stabilize.

6. Once stabilized the outlet temperature should be 2 to 3 degrees below the set point temperature. If it does not stabilize to 2 to 3 degrees then the Sensitivity (SEnS) must be adjusted.

7. To adjust the SEnS press INDEX until SEnS appears in the lower display (see figure 4.7).

8. Raise or lower this value as needed using the

!,"

arrow keys. Increasing this value will increase water temperature, decreasing it will decrease water temp

9. Press ENTER to accept the new value. Allow time for the system to settle between adjustments.

10. If the outlet temperature holds setpoint temperature stable, and within the +/_ 4 no further control adjustment is required.

11. If the outlet temperature does not maintain setpoint after a reasonable amount of time and adjustment contact your local AERCO representative.

Figure 4.8

Over Temperature Limit Switch Location

Figure 4.7

Secondary Menu Displaying Sensitivity

4.7 OVER TEMPERATURE LIMIT SWITCH

ADJUSTMENTS

There are two over-temperature limit switches that will turn off the unit when the outlet water temperature becomes too hot. The lower overtemperature limit switch is adjustable and should be adjusted to 20 temperature the system will see. The upper overtemperature limit switch is a locked manual nonadjustable reset device. It will trip the unit off at

F above the highest operating

200o F water temperature. Do NOT attempt to adjust it’s set point.

To adjust the lower over temperature switch limit switch:

1. Remove the wing nut from the top center of the shell cap. Lift the cap off the shell.

2. The two over-temperature limit switches are located at the top of the shell (see Fig. 4.8). Do not adjust the upper switch. It has been factory preset. Adjust the lower switch 20 higher than the unit’s set point.

3. Replace the shell cap and wing nut.

INITIAL START-UP

SECTION 5-SAFETY DEVICE TESTING PROCEDURES

5.1 TESTING OF SAFETY DEVICES

Periodic testing of all controls and safety devices is required to insure that they are operating as designed. Precautions must be taken while tests are being performed to protect against bodily injury and property damage.

Systematic and thorough testing of the operating and safety controls should be performed on a scheduled basis, or whenever a control component has been serviced or replaced. All testing must conform to local jurisdictions or codes such as ASME CSD-1.

NOTE:

MANUAL and AUTO modes are required to

perform the following tests. For a complete

explanation of these modes, see Section 3.

SAFETY DEVICE TESTING

1/4" NPT PLUG

(INSTALL MANOMETER

HERE)

SSOV

NOTE:

It will be necessary to remove the sheet

metal covers and cap from the unit t o

perform the following test s.

WARNING!

THIS IS A 120 VOLT AC COMBUSTION SAFEGUARD SYSTEM. POWER MUST

BE REMOVED PRIOR TO PERFORMING

WIRE REMOVAL OR OTHER TESTING

PROCEDURES THAT CAN RESULT IN

ELECTRICAL SHOCK.

5.2 GAS PRESSURE FAULT TEST

1. Shut off the gas supply to the unit.

2. Install an 0-16” W.C. manometer in the gas pipe assembly below the low gas pressure switch. (See Fig. 5.1)

3. Open the gas supply to the unit.

4. Start the unit.

5. Slowly close the manual gas supply valve while monitoring the gas pressure. The unit should fault and shutdown on “LOW GAS PRESSURE” when the manometer indicates approximately 7” W.C.

6. Open the gas supply to the unit.

7. The unit should start upon restoration of gas pressure.

Figure 5.1

1/8” Pipe Plug Position for Manometer

installation

NOTE:

After faulting the unit, the fault me ssage will

be displayed and the fault indicator light will

flash until the CLEAR button is pressed.

5.3 LOW WATER LEVEL FAULT TEST

1. Place the ON/OFF switch in the OFF position.

2. Close shut-off valves in the supply and return piping to the unit.

3. Open the drain valve on the unit.

4. Allow air-flow into the unit by either opening the relief valve or by removing the 1/4” plug in the top of the unit.

5. The LOW WATER LEVEL message will be displayed and the fault LED will flash after the water level has gone below the level of the probe.

6. The ON-OFF switch should not illuminate when placed in the ON position and the unit should not start.

7. Close the drain and pressure relief valve or reinstall the plug in the top of the unit if removed.

8. Open the water shut-off valve in the return piping to the unit to fill the shell.

9. Open the water shut-off valve in the supply piping to the unit.

10. Press the LOW WATER LEVEL RESET button to reset the low water cutoff and press the CLEAR button to reset the annunciator and LCD displays once the shell is full.

11. Place the ON-OFF switch in the ON position. The unit is now ready for operation.

5.4 WATER TEMPERATURE FAULT

TEST

1. In AUTO mode, allow the unit to stabilize at its setpoint.

2. Lower the operating temperature limit switch setting to match the outlet water temperature. (See Fig. 5.2).

SAFETY DEVICE TESTING

2. Once the unit is firing, close the manual leak-detection valve. This is the valve located between the safety shut off valve and the differential gas pressure regulator (See Fig. 5.3).

3. The unit should shut down within 1-2 seconds and indicate a LOCKOUT RUN FLAME fault on the LCD display.

4. Leaving the manual leak detection valve closed, reset the combustion safeguard and CLEAR the annunciator

5. Restart the unit.

6. The unit should lockout and display LOCKOUT START FLAME during ignition.

7. Open the leak detection valve.

Figure 5.2

Temperature Limit Switch Setting

3. Once the limit switch setting is approximately at the actual water temperature indicated by tout, the unit should shutdown. The fault light should be flashing and the message “HIGH WATER TEMP” should be displayed. The ON/OFF switch should not be illuminated and the unit should not start.

4. Reset the temperature limit switch setting to a minimum of 20 temperature.

5. The unit should start once the temperature limit switch setting is above the actual outlet water temperature.

F above the set point

5.5 FLAME FAULT TEST

1. Start the unit.

Figure 5.3

Manual Leak Detection Valve

9. Reset the Combustion safeguard and CLEAR the annunciator.

10. Start the unit.

5.6 AIR PRESSURE FAULT TEST

WARNING!

THIS IS A 120 VOLT AC COMBUSTION SAFEGUARD SYSTEM. POWER MUST

BE REMOVED PRIOR TO PERFORMING

WIRE REMOVAL, OR TESTING

PROCEDURES THAT CAN RESULT IN

ELECTRICAL SHOCK.

1. Disconnect AC power from the unit.

SAFETY DEVICE TESTING

2. Disconnect wire #17 from the air pressure switch located on the air/fuel valve (See Fig.

5.4).

3. Restore AC power to the unit.

4. Produce a “call for heat” to start the unit. The unit should fault and display the message SYSTEM FAULT AIR FLOW SWITCH.

Figure 5.4

Blower Proof Switch Location and Wiring

6. Clear the annunciator. Turn the ON/OFF switch to the OFF position.

SSOV ACTUATOR

COVER

SSOV ACTUATOR

COVER SCREW

Figure 5.5

SSOV Actuator Set Screw Location

5. Disconnect AC power to the unit.

6. Remove the air/fuel valve cover by loosening the 3 screws securing it in place. (See Fig.

5.6).

5. Disconnect AC power from the unit.

6. Replace wire #17

7. Restore AC power to the unit.

8. Reset the combustion safeguard and clear the annunciator display.

5.7 PURGE INTERLOCKS FAULT TEST

1. Turn the ON/OFF switch to the OFF position.

2. Loosen the two set screws that attach the safety shut off valve actuator to its valve body. (See Fig. 5.5).

3. Lift the SSOV Actuator clear of the valve body. This will open the proof of closure switch.

4. Start the unit in manual mode

5. The unit should shutdown and display the message SYSTEM FAULT PURGE INTERLOCKS.

Figure 5.6

Air/Fuel Valve Cover Screw Locations

9. Disconnect wire #60 from the air/fuel valve open position switch. This is the switch closest to the blower (See Fig. 5.7).

SAFETY DEVICE TESTING

10. Restore AC power to the unit.

11. Start the unit.

WARNING!

THIS IS A 120 VOLT AC COMBUSTION SAFEGUARD SYSTEM. POWER MUST

BE REMOVED PRIOR TO PERFORMING

WIRE REMOVAL, OR OTHER TESTING

PROCEDURES THAT CAN RESULT IN

ELECTRICAL SHOCK.

20. Reconnect wire #62 to the ignition position switch

21. Replace the air/fuel valve cover.

22. Restore AC power to the unit

23. Set the unit to auto mode to resume normal operation.

5.8 SAFETY PRESSURE RELIEF VALVE

TEST

Test the safety Pressure/Temperature Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.

Figure 5.7

Air/Fuel Valve Open Position Switch

Location

12. The unit should shutdown and display the message SYSTEM FAULT PURGE INTERLOCKS.

13. Disconnect AC power from the unit.

14. Reconnect wire #60 to the air/fuel valve open position switch.

15. Disconnect wire #62 from the ignition position switch. This is the switch closest to the burner of the unit (See Fig. 5.7).

16. Restore AC power to the unit, and reset the combustion safeguard.

17. Start the unit.

18. The unit should lockout and display the message LOCKOUT START FLAME

19. Disconnect AC power from the unit

SECTION 6 – MAINTENANCE

MAINTENANCE

6.1 MAINTENANCE SCHEDULE

The KC1000 requires regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures must be performed in the specified timeperiods.

WARNING!

TO AVOID PERSONAL INJURY, BEFORE

SERVICING:

(A) DISCONNECT AC POWERTO THE

UNIT

(B) SHUT OFF THE GAS SUPPLY TO THE

UNIT

SAFE TEMPERATURE

6.2 SPARK IGNITOR

The spark ignitor assembly is located in the body of the burner (see Fig. 6.1). The ignitor may be HOT. Care should be exercised. It is easier to remove the ignitor from the unit after the unit has cooled to room temperature.

CAUTION!

The ignitor must be rem oved and installed using the ignitor remo val tool pr ovided with the unit(s). Damage to t he bur ner due to using a socket for r em oval and installat ion of the ignitor is not covered under warranty

To inspect/replace the Ignitor

1. Put the green ON/OFF button on the control panel, to the OFF position and disconnect AC power to the unit. Disconnect the plastic tubing from the condensate cup to drain and remove the rear cover panels from the unit. Access to the spark ignitor may also be gained by removing the unit’s right side panel

2. Disconnect the ignitor cable from the ignitor contactor and unscrew the ignitor contactor from the burner shell.

3. Insert the ignitor removal tool into the burner shell, where the ignitor contactor was removed. Screw the outer barrel of the tool into the burner shell. Push the inner barrel up and fit the hexagonal end of the tool over the ignitor. Unscrew the ignitor from the burner head and then the tool from the burner shell.

4. The ignitor is gapped at 1/8-inch. If there is substantial erosion of the spark gap or ground electrode, the ignitor should be replaced. If carbon build-up is present, clean the ignitor using fine emery cloth. Repeated carbon build-up on the ignitor is an indication that a check of the combustion settings is required, (see Sections 4.2 and 4.3 for Combustion Calibration)

Table 1 Maintenance Schedule

Section Item 6 Mos. 12 Mos. 24 Mos. Labor Time

6.2 SparkIgnitor Inspect Replace 15 mins.

6.3 Flame Detector Inspect Replace 15 mins.

6.4

6.5

Combustion

Adjustments.

Testing of

Safety Controls

Check Check 1 hr.

Test 20 mins.

BTU

6.6

Transmittert.

Oil 15 mins.

Pump

6.7

6.8

BTU Transmitter *Manifold &

Tubes

Inspect & clean if

necessary

Inspect & clean if

necessary

50 mins.

4 hrs.

6.9 Heat Exchanger Inspect 1. 5 hr s.

* Recommended only when unit will be run in an extrem e condensing mode for prolonged periods of time.

5 Prior to reinstalling the ignitor, an anti-seize

compound must be applied to the ignitor threads.

6 Reinstall the ignitor using the ignitor removal

tool. Do not over tighten the ignitor a slight snugging up is sufficient. Reinstall the ignitor contactor (hand tight only) and reconnect the ignitor cable.

7. Replace the rear cover panels or right side panel. Replace the condensate cup to drain tubing.

6.3 FLAME DETECTOR

The flame detector assembly is located in the body of the burner (see Fig. 6.1). The flame detector may be HOT. Allow the unit to cool sufficiently before removing the flame detector.

MAINTENANCE

6. Replace the rear cover panels or left side panel. Replace the condensate cup to drain tubing.

6.4 COMBUSTION CALIBRATION

Combustion settings must be checked at the intervals shown in Table 1 as part of the maintenance requirements. Refer to Sections

4.2 and 4.3 for combustion calibration

instructions.

6.5 SAFETY DEVICE TESTING

Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1, require that these tests be performed on a scheduled basis. Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a log- book. See Section 6-Safety Device Testing Procedures.

Figure 6.1

Spark Ignitor and Flame Det ector Location

To inspect or replace the flame detector:

1. Put the green ON/OFF button on the control panel, to the OFF position and disconnect AC power to the unit.

Disconnect the plastic tubing from the

condensate cup to drain and remove the rear covers from the unit.

6.6 BTU TRANSMITTER PUMP LUBRICATION

The BTU Transmitter pump should be lubricated every six months. There are two oil ports located on the top of the pump, (see Fig. 6.2). Oil using 4 to 5 drops of SAE20 weight non-detergent oil at each port. DO NOT OVER OIL.

Disconnect the flame detector lead wire.and

unscrew the flame detector and remove it from its guide tube.

4. Inspect the detector thoroughly. If eroded, the detector should be replaced. Otherwise clean the detector with a fine emery cloth.

5. Reinstall the flame detector hand tight only, and reconnect the flame detector lead wire.

Figure 6.2

BTU Transmitter Pump Oil Hole Location

MAINTENANCE

6.7 BTU TRANSMITTER ASSEMBLY

The BTU Transmitter is a crucial part of the unit’s temperature control system. It must be inspected and kept free of scale and debris in order for the unit to maintain accurate outlet water temperatures.

To inspect the transmitter:

1. Place the ON\OFF switch in the OFF position.

2. Remove the sheet metal covers from the unit.

3. Shut the water inlet, outlet and recirculation valves to the unit.

4. Open the drain valve on the unit.

5. Slowly open the pressure relief valve to allow air-flow into the unit.

6. Drain the unit until the WATER LEVEL FAULT LED is illuminated. Drain slightly more, then release the relief valve and close the drain valve on the unit.

7. Disconnect electrical power to the unit.

8. Close the 3 ball valves on the BTU transmitter, (See Fig. 6.3).

NOTE:

It is not necessary to disconnect the

electrical wires to the pump

Figure 6.4

BTU Transmitter Pum p Disassem bly

10. Using a 5/8” and 9/16” wrench loosen the 4 compression fittings holding the lower tubing assembly in place, (See Fig. 6.5)

Figure 6.3

Ball Valve Locations

9. Remove the 4 screws holding the BTU transmitter pump to the impeller housing. Remove and set the pump aside, (See Fig.

6.4).

Figure 6.5

Compression Fitting Locations

11. Carefully remove the lower tubing as sembly taking care not to lose either the cold water or hot water mixing orifice, (See Fig. 6.6).

MAINTENANCE

12. Loosen the compression fitting holding the hydraulic zero and control orifice tube assembly to the pump’s impeller housing, (See Fig. 6.6).

13. Remove the compression fitting at the top of the impeller housing and remove the impeller housing, (See Fig. 6.7).

Figure 6.8

BTU Transmitter Hot Water Tube

Disassembly

Figure 6.6

BTU Transmitter Disassem bly

NOTE:

The cold water orifice is slightly larger than the

mixing orifice. The orifice must be correctly

installed for proper temperature control.

Figure 6.7

BTU Transmitter Pum p Com p r ession Fitting

Locations

14. Remove the compression fitting securing the pump outlet tube to the ball valve and remove the pump outlet tube.

15. Remove the ball valve connected to the hot water tube coming from the top of the shell by loosening the compression fitting securing it to the hot water tube, (See Fig.

6.8).

16. Loosen the 90 of the shell holding the hot water tube, (See Fig. 6.9). Slide the hot water tube down slightly but do not remove it from the unit. Remove the 90

17. Inspect all fittings and tubing for blockage due to scale or debris. Clean or replace as necessary.

18. Inspect the mixing orifice for blockage or degradation due to erosion, (See Fig. 6.6). Clean or replace as necessary.

19. The pump impeller may be checked by removing the 4 screws from the cover encasing the impeller in the housing, (See Fig. 6.10).

compression fitting at the top

fitting.

Figure 6.9

BTU Transmitter Shell Com ponents

MAINTENANCE

NOTE:

Compression fittings are nickel-plated and should be replaced only with nickel-plated

fittings. Do not use brass fittings

6.8 MANIFOLD AND EXHAUST TUBES

The presence of even trace amounts of chlorides and/or sulfur, in the combustion air and fuel sources, can lead to the formation of deposits on the inside of the exchanger tubes, the exhaust manifold, and/or the condensate cup. The degree of deposition is influenced by the extent of the condensing operation and the chloride and sulfur levels that vary significantly from application to application.

The following parts will be necessary for reassembly after inspection:

GP-122537 Exhaust Manifold to

Combustion Chamber

Gasket

GP-18900 Manifold to Tubesheet

Gasket GP-18899 Burner Gasket GP-122551 Burner Release Gasket GP-161151 Combustion Chamber Liner

Figure 6.10

Impeller Housing Disassembly

21 Once the BTU transmitter has been

inspected and cleaned, reassemble in the reverse order.

NOTE:

Do not attempt to adjust the Hydraulic Zero Needle Valve. This is a factory-preset item.

Refer to Figure 6.6.

To remove the manifold for inspection:

1. Disconnect AC power and turn off the gas

supply to the unit.

2. Remove the sheet metal covers from the

unit.

3. Disconnect the plastic tubing from the

condensate cup to drain and remove the rear covers.

4. Remove the condensate cup from under the

unit and the condensate drainage tubing from the manifold.

5. Disconnect the flame detector and ignition

cable wires from the flame detector and ignitor contactor. Remove the flame detector and ignitor as per sections 6.2, and 6.3.

6. Remove the grounding terminal from the

burner by loosening the upper screw and sliding the connector from the grounding rod, (See Fig. 6.11).

7. Using a 7/16” socket or open end wrench

remove the four 1/4”-20 nuts on the gas inlet pipe flange at the burner, (See Fig. 6.12).

8. Using two 9/16” wrenches remove the 3/8"-

16 hex nuts and bolts on the gas inlet pipe flange at the air/fuel valve, (see Fig. 6.12).

Figure 6.11

Grounding Terminal Location

MAINTENANCE

9. Loosen the hose clamp at the air/fuel valve outlet and slide the clamp back towards the burner, (see Fig. 6.12).

10. Using a 1/2” socket wrench remove six 5/1618 hex nuts supporting the burner, (see Fig.

6.12).

Figure 6.13

Exhaust Sensor Connector Location

13. Disconnect the air/fuel valve wire harness, the 12 pin connector, from the control panel.

14. Disconnect wires #24 and #17 from the blower proof switch (See Fig. 6.14).

Figure 6.12

Burner Disassembly Diagram

11. Lower the burner while sliding the air hose off the air/fuel valve. Remove the burner through the rear of the unit.

12. Disconnect the exhaust temperature sensor by unscrewing it from the exhaust manifold, (See Fig. 6.13).

Figure 6.14

Blower Proof Switch Wir e Locations

15. Loosen the hose clamp on the air/fuel valve inlet and slide the clamp back towards the blower, (See Fig. 6.15).

Figure 6.15

Air/Fuel Valve Inlet Hose Clamp

16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between the air/fuel valve and the differential pressure regulator. Remove the feedback tube, (See Fig. 6.16).

17. Using two 9/16” wrenches remove the two 3/8-16 hex nuts and bolts securing the air/fuel valve to the differential pressure regulator, (See Fig. 6.16).

MAINTENANCE

19. Remove the flue venting from the exhaust manifold.

20. Removing the exhaust manifold insulation will prevent it from being damaged and will make it easier to handle the exhaust manifold once it is removed. Using a 7/16” wrench or socket remove the 3 bolts and fender washers securing the insulation to the exhaust manifold.

21. Loosen the three 1-1/16” nuts that hold the manifold. Remove the two side nuts. DO NOT REMOVE THE FRONT NUT, (See Fig.

6.17).

22. Carefully pull the manifold down and back, removing it through the back of the unit.

23. Inspect the manifold and exhaust tubes for debris. Clean out any debris as necessary.

24. Inspect the combustion chamber and the combustion chamber liner. Replace the liner if any signs of cracking or warpage are evident.

NOTE:

Install the combustion chamber liner prior t o

reinstalling the exhaust manifold

18. Remove the air/fuel valve taking care not to damage the flange “O” ring.

Figure 6.16

Feedback Tube and Air/Fuel Valve to

Differential Regulator Bolts

Figure 6.17

Manifold Nut and Bolt Locations

25. Replace the gasket between the manifold and the combustion chamber (P/N GP-

122537). The use of Permatex or a similar gasket adhesive is recommended.

26. Replace the gasket between the manifold and tubesheet (P/N GP-18900). Do not use any gasket adhesive; this gasket has an adhesive backing

27. Beginning with the manifold, reinstall all the components in the reverse order that they were removed.

6.8.1 PROPANE UNITS

For propane units it will be necessary to remove the air mix assembly in addition to the steps outlined in Section 6.8. Proceed as follows:

1. Follow steps 1 through 5 under Section 6.8

2. Using a wrench, loosen the two compression fittings holding the 1/4” feedback tube between the burner and air regulator and remove the feedback tube. (See Fig. 6.18)

3. Using a 1-1/16” wrench or an adjustable wrench loosen and remove the 12” flexible gas hose.

4. Proceed back to Section 6.8 and continue at Step #6.

NOTE:

Older propane units have a 1/8” Feedback

Tube and 1/8” OD tube compression

fittings.

6.9 HEAT EXCHANGER INSPECTION

The water-side of the heating surfaces may be inspected by removal of the top heater head. (See Fig.’s 6.19 & 6.20) The following gaskets will be needed prior to performing the inspection:

GP-18856 Release Gasket

GP-18532 Shell Gasket

MAINTENANCE

Figure 6.18

Propane Air Regulator Measuring Taps

6.9.1 FLAT (NEW) STYLE HEAD

To inspect the heat exchanger watersides:

1. Disconnect the electrical power to the unit.

2. Close the water inlet, outlet, and recirculation shut-off valves to the unit.

3. Open the drain valve carefully while opening the relief valve on the right side of the unit shell to relieve pressure and allow air into the shell.

CAUTION!

Do not drain the unit without venting the

shell! A vacuum in the unit may displace the

liner causing serious damage not covered

by warranty.

NOTE:

This manual covers two different st yle

heater heads. The newer is a flat head,

the older is a concave head.

4. Remove the wing nut from the top center of the shell cap and remove the cap.

5. Remove the nuts and studs from the upper head. Remove the upper head and upper head-liner, (See Fig. 6.19).

6. Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head. AERCO recommends that NEW gaskets be used when reassembling.

7. Place a shell head gasket on top of the shell ring first, then place the release gasket on top of the shell head gasket. Align the gasket holes with those in the shell ring.

8. Place the upper head liner on top of the gaskets.

9. Place the upper head on next aligning the holes.

10. Reassemble the studs and nuts through the upper head and shell ring. Cross tighten the nuts to approximately 75 ft./lb. torque to obtain a uniform seating, then progressively tighten the nuts to 150 ft./lb.

11. Replace the unit Cap. Close the drain valve and reopen the inlet, outlet, and recirculation valves to refill the unit as per Section 2.8.1.

6.9.2 CONCAVE (OLD) STYLE HEADS

To inspect the heat exchanger watersides:

MAINTENANCE

1. Disconnect the electrical power to the unit.

2. Close the inlet, outlet and recirculation shutoff valves to the unit.

3. Open the drain valve while carefully opening the relief valve on the right side of the unit shell to relieve pressure in the shell.

4 Remove the wing nut from the top center of

the shell cap and remove the cap.

CAUTION:

Do not drain the unit without venting the

shell! A vacuum in the unit may displace

the liner reulting in damage not covered

by warranty.

Figure 6.19

Flat Style Head Configuration

5. Remove the nuts and studs from the shell ring and remove the upper head ring. Remove the upper head and head liner, (See Fig. 6.20).

6. Inspect and clean the heat exchanger thoroughly before reassembling the upper head.

7. Clean all gasket surfaces thoroughly. AERCO recommends that NEW gaskets be used when reassembling the upper head to the unit shell.

MAINTENANCE

Figure 6.20

Concave Style Head

8. Place the shell gasket then the release gasket on top of the shell ring and align the gasket holes with those in the flange.

9. Place the upper head liner (dimple facing in/down) on top of the gasket, with all holes aligned. Then place the upper head on the upper head liner.

10. Place the upper head ring on top of the upper head.

11. Reassemble the studs and nuts through the upper head and shell ring. Cross tighten the nuts to approximately 75 ft./lb, to obtain uniform seating, and then progressively tighten the nuts to 150 ft./lb.

TROUBLESHOOTING

SECTION 7- TROUBLESHOOTING GUIDE

This troubleshooting section is intended to serve as a guideline to determining and solving faults on the unit. Whenever a fault occurs, proceed as follows:

1. Determine the cause of the fault by following the procedures within this section.

2. Once the cause has been determined, take the proper actions to remedy the fault.

3. Start the unit in accordance with this manual.

In the event that a fault cannot be remedied, contact your local AERCO Representative or the factory for Technical Assistance.

WARNING!

ELECTRIC SHOCK HAZARDS EXIST

THAT CAN CAUSE SEVERE INJURY.

DISCONNECT POWER BEFORE

PERFORMING ANY MAINTENANCE

AND/OR SERVICING.

WARNING!

NEVER JUMPER (BY-PASS) ANY SAFETY

DEVICE. DAMAGE, OR PERSONAL

INJURY COULD RESULT. USE AN OHM

METER FOR CHECKING CONTINUITY

ON SAFETY DEVICES.

WARNING!

TROUBLESHOOTING PROCEDURES, AS

OUTLINED IN THIS SECTION, MUST BE

PERFORMED BY QUALIFIED SERVICE

PERSONNEL.

7.1 LOW GAS PRESSURE

The LOW GAS PRESSURE message indicates that gas pressure has gone below 7” W.C., tripping the low gas pressure switch.

7.1.1 LOW SUPPLY GAS PRESSURE

7.1.2 GAS PRESSURE SWITCHES

Recommended Troubleshooting Equipment:

16” Manometer

Analog or Digital Ohmmeter

7.1.1 LOW SUPPLY GAS PRESSURE

1. Install a manometer in the unit manifold as per Section 4.2.1

2. Check the static pressure to the unit. It should be 10” to 12” W.C

3. If the static pressure to the unit is lower than 10” W.C., readjust the supply regulator until it’s output is 10” to 12” W.C. If a static supply pressure of 10” to 12” W.C. cannot be obtained, proceed to Step 8.

4. If static pressure is already 10” to 12” W.C. or you have readjusted the static supply pressure, start the unit.

5. If gas pressure drops to below 7” W.C. during the Ignition cycle, proceed to Step 8.

6. If gas pressure does not drop below 7” W.C. in any one of the above steps slowly increase the input percentage in steps of 10% while monitoring gas pressure.

7. If gas pressure drops below 7“ W.C. tripping the gas pressure switch, proceed to step 8.

8. If gas pressure stays within the unit’s specifications of 8.5” at maximum firing rate and has a maximum static pressure of 14” proceed to Section 7.1.2.

9. Check the gas pressure to the unit’s supply regulator. It should be 14” W.C. or greater. If the supply pressure is 14” W.C. or greater, check the supply regulator and supply piping for correct sizing.

7.1.2 GAS PRESSURE SWITCHES

1. If static pressure to the unit is correct, disconnect electric power to the unit. Remove wires #20 & #32 from the low gas pressure switch.

2. Using an ohmmeter, check the gas pressure switch for continuity. supply to the unit is on.

3. Replace the switch if it does not show continuity.

4. If the switch shows continuity, reconnect wires #20 and #32 to the switch. Remove the 15-pin connector from the control panel.

Be sure that the gas

TROUBLESHOOTING

5. Referring to system schematic 161412 in the Appendix, locate and check continuity in wires #20 and #32 from the fifteen pin connector through the switch and back to the connector.

6. If there is no continuity connectors at the switch end of the wires. Check the pins in the 15-pin connector for proper insertion or signs of wear.

7. If the 15-pin connector and the switch connections are okay, reconnect the 15-pin connector to the control panel. Restore electric power.

If the gas pressure fault does not clear it will be necessary to troubleshoot the control panel. Contact a qualified service technician or your local AERCO representative for more information.

7.2 HIGH EXHAUST TEMPERATURE

A HI EXHAUST TEMP message indicates that the exhaust temperature has exceeded 500 This fault only indicates on the display and WILL NOT SHUT DOWN the unit. The fault LED and the fault relay will trip indicating the fault.

A high exhaust temperature is an indication that the unit has a carbon coating on the fireside of the heat exchanger exhaust tubes. This condition results in a loss of heat transfer and therefore high exhaust temperatures. Carbon buildup can be due to due to improper combustion calibration, a defective air or fuel component, improper stop\start levels or improper supply gas pressure. The unit should be combustion calibrated to determine if one of the above is responsible. Refer to section 4.4 for combustion calibration, or contact your local AERCO representative further assistance.

check for loose

2. Using an accurate temperature measurement device, measure the actual flue gas temperature. If the exhaust sensor measurement is less than 500 pressing the clear button does not clear the fault message, shut the unit off and remove AC power from the unit.

3. Disconnect the exhaust sensor wires from the field wiring box.

4. Check continuity between the sensor wires. (ensure that the sensor has cooled below

400°). If there is continuity exhaust sensor.

5. If there is no continuity and the exhaust temperature fault will not clear, combustion calibrate the unit as per Section 4.4.

F, and

replace the

7.3 LOW WATER LEVEL

A LOW WATER LEVEL message indicates that water level in the unit is too low. Check that the shutoff valves on the supply and return of the unit are open and that there is water in the shell. (Momentarily opening the relief valve and looking for a strong flow of water will verify that the unit shell has sufficient water level). If the unit has water sufficient water level try to reset the unit by pressing the low water level reset button and the Annunciator clear button. If the unit fires but the message will not clear, replace the Annunciator. If the unit does not fire and the message will not clear, check the following.

7.3.1 Water Level Probe

7.3.2 Wiring & Connections

7.3.3 Water level Circuit

Recommended Troubleshooting Equipment

• Digital Volt/Ohmmeter

7.2.1 Exhaust Temperature Sensor

7.2.2 Wiring & Connections

Recommended Troubleshooting Equipment

Digital Ohmmeter

Digital Temperature Meter

7.2.1 EXHAUST TEMPERATURE SENSOR

1. Start the unit and wait for the HI EXHAUST TEMP. message to display

7.3.1 WATER LEVEL PROBE

1. Disconnect the electric power to the unit.

2. Remove the unit cap and remove wire #25 from the water level probe.

3. Connect an AC voltmeter between wire #25 and the unit frame.

4. Reapply electrical power to the unit. The AC voltmeter should read approximately 12 VAC. If approximately 12 VAC is not read on the AC voltmeter, proceed to section 7.3.2.

TROUBLESHOOTING

5. If 12 VAC is read on the AC voltmeter, disconnect power to the unit and ground the probe to the unit shell.

6. Restore electrical power to the unit. If the fault does not clear, proceed to section

7.3.3. If the fault clears replace the probe.

7.3.2 WIRING AND CONNECTIONS

1. Disconnect electric power to the unit.

2. Disconnect wire #25 from the water level probe and unplug the 9-pin connector from the control box.

3. Referring to system schematic 161412 in the Appendix, locate wire #25.

4. Using an ohmmeter check wire #25 for continuity

5. If wire #25 does not have continuity, repair as necessary.

6. If wire #25 has continuity, check the probe end of the wire for a loose connector.

7. Check the pin in the 9-pin connector for proper insertion or signs of wear.

8. If the connector and pin are okay, reconnect wire #25 to the water level probe.

9. Restore the 9-pin connector to the control panel.

10. Restore electric power to the unit. If the water level fault does not clear, see Section

7.3.3.

7.3.3 WATER LEVEL CIRCUIT

1. Remove power from the unit.

2. Open the control panel to expose the wiring and internal components.

WARNING!

This a 120 VAC system.

A shodk hazard exists.

3. Locate the low water level switch as shown in Appendix E.

4. Remove wires #96 and #99 from terminals LLCO and G.

5. Using an ohm meter between wire #96 in the control box

wire # 25 on the unit. Also check continuity between wire #99 in the control box and the unit’s shell or frame.

check continuity

and

6. If there is no continuity repair as necessary. If there is continuity, replace the low water level circuit.

7.4 HIGH WATER TEMPERATURE

A HIGH WATER TEMPERATURE fault indicates when the temperature of the discharge water has exceeded the setpoint of the over temperature switches.

First try to clear the fault message from the Annunciator and start the unit. If the unit fires but continues to display a HIGH WATER TEMP message, replace the Annunciator. If the fault message will not clear and the unit does not fire check the following.

7.4.1 Determining the Cause

7.4.2 Over Temperature Limit Switches

7.4.3 BTU Transmitter Pump

7.4.4 Temperature Sensors

Recommended Troubleshooting Equipment

Digital Voltmeter

Digital Ohmmeter

7.4.1 DETERMINING THE CAUSE

Remove the unit cap to expose the over temperature limit switches. Check the setpoint of the unit and the setpoint of the lower over temperature switch. The lower over temperature switch must be set a minimum of 20 than the setpoint of the unit. Make adjustments if necessary.

1. If the over temperature switch was correctly set, 20°F above the unit setpoint, check that the feedback is set to ON in the temperature controller.

2. If the feedback was on, check that the 3 ball valves on the BTU Transmitter are open.

3. Check that the BTU transmitter is running. If the pump is not running, proceed to section

7.4.3.

4. If all the above are okay but the High Water Temp fault persists, recalibrate the unit for temperature control as per Section 4.7.

5. If the unit cannot be temperature calibrated, The BTU transmitter must be checked for scale or blockage as per Maintenance Section 6.7.

6. If the BTU transmitter has no blockage or scale, check the temperature sensor probes as per Section 7.4.4.

F higher

TROUBLESHOOTING

7. Reset the unit and if necessary, the upper over-temperature limit switch. If the unit will not reset proceed to section 7.4.2.

7.4.2. OVER TEMPERATURE LIMIT

SWITCHES

1. Disconnect electrical power to the unit.

2. Raise the temperature limit switch setpoint a minimumof 10 water temperature.

3. Referring to system schematic 161412 in Appendix F, remove wires #18 and #33 from the lower switch and wires #19 and #33 from the upper switch.

4. Using an ohmmeter, check for continuity across the C, common, and NC, normally closed, terminals of both switches.

5. Replace the switches if either or both show no continuity

6. If the switches show continuity, disconnect the 15-pin connector from the control panel.

7. Using an ohmmeter, check wires #18, #19 and #33 back to the 15-pin connector for continuity.

8. Check for loose connectors on the switch end of wires #18, #19 and #33.]

9. Check the pins of the 15-pin connector for proper insertion or wear.

10. If the connectors, pins, and continuity are okay, restore wires #19 and #33 to the lower switch and wires #18 and #33 to the upper temperature switch.

11. Restore the 15-pin connector to the control panel.

12. Reapply electrical power to the unit.

13. If the over temperature fault does not clear consult your local AERCO representative or contact aqualified service technician.

F above the actual discharge

7.4.3 BTU TRANSMITTER PUMP

1. Disconnect electric power to the unit.

2. Referring to system schematic 161412 in Appendix F, locate wires #10, #30, and #31.

3. Remove the wire nuts from wires #10 and #31 and connect an AC voltmeter across wires #10 and #31.

4. Restore electric power to the unit.

5. If there is 120 VAC across wires #10 and #31, and the pump is not runing, replace the pump.

6. If 120 VAC is not present across wires #10 and #31, disconnect electric power to the unit.

7. Disconnect the 9-pin connector from the control panel and remove the cover from the unit’s AC wiring box.

8. Check for continuity in wires #10, #30 and #31. Check for loose connections on wires #30 and #31 located in the AC wiring box.

9. Check the pin in the 9-pin connector for proper insertion or signs of wear.

10. If all wire connectors and pins are okay, replace the control panel.

7.4.4. TEMPERATURE SENSORS

1. Close off the shutoff valves on the water inlet and outlet lines of the unit. Close off any recirculation lines to the unit.

2. Drain the unit while venting the shell, through the relief valve, until a water level fault light is observed.

3. Drain slightly more, then close the drain valve.

4. Close off the three ball valves on the BTU transmitter assembly.

5. Disconnect and remove the BTU transmitter sensor.

6. Remove the unit cap. Disconnect and remove the header sensor.

7. Allow the sensors to cool to ambient temperature.

8. Referring to the Temperature Sensor Chart in Appendix C of this manual, measure the resistance of the probe and determine the corresponding temperature from the chart.

9. Compare the reading with the ambient room temperature. If there is a significant discrepancy, greater than 10 erroneous sensor.

F, replace the

TROUBLESHOOTING

10. Place the entire length of the sensors in a water bath of known temperature. Measure the resistance of the probe, and determine the corresponding temperature from the temperature sensor chart. If there is a significant discrepancy, greater than 10°F then replace the sensor.

11. Disconnect the 6 pin connector from the control panel.

12. Referring to system schematic 161412 in Appendix F, locate wires #1, #2, #3, #4 and #5.

13. Check all wires for continuity and all connectors for proper pin insertion and/or worn pins. Repair as necessary.

14. If the sensors wiring and connectors are okay. Place a 1000Ω ± 1% accuracy resistor across the pins in the plugs that the sensors were removed from.

NOTE:

The resistors must be placed across the

pins simultaneously to get accurate

readings.

NOTE:

If the sensors are removed and power is

applied to the unit the message bAd.I nP will

be displayed on the temperature control.

To clear this error press and hold the

INDEX and ENTER buttons simultaneously.

15. Reapply power to the unit.

16. Check the temperature control displays tout in the primary menu and FFt in the secondary menu. They should both read 70°F ± 10°F.

17. Place a 1.3 KΩ ± 1% resistor across the pins in the plugs that the sensors were removed from.

18. The temperature controller displays tout in the Primary menu and FFt in the Secondary menu should read 196° F ±10° F.

19. If the temperatures displayed are not within tolerance the control should be replaced.

NOTE

If the display reads UFL or OFL or bAd InP,

this is an indication that the sensor wires

are shorted or in an open circuit condition,

which may indicate a wiring problem.

20. If the sensors wiring and connectors are okay, reinstall the sensors.\

21. Reconnect the connectors to the sensors and control panel, ensuring that they lock firmly into place.

22. Refill the unit as per Section 2.8.1.

23. Restore electrical power to the unit.

7.5 LOCKOUT RUN FLAME

A LOCKOUT RUN FLAME message indicates that the flame signal was lost after the unit proved flame and was released to modulate. A FLAME FAULT DURING IGN TRIAL message indicates that flame was not recognized during the ignition trial period.

7.5.1 Flame Fault While Firing

7.5.2 Flame Fault During Ignition Cycle

7.5.3 Safety Shut Off Valve

7.5.4 Spark Ignitor

7.5.5 Flame Detector

7.5.6 Ignition Circuit

7.5.7 Air Fuel Valve Ignition Position witch

7.5.8 Flame Detector Voltage

7.5.9 Residual Flame

Recommended Troubleshooting Equipment

Digital or Analog Voltmeter

Combustion Analyzer

and 16” Manometers

7.5.1 FLAME FAULT WHILE FIRING

1. Install a DC voltmeter in the flame test jacks located on the front of the combustion safeguard. Start the unit in manual mode

2. Once flame is established, a steady reading of approximately 5 VDC should be observed.

3. While in manual mode, fire the unit at various firing rates (i.e., 16%, 30%, 50%, 100% etc.)

4. If flame signal is erratic at any time during the test, combustion calibrate the unit as per Section 4.this manual.

5. If combustion calibration is okay, remove the burner and inspect it for debris that may have fallen on it.

7.5.2 FLAME FAULT DURING IGNITION

TRIAL

1. Check that all gas supply valves are open

TROUBLESHOOTING

2. If the gas supply valves were open, restart the unit.

3. Remove the cover to the Air Fuel Valve. Ensure that the Air Fuel Valve rotates to the ignition position, and engages the ignition position switch. If the air\fuel valve does not

rotate to the ignition position Section 7.7.7.

4. If the air\fuel valve rotates and engages the ignition position switch during the trial for ignition, then visually watch/inspect the safety shutoff valve, through the window on the actuator half, to determine if it is opening.

proceed to

NOTE:

At the ignition cycle, the low fire switch is

made, and the safety shutof f valve is

energized. The OPEN disk in the safety

shut-off valve actuator window should

slowly move downward indicating that the

valve is operating correctly. If the valve

does not open, proceed to Section 7.5.3

5. If the safety shutoff valve opens, check the spark ignitor as per Section 7.5.4 and the flame detector, as per Section 7.5.5.

6. If the spark ignitor and flame detector are okay, or require replacement and the flame fault persists, check the ignition circuit as per Section 7.5.6.

7. If the flame fault persists after checking the above, measure the flame detector lead voltage as per Section 7.5.8.

8. If the flame fault persists, after checking the above, remove the burner and inspect for debris.’

9. If the flame fault persists after the above, replace the combustion control.

7.5.3 SAFETY SHUTOFF VALVE

1. Start the unit.

2. When the starting sequence reaches the Ignition trial cycle, observe the response of the safety shutoff valve through the window in the actuator portion

3. If the actuator does not open the valve, disconnect electrical power to the unit.

4. Remove the actuator portion from the valve body and inspect for signs of leaking hydraulic fluid.

5. If the actuator is not leaking, set it back on the valve body and remove the cover plate exposing the control wiring.

6. Temporarily re-secure the actuator to the valve body with the control wiring facing outward for easy access.

7. Referring to system schematic 161412 in Appendix F, connect an AC voltmeter across wires #14 and #28.

8. Restore electrical power to the unit.

9. Start the unit.

10. At the ignition trial cycle 120 VAC should be observed on the AC voltmeter.

11. If 120 VAC is observed on the voltmeter, replace the safety shutoff valve actuator.

12. If 120 VAC is not observed on the AC voltmeter, disconnect electrical power to the unit.

13. Disconnect the 9-pin connector from the control panel, and remove the cover from the AC wiring box.

14. Referring to system schematic 161412 in Appendix F, locate wire's #14, #28 and #27 and check each for continuity.

15. Check each wire for loose connectors at the safety shut-off valve end. Check wires #28 and #27 for loose connectors in the KC1000 AC wiring box

16. Check the pin on wire #9 at the 9-pin connector end, for proper insertion or wear.

17. If all wires show continuity and all connections are okay, reconnect wire's #14, #28 and #29 to the safety shutoff valve and wires #28 and #29 to their proper locations in the AC wiring box.

18. Replace the cover plates on the safety shutoff valve actuator and the AC wiring box.

19. Reconnect the 9-pin connector to the control panel ensuring that it locks into place.

TROUBLESHOOTING

20. Restore electrical power to the unit and restart the unit.

21. If the safety shutoff valve still does not open, proceed to section 7.7.8.

22. Be sure to return the safety shutoff valve to its original position and replace all cover plates.

7.5.4 SPARK IGNITOR

1. Disconnect electrical power to the unit.

2. Remove the spark ignitor as per Maintenance Section 6.3 of this manual.

3. Inspect the ignitor for signs of erosion.

4. Replace the ignitor if eroded.

Check for carbon buildup on the ignitor.

5. If there is carbon build-up on the ignitor, the combustion calibration settings must be checked as per Section 4. If the spark ignitor is not eroded, it may be cleaned and reused.

7.5.5 FLAME DETECTOR

1. Disconnect electrical power to the unit.

2. Remove the flame detector as per Maintenance Section 6.3.

3. Check the detector for signs of erosion or carbon buildup.

4. If the flame detector is eroded, replace it. Otherwise, clean it using emery cloth.

5. Carbon buildup on the flame detector indicates that unit may require combustion calibration.

6. Check the combustion calibration settings as per Start-Up Sections 4.3 and 4.4.

7.5.6 IGNITION CIRCUIT

1. Disconnect electrical power to the unit.

2. Close the manual-leak detection valve, located between the safety shutoff valve and the differential pressure regulator, on the unit’s gas manifold.

3. Using either a spare ignitor, connect the ignition cable directly to the ignitor.

4. Ground the ignitor to the frame of the unit.

5. Restore electrical power to the unit.

6. Start the unit.

7. At ignition, an arc should be observed. It should last for approximately 15 seconds.

8. If there is no arc, disconnect electrical power to the unit.

WARNING!

ELECTRIC SHOCK HAZARD. THE

SECONDARY OF THE IGNITION

TRANSFORMER HAS A POTENTIAL OF

6000 VOLTS. DO NOT HOLD OR TOUCH

ANY IGNITION CIRCUI T COMPONENTS

WHILE TESTING.

9. Remove the ignition cable and check it for continuity or loose connections.

10. Replace the cable if there is no continuity. If there is a loose connection, replace or repair the cable as necessary.

11. If the ignition cable is okay, remove the ignition transformer cover plate.

12. Referring to system schematic 161412 in Appendix F, locate wires #12 and #29.

13. Connect an AC voltmeter across wires #12 and #29.

14. Restore electrical power to the unit and start the unit.

15. At the ignition cycle check for 120 VAC across wires #12 and #29.

16. If 120 VAC is observed across wires #12 and #29, replace the ignition transformer.

17. If 120 VAC is not observed on the AC voltmeter during the Ignition cycle, disconnect electrical power to the unit.

18. Disconnect the 9-pin connector from the control panel, and wires #12 and #29 from the ignition transformer.

19. Remove the cover plate from the AC wiring box.

20. Referring to system schematic 161412 in the Appendix, check wires #12 and #29 for continuity.

TROUBLESHOOTING

21. If wires #12 and #29 have continuity, inspect the pin on wire #12 in the 9-pin connector for proper insertion or signs of wear

22. Inspect the connector on wire #29 at the AC wiring box end for a loose connection.

23. Make any necessary repairs.

24. Once all wiring and connections have been inspected or repaired, reconnect wires #12 and #29 to the ignition transformer. Reconnect wire #29 to its proper position in the AC wiring box.

25. Reconnect the 9-pin connector to the control panel ensuring it is locked into place.

26. Reinstall the cover plates on the ignition transformer and the AC wiring box.

27. Be sure to reinstall the spark ignitor and ignitor contactor if necessary and reconnect the ignition cable to the ignition transformer and the ignition contactor.

28. Reopen the leak detection valve.

29. Restore electrical power to the unit and start the unit.

7. If 345 VAC is not observed, disconnect electrical power to the unit.

8. Disconnect the 9-pin connector from the control panel.

9. Referring to system schematic 161412 in Appendix F, locate wire #9.

10. Check wire #9 for continuity

11. Check the flame detector end of wire #9 for loose connections. Inspect the pins in the 9pin connector for proper insertion and signs of wear.

12. Repair if necessary.

13. If wire #9 has continuity and all connections are okay or a repair was performed, reconnect the flame detector lead to the flame detector. Reconnect the 9-pin connector to the control panel.

14. Restore electrical power to the unit and restart the unit.

15. If the flame fault persists, replace the combustion control.

30. If the flame fault persists, replace the Combustion Control

7.5.7 FLAME DETECTOR VOLTAGE

1. Disconnect electrical power to the unit.

2. Remove the flame detector lead wire from the flame detector.

3. Connect an AC voltmeter between the flame detector lead wire and the unit’s frame.

WARNING!

A SHOCK POTENTIAL OF 230 TO 400

VAC EXISTS ON THE FLAME DETECTOR

LEAD WIRE.

4. Restore electrical power to the unit.

5. An AC voltage reading of approximately 345 VAC should be observed.

6. If 345 VAC is observed, proceed to Section

7.6.2, Step 8.

7.5.8 RESIDUAL FLAME

Once the KC1000 has stopped firing, it continues to monitor the flame circuit. If a residual flame exists, the unit will indicate a LOCKOUT fault. The source of a residual flame is a leaking safety shutoff valve. To check for a leaking safety shutoff valve proceed as follows:

1. Shut the unit off by switching the ON-OFF switch to the Off position

2. Locate the leak detection valve, between the safety shutoff valve and the differential pressure regulator.

3. Shut the valve and remove a set-screw from its 1/8” leak detection port.

4. Install an 8” or 16” manometer.

5. Monitor the manometer for signs of an increase in gas pressure.

6. If there is an increase in gas pressure, replace the gas train.

TROUBLESHOOTING

7.6 LOCKOUT RUN AIR FLOW

A LOCKOUT RUN AIR FLOW indicates that the air pressure while running is too low for operation. Oscillations or rumbling of the unit is also a common cause of Air Pressure faults.

7.6.1 Determining the Cause of the Fault

7.6.2 Oscillations

7.6.3 Blower

7.6.4 Blower Proof Switch

7.6.5 Solid State Relay

Recommended Troubleshooting Equipment

AC Voltmeter

Ohmmeter

7.6.1 DETERMINING THE CAUSE OF THE FAULT

1. Clear the Annunciator and restart the unit.

2. If the unit does not fault after proving flame, proceed to Section 7.6.2.

3. If the blower does not start Section 7.6.3.

4. If the blower starts but the Annunciator displays LOW AIR FLOW, proceed to Section 7.6.4.

5. If the unit has sealed combustion air ducted in right up to the blower, check the ducting for blockage.

proceed to

3. If a rumbling sound is heard when approaching firing rates above 75%, combustion calibrate the unit as per section 4 of this manual.

7.6.3 BLOWER

1. Disconnect power to the unit.

2. Remove the cover plate from the AC wiring box.

3. Locate wire #13 and the blower hot lead wire inside the AC wiring box. They will be the only two wires connected by a wire nut.

4. Remove the wire nut and separate wire #13 from the blower hot lead wire.

5. Connect an AC voltmeter between wire #13 and the unit frame.

6. Restore electrical power to the unit.

7. Restart the unit.

8. The AC voltmeter should display 120 VAC.

9. If 120 VAC is not displayed, proceed to section 7.6.5.

10. If 120 VAC is displayed, check the blower capacitor using an analog ohmmeter or substitute the capacitor.

11. If the capacitor is okay or has been substituted and the blower still does not start, replace the blower.

6. If combustion air is ducted into the room or brought in through a louver, ensure that the sizing is adequate and that the louvers are open while the unit is firing.

7.6.2 OSCILLATIONS

Oscillations, also known as rumbling, typically occur when the air/fuel mixture is too lean. This causes the flame to burn at various distances from the burner at a rapid pace. Oscillations create pressure waves that can trip the air pressure switch shutting the unit down on an air pressure fault.

1. Start the unit in manual mode. Be sure to have sufficient water flow through the unit to avoid over temping.

2. Slowly increase the firing rate percentage while listening to the unit.

7.6.4 BLOWER PROOF SWITCH

1. Remove wires #17 and #24 from the blower proof switch

2. Connect an ohmmeter across the blower proof switch and restart the unit.

3. The blower proof switch should show continuity with the blower running.

4. If the blower proof switch does not show continuity, remove the switch and check for signs of blockage. Remove any debris and reinstall the switch. Retest as per Steps 2 through 3.

5. If the blower proof switch shows continuity, disconnect electrical power to the unit.

6. Disconnect the 15-pin connector from the control panel.

TROUBLESHOOTING

7. Referring to system schematic 161412 in Appendix F, locate wire #17 and #24 and check both for continuity.

8. Check the switch end of wires #17 and #24 for loose connections.

9. Check the pins on the 15-pin connector for proper pin insertion or wear.

10. If continuity, the connector, and pins are okay, reconnect wires #17 and #24 to the blower proof switch.

11. Reconnect the 15-pin connector to the control panel.

12. Restore electrical power to the unit and start the unit.

13. If the blower proof fault persists, replace the Combustion Control

7.6.5 SOLID STATE RELAY

1. Open the control box and locate the solid state relay.

2. Locate wire 81 on terminal 6 of the relay. Measure the AC voltage on terminal 6 when the unit is attempting to start. There should be 120 VAC on terminal 6 at this point

3. If there is 120 VAC on terminal 6 and the blower still does not start, replace the solid state relay.

4. If 120 VAC is not measured, replace the combustion safeguard chassis.

7.7 SYSTEM FAULT

A system fault indicates when the unit faults during the starting sequence, but prior to ignition. An internal 30-second fault timer starts timing when the unit start sequence is initiated. If ignition is not reached within the specified time, the Annunciator displays the message SYSTEM FAULT LOW AIR PRESSURE or PURGE INTERLOCKS depending on the cause. A system fault usually occurs when the system does not acknowledge either the safety shutoff valve proof of closure switch, the blower proof switch, or the air/fuel valve open switch.

7.7.1 Determining the cause.

7.7.2 Blower

7.7.3 Combustion Air Supply and Blower Proof Switch

7.7.4 Purge Interlocks

7.7.5 SSOV Proof of Closure Switch

7.7.6 Air/Fuel Valve Open Proving Switch

7.7.7 Air Fuel Valve not Rotating

Recommended Troubleshooting

Equipment

AC Voltmeter

Ohmmeter

7.7.1 DETERMINING THE

1. Clear the Annunciator and restart the unit.

2. If the unit does not fire SYSTEM FAULT LOW AIR PRESSURE is

displayed

3. If the unit does not fire a and the message SYSTEM FAULT PURGE INTERLOCKS is displayed proceed to section 7.7.4.

4. If the unit does not fire and the message SYS FLT is displayed on the temperature controller but the Annunciator does not display a fault proceed to section 7.7.8.

proceed to section 7.7.2.

CAUSE

and the message

7.7.2. BLOWER

1. Disconnect power to the unit

2. Remove the cover plate from the AC wiring box

3. Locate wire #13 and the blower hot lead wire inside the AC wiring box. These will be the only two wires connected by a wire nut.

4. Remove the wire nut and separate wire #13 from the blower hot lead wire.

5. Connect an AC voltmeter between wire #18 and the unit frame.

6. Restore electrical power to the unit.

7. Restart the unit.

8. The AC voltmeter should display 120 VAC.

9. If 120 VAC is not displayed, replace the control panel.

10. If 120 VAC is displayed, check the capacitor using an analog ohm meter or substitute the capacitor.

11. If the capacitor checks okay or is substituted and blower still does not start, replace the blower.

TROUBLESHOOTING

7.7.3 AIR SUPPLY AND BLOWER PROOF SWITCH

1. If the unit has sealed combustion, check the ducting for any signs of blockage

2. If combustion air is brought in through an opening in a wall, be sure that the size of the opening is adequate and that louvers are open while the unit is firing. (Refer to AERCO GF-1050 for sizing.)

3. If the combustion air supply is okay, remove wires #17 and #24 from the blower proof switch.

4. Connect an ohmmeter across the blower proof switch and restart the unit.

5. The blower proof switch should show continuity while the blower is running.

6. If the blower proof switch does not show continuity, remove the switch and check for signs of blockage. If blockage is present, clean the switch and retest.

7. If the blower proof switch shows continuity, disconnect electrical power to the unit.

8. Disconnect the 15-pin connector from the control panel.

9. Referring to system schematic 161412 in Appendix F, locate wires #17 and #24 and check both for continuity.

10. Check the switch end of wires #17 and #24 for loose connections.

11. Check the connector end for worn pins and/or proper pin insertion.

12. If continuity, the connectors, and pins are okay, reconnect wires #17 and #24 to the blower proof switch.

13. Reconnect the 15-pin connector to the control panel.

14. Restore electrical power to the unit and start the unit.

15. If the SYSTEM FAULT LOW AIR PRESSURE fault persists, replace the control panel.

7.7.4 PURGE INTERLOCKS

If SSOV proof of closure switch or the air\fuel valve purge position switch fail to prove during the start sequence, the unit will shut down and

the Annunciator will display the message SYSTEM FAULT, PURGE INTERLOCKS. To determine the cause of the fault perform the following:

1. Remove the Air\Fuel valve cover.

2. Clear the Annunciator and restart the unit.

3. If the Annunciator displays the message PURGE INTLK OPEN and the air\fuel valve does not rotate, proceed to section 7.7.7.

4. If the air\ fuel valve rotates to its full open position and engages the valve open proving switch, and the Annunciator still displays SYSTEM FAULT, PURGE INTERLOCKS, proceed to section 7.7.6.

7.7.5 SSOV PROOF OF CLOSURE

SWITCH

1. Disconnect electrical power to the unit.

2. Loosen the two set screws holding the safety shutoff valve actuator to the safety shutoff valve body.

3. Rotate the actuator portion clockwise exposing the cover plate and tighten the two previously loosened set screws.

4. Remove the cover plate exposing the control wiring

5. Referring to the system schematic 161412 in Appendix F, remove wires #21 and #22 from the proof of closure switch.

6. Connect an ohm meter across the NC, normally closed, and the C, common, terminals.

7. The switch should show continuity. If it does proceed to step 16.

8. If the switch does not show continuity, remove the actuator from the valve body.

9. Looking at the actuator from the bottom, push on the lever closest to the bottom of the actuator.

10. Observe the ohm meter while pushing on the lever. Pushing downward on the lever should make continuity. Releasing the lever should break continuity

11. If continuity makes and breaks, slightly bend the arm toward the bottom of the actuator.

TROUBLESHOOTING

12. Reset the actuator onto the valve body while observing the ohm meter

13. If continuity is now okay, reconnect wires #21 and #22, replace the cover plate and reassemble the actuator to the valve body

14. If there is no continuity, replace the actuator or switch

15. Restart the unit. If the unit sequence resumes normal operation, proceed no further. If the Lockout persists, proceed to Step 16.

16. Disconnect electrical power and remove wires #21 and #22 from the proof of closure switch. Disconnect the 15-pin connector from the control panel.

17. Referring to system schematic 161412 in the Appendix, locate wires #21 and #22, check each for continuity using an ohm meter.

18. Check for loose connectors at the proof of closure switch end.

19. Check wires #21 and #22 at the control panel connector for worn pins and/or proper pin insertion.

20. Repair as necessary.

21. If connections and continuity are okay, reconnect wires #21 and #22 to the proof of closure switch and reconnect the 15-pin connector to the control panel ensuring it locks into place.

22. Replace the cover plate on the actuator and reposition the actuator on the valve body and lock into place using the set screws.

23. Restore electrical power to the unit.

24. Restart the unit. If the condition persists, contact a certified Aerco Service personnel or your local Aerco representative.

7.7.6 AIR/FUEL VALVE OPEN PROVING

SWITCH

1. Remove the air/fuel valve cover.

2. Restart the unit.

3. If the air/fuel valve rotates to its full open position and engages the valve open proving switch, proceed to Step 5.

4. If the air/fuel valve does not rotate, proceed to 7.7.7.

5. Disconnect electrical power to the unit.

6. Referring to system schematic 161412 in Appendix F, locate wires #59 and #60. Remove wires #59 and #60 from the air/fuel valve open proving switch, noting their location. (The air/fuel valve open proving switch is the one closest to the blower.)

7. Connect an ohm meter across the terminals of the switch, where wires #59 and #60 were located

8. Manually depress the switch and check the ohm meter for continuity.

9. If the switch does not show continuity, replace the switch.

10. If the switch shows continuity, disconnect the 12-pin connector from the control panel.

11. Referring to system schematic 161412 in Appendix F, locate wires #59 and #60. Check wires #59 and #60 for continuity.

12. Check for loose connectors, at the switch end, of wires #59 and #60.

13. Check the 12-pin connector end for worn and/or properly inserted pins.

14. If connections and continuity are okay, replace wires #59 and #60 and rconnect the 12-pin connector to the control panel and restart the unit.

15. If the fault persists, restart the unit and check for AC voltage at wires #59 and #60.

16. If 120 VAC is present, go to section 7.7.3.

17. If 120VAC is not present proceed to section

7.7.5.

7.7.7 AIR/FUEL VALVE NOT ROTATING

1. Disconnect electrical power to the unit.

2. Remove the air/fuel valve cover.

3. Check for loose wires at the wire nuts connecting the air/fuel valve wiring harness to the stepper motor.

4. Holding the coupling between the top of the stepper motor and the potentiometer with your thumb and forefinger, rotate the valve.

NOTE:

Do not rotate the air/fuel valve with power

applied to the unit.

5. If the air/fuel valve does not rotate or is extremely difficult to rotate, replace the air/fuel valve.

6. Disconnect the 12-pin connector from the control panel. Referring to schematic 161412 in Appendix F, check all wires for continuity.

7. Check all the pins in the 12-pin connector for proper insertion or signs of wear

8. If all connections, continuity, and the rotation of the air/fuel valve in Step 4 were okay, open the control box to expose the wiring and components

9. Locate the air\fuel valve stepper motor driver board.

10. Ensure the connectors and wires are not loose and are making good contact.

11. If the wiring to the driver board is okay, place a voltmeter across terminals 7 and 8 on the back of the temperature controller.

12. Apply power to the unit.

13. Place the ON-OFF switch in the off position.

14. Measure the DC voltage across these two terminals. It should be 15 V ± 2 V

15. Place the ON\OFF switch in the On position

16. Measure the DC voltage again it should be approximately 3 volts DC during PURGE and 1 to 1.3 volts during ignition.

17. If the voltage is correct motor driver board.

18. If the voltage remains at 15 V ± 2 VDC during PURGE or remains at 3 V DC during ignition replace the relay board.

19. If the DC voltage is at 0 VDC temperature control.

replace the stepper

replace the

TROUBLESHOOTING

2. Remove the air/fuel valve cover

3. Referring to system schematic 161412 in Appendix F, locate wires #60 and #61. Remove wires #60 and #61 from the air/fuel valve ignition position switch, noting their position. (The air/fuel valve ignition position switch is the one closest to the shell of the unit.)

4. Place an ohm meter across the terminals of the switch, where wires #60 and #61 were located

5. Manually depress the switch and check the ohm meter for continuity.

6. If the switch shows continuity, proceed to Step 8.

7. If the switch does not show continuity, replace the switch.

8. Disconnect the 12-pin connector from the control panel.

9. Referring to system schematic 161412 in Appendix F, locate wires #60 and #61. Check wires #60 and #61 for continuity.

10. Check for loose connectors, at the switch end of wires #60 and #61.

11. Check the 12-pin connector end for worn and/or properly inserted pins.

12. If continuity, pins and connections are okay, reattach wire #60 and #61 to the air/fuel valve ignition position. Reconnect the 12-pin connector to the control panel and restart the unit.

13. If the system fault persists local AERCO representative for further assistance.

contact your

7.7.8 AIR/FUEL VALVE IGNITION POSITION SWITCH

1. Disconnect electrical power to the unit.

APPENDICES

APPENDIX A

Temperature Controller Menus

APPENDIX B

Temperature Controller Quick Programming Guide

APPENDIX C

Temperature Sensor Resistance Chart

APPENDIX D

Mode of Operation Default Settings

APPENDIX E

Dimensional & Parts Drawings

APPENDIX F

Piping Drawings

APPENDIX G

Wiring Schematics

APPENDIX H

Control Box isometric drawing

PRIMARY MENU ITEM DESCRIPTIONS

APPENDIX A

tout

pct

Setp

This is the actual outlet water temperature of the heater. It is designated by the code (tout).

Setpoint is the desired outlet water temperature that is to be maintained by the heater when operating in automatic mode.

Auto

When set to automatic mode the temperature 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 upper display shows OFF and the controller no longer automatically controls the firing rate of the heater. It is up to the operator who put it into manual mode to control the outlet temperature and firing rate.

Secondary Menu Item Description

APPENDIX A

FUNC

tout

FFt

Pct

This indicates the mode of operation the temperature controller is in. Common modes are Oart, indoor\outdoor reset, Cont, constant setpoint, and FDFO for a water heater.

Displays the current outlet wa ter temperature of the heater.

Displays the temperature of the BTU transmitter sensor. Note: this temperature will be less than “tout” when there is flow through the heater.

Displays the output percentage of the heater. It can be adjusted when in manual mode.

SetP

SEnS

Displays the desired outlet water temperature of the heater.

This is maximum load adjust used during a water heater temperature calibration. It adjusts the controllers sensitivity relative to the temperature of the BTU transmitter sensor. This should be adjusted when the output of the controller is greater than 40% and th oulet temperature is below the desired setpoint temperature.

APPENDIX A

OFSt

LLt

HLt

This is minimum load adjust used during a water heater temperature calibration. It adjusts the controller’s linear offset relative to the temperature of the BTU transmitter sensor. Similar to SEnS it is adjusted when the controllers output is less than 30%.

This is the Low Limit Temperature. It is the minimum value that the Setpoint, (SetP), can be set to.

This is the High Limit Temperature. It is the maximum value that the controllers setpoint, (SetP), can be adjusted to.

Pb1

int

drt

This is the Proportional Band in °F for the feedback of the controller. This feature is useful in correcting outlet temperature errors when under steady load conditions.

This is the integral rate, in minutes, for the feedback of the controller.

This is the derivative rate in % / .1°/sec. This is used to adjust the response time to temperature changes at the outlet of the heater.

iii

Fdb

Addr

lore

APPENDIX A

Turns the outlet sensor feedback ON or OFF. Used during factory calibration of the BTU transmitter. Feedback should always be in the ON position during normal operation.

This displays the address for the controller. It is used for external communication with a computer.

This is used to change the local/remote status of the temperature controller. In local mode all external computer write commands are ignored. Read commands will still function.

APPENDIX B

TEMPERATURE CONTROLLER QUICK REFERENCE

PROGRAMMING GUIDE

The following is a “How To” gu ide that quickly shows how to access menu levels and

their paramters, and how to make changes to them.

•

PRIMARY MENU to SECONDARY MENU

Press ENTER and the ⇑ arrow key.

The display will indicate:

• SECONDARY MENU to PRIMARY MENU

Press INDEX and the ⇓ arrow key.

The display will indicate:

NOTE:

When in the Secondary menu the first menu parameter, (Func), must be displayed in

order to switch to another menu.

NOTE:

The number 120, shown above, is arbitrary. This number is dependent on the actual

outlet water temperature of t he uni t bei ng serviced.

APPENDIX B

NOTE:

The temperature controller defaults back to the PRIM ARY menu from the SECONDARY

menu or the SECURE menu if there is no activity in either of those menus after 4

minutes.

• TO CHANGE TO THE SECURE MENU

While in the primary menu press the INDEX key and ⇓ arrow key.

⇑

OR while in secondary menu press and hold ENTER and

The display will indicate:

for 5 seconds.

• SECURE MENU to the SECONDARY MENU

Pressing either INDEX and ⇓ arrow key or ENTER and the⇑ arrow key will return you to the SECONDARY menu.

The display will indicate:

NOTE:

Anytime the SECURE menu is entered

operation upon going back to the PRIMARY or SECONDARY menu.

the unit will shut down. It will resume normal

• SECURE MENU TO THE MAIN MENU

While in the SECURE menu press INDEX and the ⇓ arrow key. This will place you in the SECONDARY menu. Press INDEX and the

The display will indicate:

⇓

arrow key again to return to the MAIN menu.

APPENDIX B

• SCROLLING THROUGH MENU ITEMS

To scroll through Menu items, in any menu level, Press I NDEX. To scroll through the PRIMARY, SECURE, or SECO NDARY menus in reverse,

⇓

arrow key.

simultaneously press INDEX and the To return to the first m enu item of the SECONDARY menu from any other

SECONDARY menu item, without scr olling, simultaneously press the ENTER and

⇑

arrow key.

• CHANGING MENU ITEM VALUES

To change the value of a selected menu item press either t he ⇑ arrow key to

⇓

increase the item value or the accept the change.

ENTER must be pressed after changing the value of a parameter If ENTER is not

pressed the controller will default to the value displayed prior to the change.

arrow key to decrease the item value. Pr ess ENTER t o

NOTE:

vii

APPENDIX C

viii

WATER HEATER DEFAULT SETTINGS

APPENDIX D

MENU LEVEL

& CODE

PRIMARY MENU

setp UNIT’S SETPOINT TEMPERATURE 130 auto AUTOMATIC\MANUAL MODE AUTO ON

SECONDARY MENU

func MODE OF OPERATION FDFO

setp UNIT’S SETPOINT TEMPERATURE 130

sens MAX LOAD ADJUST Factory Set

HLT UNIT’S HIGHEST SETPOINT TEMPERATURE 200

addr ADDRESS 32

bp_0 BREAK POINT 0 135

bp 0

bp_1 BREAK POINT 1 128

bp 1

bp_2 BREAK POINT 2 120

bp 2

bp_3 BREAK POINT 3 115

bp 3

bp_4 BREAK POINT 4 110

bp 4

bp_5 BREAK POINT 5 105

bp 5

bp_6 BREAK POINT 6 97

bp 6

bp_7 BREAK POINT 7 91

tout OUTLET TEMPERATURE ACTUAL

pct PERCENTAGE OF FIRING ACTUAL

tout OUTLET TEMPERATURE ACTUAL

fft TEMPERATURE OF BTU TRANSMITTER SENSOR ACTUAL

pct PERCENTAGE OF FIRING RATE ACTUAL

ofst MNIMUM LOAD ADJUST Factory Set

LLT UNIT’S LOWEST SETPOINT TEMPERATURE 40

pb1 PROPORTIONAL BAND 8

int INTEGRAL .6 drt DERIVATIVE .15

fdb FEED BACK ON OR OFF ON

lore LOCAL/REMOTE MODE LOC

DESCRIPTION OF CODE0 FACTORY

DEFAULT

APPENDIX D

bp 7

bp_8 BREAK POINT 8 85

bp 8

bp_9 BREAK POINT 9 81

bp 9

bp_A BREAK POINT 79

bp A

bp_B BREAK POINT 77

bp B

SECURE MENU

SECr SECURITY LEVEL 3

Func MODE OF OPERATION fDfO

gAin GAIN .05

Pb3 PROPORTIONAL BAND 5000

Lofi LOW FIRE 29 LFti LOW FIRE TIMER 0

Purg PURGE 100

O2-O STOP LEVEL 16%

O2-C START LEVEL 20%

FLti FAULT TIMER 0SEC. dFil DISPLAY FILTER 2

ArUP ANTI RESET WINDUP ON

PEA PEAK(Highest Temp. Unit Has Seen Since Reset) ACTUAL VAL VALLEY(Lowest Temp. Has Seen Since Reset) ACTUAL

bp BREAK POINTS ON or OFF OFF

InPC INPUT CORRECTION 0

InPt INPUT TIMER OFF

FiLt SENSOR FILTER 4

Unit UNIT OF DISPLAY F

Addr ADDRESS 32

bAUd BAUD RATE 9600

InP INPUT CAL

APPENDIX E

(182.6)

71-7/8

(PSIG)

TEST PRESS.

240210

3(8)

2"NPT

RECIRC

CONN.

1"NPT

DRAIN

VALVE

MATERIALS OF CONSTRUCTION

1-1/4"CARBON STEEL HEAD,SA-515/516 GR.70

1/4" CARBON STEEL SHELL, SA-53, GRADE B

VESSEL

PRESSURE

c.g.

TEMP. (°F)

MAXIMUMMAX. WORKING

5-3/4(14.6)

160

INLET ADAPTER

TRAIN OPTION" ONLY

(OPTIONAL O.A.

COMB. AIR INTAKE

AVAIL. - 6" OD)

(34.4)

13-9/16

PRESS. (PSIG)

1/4"WALL CU-NI WELDED TUBE SB-171,CDA-706

CU-NI TUBESHEET,SB-171,CDA-706

CU-NI UPPER HEAD,SB-171,CDA-706

CU-NI HELICAL TUBE, SB-111, CDA-C70600

COMBUSTION

CHAMBER

HEAT EXCHANGER DESIGN STANDARDS

SHELL SIDE

ASME B & PV CODE SECTION IV STAMP HLW

RELIEF

VALVE

LIFTING LUG

3/4" NPT GAS VENT

CONN. FOR "IRI GAS

AC SERVICE C0NN.

3/4 CONDUIT

120VAC SINGLE PHASE

20 AMP W/GRD

1-1/4 NPT GAS INLET

3-1/8(7.9)

NORTHVALE, NEW JERSEY 07647

INTERNATIONAL INC.

POTABLE WATER HEATER

MODEL KC1000 GAS FIRED

AP-A-576

2-1-95

DATE

SIZE

APPD

DIMENSIONAL DRAWING

1:24

P.K./G.K.

DWN BY

CHKD

SCALE

PRESS./TEMP.

78-1/2

22(56)

(FLOOR FLANGE)

(199.4)

REMOTE ALARM & CONTROL

CONNECTION - 3/4 CONDUIT

19(48)

2" NPT HOT

35(89)

47(119.4)

c.g.

15-1/2(39.4)

WATER OUTLET

WATER INLET

2" NPT COLD

49(124.5)

18(45.7)

57(144.8)

)

(ENCLOSURE)

6(15.2) I.D.

FLUE CONN.

22-1/4(57)

TYP.

4-PLCS

3/4(1.9) DIA.

(

71-7/8

(182.6)

xii

22-5/8

(57.5)

16-3/4

(42.5)

5/8" I.D.

MALE HOSE

CONDENSATE

DRAIN

NOTES:

1) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS)

2) DRAIN VALVE & RELIEF VALVE ARE INCLUDED SEPARATELY IN SHIPMENT

APPENDIX E

xiii

APPENDIX E

xiv

APPENDIX F

xvi

APPENDIX F

xvii

APPENDIX F

xviii

APPENDIX F

xix

FLOOR

APPENDIX F

FLOOR

APPENDIX G

xxi

APPENDIX G

xxii

APPENDIX H

13 123446 FAN GUARD 12 123402 #6-32 X 3/8 LG PAN HEAD MACH. SCREW 11 123459 #6-32 X 2 LG PAN HEAD MACH. SCREW 10 123452 #8-32 X 5/16 LG PAN HEAD MACH. SCREW

9 123437 #6-32 X 5/8 LG PAN HEAD MACH. SCREW 8 123389 LINE FILTER 7 123436 FAN 6 123393 TERMINAL BLOCK 5 123388 TRANSFORMER 4 123399 VALVE INTERFACE BOARD

123747 HONEYWELL FLAME RECIFICATION AMPLIFIER

2 123435 LOW WATER CUT OFF 1 201076 CONTROL BOX BASE

ITEM PART NUMBER DESCRIPTION

123746 HONEYWELL PURGE TIMER 123745 HONEYWELL MODULE BASE 123744 HONEYWELL RELAY MODULE

PARTS LIST

xxiii

APPENDIX H

18 123280-W1 WATER HEATER TEMPERATURE CONTROLLER 17 123803 SOLID STATE TIMER-ARTISAN CORP(123469 FOR SSAC INC.) 16 123438 CIRCUIT BREAKER 15 123391 RELAY BOARD 14 123390 STATUS ANNUNCIATOR

ITEM PART NUMBER DESCRIPTION

PARTS LIST

xxiv

HEAT EXCHANGERS • WATER HEATERS • BOILERS

HEAT RECLAMATION SYSTEMS • CONTROL VALVES

STEAM GENERATORS

HOT WATER SYSTEMS

AERCO INTERNATIONAL, INC. • 159 PARIS AVE. • NORTHVALE,

N.J. 07647

201-768-2400 • TELEX 135450 • FAX 201-768-7789

Visit Us at www.aerco.com

AERCO GF-105 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Telephone Support

Figure 2.1

Figure 2.2

Lifting Lug Location

Figure 2.3

Inlet and Outlet Location

Figure 2.4a

Hose Bibb Location

Figure 2.4b

Figure 2.5

Condensate Drain Assembly Location

Figure 2.6

Figure 2.7

AC Wiring Box Location

Figure 2.8

Electrical W ir ing Diagram

Figure 2.9

Field Control W ir ing Box Location

Figure 2.10

Field Control Box Wir ing

FIGURE 3.1

Front Panel Controls Location

Figure 3.2

Figure 3.3

Outlet Temperature Display

Figure 3.4

Percent of Firing Rate Display

Figure 3.5

Setpoint Display

Figure 3.6

Figure 3.7

Auto/Manual Display with Manual ON

Figure 3.8

Figure 3.10

Water Level Test and Reset Switch Locations

Figure 3.9

Figure 3.12

Figure 3.11

Proof of Closure Switch Location

Figure 3.13

Blower Proof Switch Location

Figure 3.15

Flame Test Jack Location

Figure 3.14

Figure 4.1

1/8” Gas Plug Location

Figure 4.3

Figure 4.2

Analyzer Probe Hole Location

Figure 4.4

Air Shutter Locking Nut Locat ion

Figure 4.5

Propane Air Different ial Pressure Taps

FIigure 4.6

Figure 4.8

Over Temperature Limit Switch Location

Figure 4.7

Secondary Menu Displaying Sensitivity

Figure 5.1

Figure 5.2

Temperature Limit Switch Setting

Figure 5.3

Manual Leak Detection Valve

Figure 5.4

Blower Proof Switch Location and Wiring

Figure 5.5

SSOV Actuator Set Screw Location

Figure 5.6

Air/Fuel Valve Cover Screw Locations

Figure 5.7

Figure 6.1

Spark Ignitor and Flame Det ector Location

Figure 6.2

BTU Transmitter Pump Oil Hole Location

Figure 6.4

BTU Transmitter Pum p Disassem bly