AERCO GF-106 User Manual

Instruction

GF-106

No.

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

Installation, Operation

& Maintenance Instructions

KC Series
Gas Fired
Boiler System

Semi-Instantaneous, Condensing,

Forced Draft,

Natural Gas and Propane Fired,

Hot Water Boiler

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 01/03/05

Telephone Support

Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through

Friday)
[phone]

AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128

© AERCO International, Inc., 2005

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.

GF-106 THE AERCO KC1000 GAS FIRED BOILER

Operating & Maintenance Instructions

FOREWORD

Section 1 SAFETY PRECAUTIONS---------------------------1

Section 2 INSTALLATION PROCEDURES------------------2

CONTENTS

2.1 Receiving the Unit

2.2 Unpacking

2.3 Installation

2.4 Gas Supply Piping

2.5 Electrical Supply

2.6 Mode of Operation and Field Control
Wiring

Section 3 CONTROL PANEL COMPONENTS and

OPERATING PROCEDURES----------------------10

3.1 The Control Panel

3.2 The Temperature Controller

3.3 The Primary Menu

3.4 The Secondary Menu

3.5 The Annunciator Circuit

3.6 The Combustion Safeguard

3.7 Water Level Test and Reset
Switches

Section 4 INITIAL START-UP-----------------------------------18

2.7 Enable/Disable Interlock

2.8 Fault Relay Wiring

2.9 Flue Gas Vent Installation

2.10 Combustion Air

2.11 Unit Initial Fill

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

4.1 Initial Start-Up requirements

4.2 Tools and Instrumentation for
Combustion Calibration

4.3 Combustion Calibration

4.4 Propane Combustion Calibration

Section 5 BOILER MODE of OPERATION-------------------24

5.1 Indoor/Outdoor Reset Mode

5.2 Constant Setpoint Mode

5.3 4-20 ma Remote Setpoint Mode

5.4 4 to 20 ma Direct Drive Mode

4.5 Boiler Reassembly

4.6 Mode of Operation Setup

4.7 Over Temperature Limit
Adjustments

5.5 Boiler Management System

5.6 Combination Control System

5.7 Using the Outside Air Sensor Feature

i

Switch

Section 6 SAFETY DEVICE

TESTING PROCEDURES---------------------------29

CONTENTS

6.1 Testing of Safety Devices

6.2 Gas Pressure Fault Test

6.3 Low Water Level Fault Test

6.4 Water Temperature Fault Test

Section 7 MAINTENANCE REQUIREMENTS----------------33

7.1 Maintenance Schedule

7.2 Spark Ignitor

7.3 Flame Detector

Section 8 TROUBLESHOOTING--------------------------------38

8.1 Gas Pressure Fault

8.2 Exhaust Temperature Fault

8.3 Water Level Fault

8.4 Water Temperature Fault

APPENDICES:

A. Temperature Controller Menus
B. Temperature Controller Quick Reference

Chart

C. Temperature Sensor Resistance

Charts

D. Indoor\Outdoor Reset Ratio Charts

6.5 Flame Fault Test

6.6 Air Pressure Fault Test

6.7 Purge Interlocks Fault Test

6.8 Safety Pressure Relief Valve Test

7.4 Combustion Calibration

7.5 Safety Device Testing

7.6 Manifold and Exhaust Tubes

8.5 Flame Fault

8.6 Air Pressure Fault

8.7 System Fault

E. Mode of Operation Factory Default Settings
F. Dimensional & Parts Drawings
G. Piping Drawings
H. Wiring Schematics
I. Control Box Isometric Drawing

WARRA NTIES

ii

FOREWORD

Foreword

The AERCO KC boiler is a true industry advance that meets the needs of today's energy and
environmental concerns. Designed for applicat ion in any closed loop hydronic system, t he load
tracking capability relates energ y input dir ect ly to fluctuating system loads through a 14: 1
modulating turndown ratio. The boiler’s condensing capability offers extremely high efficiencies
and makes the KC boiler ideally suited for m oder n low tem per at ure, as well as, conventional
heating systems.

The KC boiler can be used singular or in modular arr angements for inherent standby with
minimum space requirements. Venting capabilities offer m a ximum flexibility and allow
installation without normal restrictions. The advanced electr onics of each boiler module offer
selectable modes of operation and interface capabilities.

After prolonged shutdown, it is recom mended that the startup procedures in Section 4 and t est
procedures in Section 6 of this manual be performed, to verify system operating par am eters. If
there is an emergency, turn of f the electrical power supply to the Aerco boiler or close the
manual gas valve located before the unit. T he inst aller is to identify the emergency shut-off
device. FOR SERVICE OR PARTS, contact your local sales repr esentative or AERCO
INTERNATIONAL.

NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________

iii

SAFETY PRECAUTIONS

SECTION 1 - SAFETY PRECAUTIONS

Installing or operating personnel 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 all the requirements included in
this instruction manual by AERCO, the
installation of unit’s MUST conform with local
building codes, or, in the absence of local
codes, ANSI Z223.1 (National Fuel Gas
Code Publication No. NFPA-54) for gas-fired
units, and ANSI/NFPA58 for LP gas-fired
units. Where applicable, the equipment
shall be installed in accordance with CGA
B149. Where ASME CSD-1 is required by
local jurisdiction, the installer must conform
to CSD-1.

WARNINGS!

MUST BE OBSERVED TO PREVENT

SERIOUS INJURY.

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.

WARNING !

DO NOT USE MATCHES, CANDLES,

FLAMES, OR OTHER SOURCES OF

IGNITION TO CHECK FOR GAS

LEAKS.

WARNING !

THE EXHAUST VENT PIPE

OPERATES UNDER A POSITIVE

PRESSURE AND MUST BE

COMPLETELY SEALED TO PREVENT

LEAKAGE OF COMBUSTION

PRODUCTS INTO LIVING SPACES.

CAUTIONS !

Must be observed to prevent equipment

damage or loss of operating

effectiveness.

CAUTION !

Soaps used for gas pipe leak testing

can be corrosive to metals. Piping must

be rinsed thoroughly with clean water

after leak checks have been completed.

CAUTION !

Do not use this boiler if any part has

been under water. Call a qualified

service technician to inspect and

replace any part that has been under

water.

NOTES:

Must be observed for effective

operating procedures & conditions.

1

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
pounds, and must be moved with the proper
rigging equipment for safety and to avoid
damages. The unit should be completely
inspected for shipping damage and
completeness at the time of receipt from the
carrier and before the bill of lading is signed.
Each unit has Tip-N-Tell indicator on the outside
of the crate, that indicates if the unit has been
turned on its side. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Request a
freight claim and inspection by a claims adjuster
before proceeding or refuse delivery of the
equipment.

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. An inspection of the unit should be
made to determine if damage during shipment
occurred that was not indicated by the Tip-N­Tell. The freight carrier should be notified

INSTALLATION

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 Relief Valve

•Ignitor Removal Tool (One per Site)

•Regulator Adjustment Tool (One per

Site)

•Temperature/Pressure Gauge and

Fittings

•2 Lifting Lugs

•Stainless Steel Condensate Cup

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 or use.

Figure 2.1

Boiler Clearances

2

2.3 INSTALLATION

The unit must be installed with the prescribed
clearances for service as shown in Figure 2.1.
The minimum
AERCO, are listed below. Local building codes
may require more clearance and take
precedence

Minimum clearances required:
Sides 24"
Front 18"
Rear 18"
Top 18"

All gas piping, water piping, and electrical
conduit or cable must be arranged so that they
do not interfere with the removal of any cover, or
inhibit service or maintenance of the unit.

clearance dimensions, required by

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 ONLY THE LIFTING LUGS TO MOVE
THE UNIT.

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.

It is suggested that units be secured using the
holes provided in the frame base. Piping must
not be used to secure the unit in place. See
drawing AP-A-568 in Appendix F 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 future maintenance
requirements must be given. All piping must
include ample provision for expansion.

If installing a Combination Control, (CCP),
system, it is important to identify and place the
Combination Mode units in the proper physical
location.

INSTALLATION

Figure 2.2

Lifting Lug Location

2.3.2 SUPPLY AND RETURN PIPING

The locations of the 4" flanged system supply,
and return piping connections, to the unit are
shown in figure 2.3. The return connection is
located on the left side near the base of the
unit’s shell. The supply connection is located on
the left side near the top of the unit’s shell.

Figure 2.3

Supply and Return Location

3

INSTALLATION

Whether installing single or multiple units, install
the piping and accessories as shown in the
appropriate piping diagram located in the
Appendix G.. For applications other than
standard space heating, consult the AERCO
Boiler Application Guide, GF-1070, or AERCO
for the appropriate piping schematics.

The minimum flow rate through the unit is 25
GPM and the maximum flow rate is 150 GPM.
Each unit is fitted with 4" flanges for high flow
application and the system velocity at the unit
return should not exceed 5 feet per second.
Each unit must have individual valves on the
supply, and return, for maintenance. In multiple
unit installations, the flow through each unit must
be balanced.

Every boiler plant must have a source of make­up water to it. As with any closed loop hydronic
system, air elimination and expansion
equipment must be provided as part of the
overall installation. All piping MUST include
ample provision for expansion.

2.3.3 PRESSURE RELIEF AND DRAIN
VALVE INSTALLATION

An ASME rated Relief Valve is supplied with
each unit. The supplied pressure relief valve
setpoint will be 30, 50, 75, 100, or 150
ordered from the factory. Install the pressure
relief valve in the tapping provided opposite the
system supply connection, (see figure 2.4). The
pressure relief valve should be piped in the
vertical position using the fittings supplied. A
suitable pipe compound should be used on the
threaded connections, and excess should be
wiped off to avoid getting any into the valve
body. The discharge from the relief valve should
be piped to within 12 inches of the floor to
prevent injury in the event of a discharge.

The relief piping must be full size without
reduction. No valves, restrictions, or other
blockages should be allowed in the discharge
line. In multiple unit installations the relief valve
discharge lines must not
(connected), together. Each must be individually
run to a suitable discharge location. The drain
valve provided should be installed on the right
hand side of the unit towards the bottom of the
shell. The valve should be pointed in the down
position, (see Fig. 2.4).

psig as

be manifolded,

2.3.4 TEMPERATURE/PRESSURE

INDICATOR

The unit is supplied with one of two styles of
Temperature/Pressure Indicators that must be
installed in the tapping on the supply flange of
the unit (see Figs. 2.5a and 2.5b). A suitable
pipe compound should be used sparingly to the
threaded connection.

Figure 2.4

Relief and Drain Valve Location

Figure 2.5a

Pressure /Temperature Gauge Installation

4

Figure 2.5b

Pressure/Temperature Gauge Installation

2.3.5 CONDENSATE PIPING

The KC Boiler is designed to condense and the
installation must have provisions for drainage to
a suitable waste. A 1-3/4” inch O.D. 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 (see FIG. 2.6). A 5/8-inch O.D.
flexible polypropylene tubing (or suitable
equivalent) can 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 drain. The
maximum condensate flow rate is 5 GPH. The
condensate cup and line must be removable for
routine maintenance. Do not

hard pipe.

2.4. GAS SUPPLY PIPING

The AERCO Gas Fired Equipment Gas
Components and Supply Design Guide (GF-

1030) must be consulted before any gas piping
is designed or started.

WARNING!

DO NOT USE MATCHES, CANDLES,

FLAMES OR OTHER SOURCES OF

IGNITION TO CHECK FOR GAS LEAKS.

INSTALLATION

Condensate Drain System Location

Figure 2.6

CAUTION!

Soaps used for gas pipe leak testing can be

corrosive to metals. Piping must 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 is
on the right side of the unit as shown in Figure

2.7.

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.

A suitable piping compound, approved for use
with gas, should be used sparingly. Any excess
must be wiped off to prevent clogging of
components.

5

To avoid damage to the unit, when pressure
testing gas piping, isolate the unit from the
supply gas piping. At no time should there be
more than 14” W.C. 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.

2.4.1 GAS SUPPLY PRESSURE
REGULATOR

An external, in-line, supply gas regulator
(supplied by others) should be positioned as
shown in figure 2.7. 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 KC1000. The

regulator must regulate gas pressure to 8.5”

W.C. 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. for IRI gas trains when the
unit is firing at maximum input. Gas pressure
should not exceed 10.5” W.C. at any time when
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
regulated 8.5” W.C. minimum for FM gas trains
and 8.9” W.C. for IRI gas trains at maximum
BTU input (1,000,000 BTU/HR) for natural gas
and propane installations. The supply gas
regulator must be of sufficient capacity volume,
(1000 cfh), for 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 to
it. 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.

INSTALLATION

Figure 2.7

Gas Supply Regulator and Manual Shut -Off

Valve Location

2.4.2 MANUAL GAS SHUTOFF VALVE

A 1-1/4” manual gas shut-off valve is furnished
with each unit. The valve should be positioned
as shown in Figure 2.7. The manual gas shut-of
valve must be installed upstream of the 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. (See appendix F)

2.5 ELECTRICAL SUPPLY

The 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 2.8.

6

ELECTRICAL WIRING BOX

FRAME

SSOV
ACTUATOR

BLOWER

Figure 2.8

AC Wiring Box Location

NOTE:

All electrical conduit and hardware should

be installed so that it does not 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

2.9. Conduit should be run from the knockouts in
the side of the 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.

INSTALLATION

Figure 2.9

Electrical Wiring Diagram

2.6 MODE OF OPERATION and FIELD

CONTROL WIRING

The KC Boiler is available in several different
modes of operation. While each unit is factory
configured and wired for a particular mode,
some field wiring may be required to complete
the installation. This wiring is typically to the
Field Control Wiring Box located on the left side
of the unit beneath the removable side panel
(see Fig. 2.10). Field wiring for each particular
mode of operation is described in the following
sections.

AERCO INTERNATIONAL INC.

FIELD WIRING

168

OUTDOOR

START

BLOWER

INDICATION

FAULT

-

BMS

+

SHIELD

FIELD
CONTROL
WIRING
BOX

GAS SHUT-OFF VALVE

Figure 2.10

Field Control Wiring Box Location

AIR
SENSOR

157

14

6

-

4-20 mA

13

5

+

12

4

3

11

2

10

EXH.
TEMP.
SWITCH

91

7

INSTALLATION

2.6.1 CONSTANT SETPOINT MODE

No external field wiring connections other than
electrical supply connectins are required for this
mode. Although fault monitoring or
enable/disable interlocking wiring can be utilized
(see sections 2.7 and 2.8).

2.6.2 INDOOR/OUTDOOR RESET MODE

This mode of operation increases supply water
temperature as outdoor air temperature
decreases. An Outside Air Temperature Sensor
(AERCO PN 123525 MUST BE wired to the
Field Control Wiring Box using a two wire
shielded cable having a minimum of 22 AWG
(see Fig. 2.11). The cable shield is connected
only at the terminals provided in the field wiring
box. The sensor end of the shield must be left
free and ungrounded. There is no polarity in
terminating the sensor wires. When mounting
the Outdoor Air Temperature Sensor, it should
be mounted on the north side of the building in
an area where the average outside air
temperature is expected. The sensor should be
shielded from sun's direct rays, as well as direct
impingement by the elements. If a cover or
shield is used, it must allow free air circulation.
The sensor may be mounted up to two hundred
feet from the unit.

2.6.3 BOILER MANAGEMENT SYSTEM
MODE

When using multiple units, with an AERCO
Boiler Management System Panel, Model 168,
the field wiring is between the BMS Panel and
each unit’s field wiring box (see Fig. 2.11). A
twisted pair of 18 to 22 AWG wire must be
utilized for the connections. No shield is utilized
and polarity must be maintained. The Supply
Header Temperature Sensor (AERCO P/N

122790) must be wired back to the BMS Panel,
regardless of mode of operation. See the
instructions provided with the BMS for proper
location and wiring instructions.

2.6.4 4 to 20 ma REMOTE SETPOINT
MODE

The KC1000 can be controlled with a 4-20 ma
signal from a Building Management System or
an external controller. The supplied 4-20 ma
signal must be a floating (ungrounded) signal.
Connections between the 4-20 ma source and
the unit's field wiring box must be made using a
two wire shielded cable having a minimum
gauge of 22 AWG (see Fig. 2.11). The shield is
connected only at the terminal provided in the
field wiring box. The
ungrounded at the source end. Polarity must be
maintained when connecting the wires.

shield must be left free and

2.6.5 COMBINATION MODE

With a Combination Mode unit, field wiring is
between the unit’s field wiring box, the CCP
(Combination Control Panel), and the BMS
(Boiler Management System). The wiring must
be done using a shielded twisted pair of 22
gauge wire and polarity must be maintained
between the unit, the CCP, and the BMS.
Control wire shielding should be secured at each
end of the wiring connections to the terminals
provided. For further instructions and wiring
diagrams consult the BMS and CCP instructions

2.7 ENABLE/DISABLE INTERLOCK

Each unit has an enable/disable interlock circuit
located in the field wiring box. 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.

Figure 2.11

Field Control Box Wiring

2.8 FAULT RELAY WIRING

The fault relay is a normally open, 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 2.11. The relay contacts are
rated for 5 amps at 250 VDC and 5 amps at 30
VDC.

8

INSTALLATION

2.9 FLUE GAS VENT INSTALLATION

The AERCO Venting and Combustion Air Guide,
GF-1050, must be consulted before any flue or
inlet air venting is designed or installed.
Suitable, U/L approved, positive pressure,
watertight vent materials as specified in
AERCO’s GF-1050, 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 to the unit a minimum
of 1/4" per foot to avoid any condensate pooling
and to allow for proper drainage.

While the has 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
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.

2.10 COMBUSTION AIR

The AERCO Venting and Combustion Air Guide,
GF-1050, MUST be consulted before any flue
or combustion supply air venting is designed or
started. Combustion 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.

The more common methods of combustion air
supply venting are outlined below. For
combustion air supply from ducting, consult the
AERCO GF-1050, Venting and Combustion Air
Guide.

2.10.1 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.

2.10.2 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.

2.10.3 SEALED COMBUSTION

The KC Boiler is UL approved for 100% sealed
combustion application when installed properly.
When a sealed combustion air application is
installed, the sealed combustion air piping must
be deducted from the maximum allowable
discharge piping amounts. Each unit must have
a minimum 6" diameter connection made to the
special Inlet Air Adapter # GP-18917 available
from AERCO. This adapter bolts directly on to
the air inlet of the unit’s blower. See installation
instructions with adapter. All inlet air ducts must
be sealed air tight.

2.11 UNIT INITIAL FILL

Before filling the unit’s 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 before filling
the unit.

The following steps should be followed when
filling the unit:

1. Close the unit’s drain valve.

2. Open the system return connection on
bottom of the unit.

3. Make certain that the system pressure
reducing fill valve is on to replenish pressure
in the system as the unit fills.

4. Using the pressure/temperature gauge,
supplied with the unit, as a guide, allow
pressure to slowly build up in the unit.

5. Slowly open either the manual vent valve or
the supply valve off its seat, allowing air to
vent from the unit’s shell.

the

9

CONTROL PANEL OPERATING PROCEDURES

SECTION 3- CONTROL PANEL OPERATING PROCEDURES

The following is a guide to the operation of the
control panel. Initial start-up of this unit must be
performed by factory trained start-up personnel.
Operation prior to initial start-up by factory
trained personnel will void the warranty.

CAUTION:

All initial installation procedures must be

satisfied before attempting to start the unit.

WARNING:

DO NOT ATTEMPT TO DRY FIRE THE KC

1000. STARTING THE UNIT WITHOUT A
FULL WATER LEVEL CAN SERIOUSLY

DAMAGE THE UNIT AND MAY RESULT IN

PERSONNEL INJURY OR PROPERTY

DAMAGE. THIS SITUATION WILL VOID

ANY WARRANTY.

3.1 THE CONTROL PANEL

The KC 1000 Control Panel has been designed
to provide the operator with all the necessary
information required for operating and
troubleshooting this unit. There are six separate
accessible controls or displays, available to the
operator, (see Fig. 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 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 consists of
four, 8 segment LED’s (see Fig. 3.2). When
choosing an operating parameter 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 or in
the system, or by signals from an energy
management system.

The second LED, “REM”, designates whether
the controller is being controlled locally or
remotely, (see Fig. 3.2). 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.

10

CONTROL PANEL OPERATING PROCEDURES

The third LED, “ON”, indicates the status of the
start relay, (see 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,

(see Fig. 3.2).

o

F” and “oC”, indicate

NOTE:

When the temperature controller is displaying in

o

C only the temperature being displayed is

affected. All other settings remain in oF.

Figure 3.2

Temperature Controller Operating Status Lights

For more data concerning the minimum and
maximum range, and factory defaults of menu
parameters, see Appendix E of this manual.
Each menu level is described below.

3.3 THE PRIMARY MENU

The primary menu is the default menu. When in
another menu level and there is no activity for 5
minutes the temperature controller will default
back to the primary menu. The Primary menu
allows the operator access to the following
temperature controller parameters:

Code Meaning

tout Actual unit outlet water temper ature.

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 unt il (tout)
is displayed in the lower LED. The variables
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 Secondar y 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 ! " arrow keys to change the
parameters value. Once a parameters value has
been changed the ENTER key must be
depressed for the change to be recognized by
the controller. Leaving the desired parameter
without entering the new value will result in that
parameters value defaulting back to the original
value. Detailed descriptions and instructions for
accessing each menu parameter are listed
within this section.

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% firing rate equals approximately
500,000 BTU gas input while a 75 % firing rate
equals approximately 750,000 BTU gas input.

CAUTION:

Do not leave the unit unattended while in

the manual mode of operation.

11

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 ! " arrow keys until ON is
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 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 ! " arrow keys. Press the ENTER button to
accept the change.

Figure 3.5

Setpoint Display

Figure 3.6

Auto/ Manual Display with Auto On

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.

12

CONTROL PANEL OPERATING PROCEDURES

Figure 3.7

Auto/Manual Display with Manual On

3.4 THE SECONDARY MENU

The secondary menu is primarily related to
temperature control. It is necessary to access
this menu when setting PID values or changing
the unit mode of operation. All the parameters
accessible in the primary menu are also
accessible in the secondary menu.

These displays are accessed using the four
membrane switches located directly under the
LCD display on the front of the control panel.
They are labeled CLEAR, !, ", and AUX.

To access the secondary menu, press the !
arrow key and ENTER simultaneously. To scroll
through the menu press the INDEX button. For a
complete explanation of the secondary menu
parameters see Appendix A of this manual.

3.5 THE ANNUNCIATOR CIRCUIT

The annunciator consists of the annnciator
circuit board, the front panel LCD display, and 4
function switches, (see Fig. 3.8 for the display
and function switch locations and see Appendix I
for the circuit board locations). 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.

The annunciator circuit board and LCD display
are not an integral part of the start sequence or
combustion safeguard system.

The annunciator start sequence messages, fault
messages, function switches and function
displays are explained below.

3.5.1 ANNUNCIATOR FUNCTION
SWITCHES and DISPLAYS

The Annunciator has three function displays
available to the operator. These are the MAIN,
the CYCLES, and the SET DATE displays.

Figure 3.8

Annunciator Function Switches and LCD Display
The MAIN display is used during normal

operation of the unit. In the MAIN display, start
sequence and fault messages can viewed. To
return to the MAIN display from any other
display, simultaneously press CLEAR and the !
arrow 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 0, simultaneously press the
!, and " arrow 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 th e
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.

13

CONTROL PANEL OPERATING PROCEDURES

The number of times

# CYCLES =

“DATE” “TIME”

SET DATE:

“DATE” “TIME”

the controller has

completed it’s start

cycle, and the time

and date

Displays and allows

setting of the date

and time

3.5.2 ANNUNCIATOR FAULT
MESSAGES

The following table lists the Annunciator MAIN
display fault messages and their meanings.

MESSAGE MEANING

AC power has been

interrupted. Power must

RESET MAIN

POWER

HIGH WATER

TEMP

LOW GAS

PRESSURE

LOW WAT ER

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

be shut off for 5

seconds to reset the

display.

The unit has tripped

due to the outlet water

temperature exceeding

the high temperature

limit setting.

The unit has tripped

due to low gas

pressure.

The shell water level is

below the probe level.

The interlock terminals,

in the relay box, are not

closed.

The proof of closure, or

the purge switch did not

prove closed during the

start sequence.

The airflow switch did

not prove closed during

the start sequence.

The proof of closure or

purge switch did not

prove 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

LOCKOUT RUN

HI EXHAUST

TEMP

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 MAIN
display start sequence messages.

MESSAGE MEANING

The unit is in standby

STANDBY
PURGING

IGNITION TRIAL

FLAME PROVEN

3.6 THE COMBUSTION SAFEGUARD

The Combustion Safeguard is responsible for
monitoring the safety components during the
start sequence, and after flame is established. It
is also responsible for the timing 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 LED’s 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 LED’s
is to reset the combustion safeguard a lockout.

DESCRIPTION FUNCTION

POWER

PILOT

FLAME

MAIN

ALARM

mode waiting for a call

for heat

The unit is in the 7-sec

purge.

The unit is in ignition

position attempting to

light the burner

The unit has

established flame and

is firing.

Lights upon power up of

the unit.

Lights when the re 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.

14

CONTROL PANEL OPERATING PROCEDURES

Figure 3.9

Combustion Safeguard Status Indicator LED

Location

3.7 WATER LEVEL TEST and RESET
SWITCHES

The water level switches are located on the left
side of the control box, 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 low 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 showing LOW WATER
LEVEL.

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 panel above the temperature
controller (see Fig. 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, and that the alarm relay is not

activated. The unit at this point is in standby
mode and ready to run.

Figure 3.10

Water Level Test and Reset Switch Locations

3.9 STARTING 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 condit ions are m e t.
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 7­second purge cycle.

15

CONTROL PANEL OPERATING PROCEDURES

145

146

Proof of Closure Switch Location

147

149

148

PROOF OF
CLOSURE
SWITCH

SAFETY
SHUT-OFF
VALVE

Figure 3.11

FROM
CONNECTOR
9A

Figure 3.13

Blower Proof Switch Location

8. Once the combustion safeguard detects
flame, its flame LED lights. Power is
removed from the ignition transformer and
the MAIN LED lights of the combustion
safeguard.

At this point, the annunciator will display FLAME
PROVEN. The unit, provided it is in the
automatic mode, is released to modulate and
will be controlled by the temperature contr ol
system.

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 sim ultan eous ly
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).

Figure 3.14

Air/Fuel Valve in Ignition Position, Engaging the

Ignition Microswitch

16

CONTROL PANEL OPERATING PROCEDURES

3.10 AFTER FLAME

Once the control signal has gone below the stop
level (see section 3.12 for Stop Level
explanation), the temper ature contr o ller ’s gre en
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 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.

17

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

• mode of operation settings (see Section 5)

• safety device testing (see Section 6)

Installation procedures should be completed
100% before performing initial start-up and initial
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.

18

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 Regulator 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 comes 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.

19

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” 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. or 8.9”
W.C.

NOTE:

If 8.5” W.C. for FM gas t r ains or 8.9” W. C.

for IRI gas trains cannot be obt ained 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. or 8.9” 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 differ ence in oxygen
readings for the same firing 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 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
clockwise 1/4-1/2 revolution to increase gas
flow.

Carbon

Monoxide

20

INITIAL START-UP

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 16%.

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 than 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 16%

Oxygen Carbon

Monoxide

Firing Rate

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 Location

SCREEN

SHUTTER

SHUTTER LOCKING

NUTS

BLOWER OUTLET

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).
Open the shutter 1/4” to 1/2”, to increase the
oxygen level then tighten the nuts.

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.

26. Allow the analyzer to settle. Repeat the
adjustment until the oxygen is within the

21

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 a 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. It adjustments are made to this regulator it
will be necessary to recheck oxygen settings
at 16%, 30%, and 100% firing rates

INITIAL START-UP

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 Differential 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.

8. Replace the unit’s panels and hood.

22

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

4.6 OVER TEMPERATURE LIMIT SWITCH

ADJUSTMENTS

There are two Over-Temperature Limit switches
that turn off the unit when the outlet water
temperature becomes too hot. The lower over­temperature limit switch is adjustable and should
be adjusted 20
header temperature. The upper over­temperature limit switch is a manual reset device
and is not adjustable. It will shut the unit off if the
water temperature reaches 240
attempt to adjust its 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. 4.6).
Do not adjust the upper switch it has been
factory preset. Adjust the lower switch
between 20
maximum header temperature the unit may
see.

3. Replace the shell cap and wing nut.

0

to 40o F above the operating

o

F. DO NOT

0

to 40o F higher than the

INITIAL START-UP

Figure 4.6

Over Temperature Limit Switch Location

23

SECTION 5- MODE OF OPERATION

The following is a detailed description of the
KC1000’s six modes of operation. Each unit is
shipped from the factory tested and configured in
the mode of operation it was ordered. All
temperature related parameters are at factory
defaults and work well in most applications.
However, it may be necessary to change certain
parameters to customize the unit to the system.
A complete listing and description of temperature
related parameters is in Appendix A. Factory
defaults are located in Appendix E. After reading
this section, parameters can be customized to
suit the needs of the application.

5.1 INDOOR/OUTDOOR RESET MODE

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

5.1.1 RESET RATIO

Reset ratio is an adjustable number from 0.1 to

9.9. Once adjusted the supply header

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

5.1.2. BUILDING REFERENCE

TEMPERATURE

Building reference temperature is the
temperature that the inside of the structure is to
be maintained. This is a number from 0 to 300
and once chosen, is the temperature that the
system references to begin increasing its
temperature. For instance if a reset ratio of 1.6 is
used, and we choose a building reference
temperature of 70 degrees, then at 69 degrees
outside temperature, the supply header
temperature will increase by 1.6 degrees to 71.6
degrees.

5.1.3 OUTDOOR AIR SENSOR

INSTALLATION

When mounting the Outdoor Air Temperature
Sensor, it should be mounted on the north side
of the building in an area where the average
outside air temperature is expected. The sensor
should be shielded from the sun's direct rays, as
well as direct impingement by the elements. If a
cover or shield is used, it must allow free air

MODE OF OPERATION

circulation. The sensor may be mounted up to
two hundred feet from the unit.

The outdoor air sensor must be connected to the
external field wiring box located under the control
panel on the left-hand side of the unit.
Connections are to be made to terminals 16 and

15.

5.1.4 INDOOR / OUTDOOR STARTUP

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

2. Choose the building reference temperature
that the structure is to be maintained.

3. Go down the left column of the chart to the
coldest degree day reachable in that area

NOTE:

Degree day and supply water temperature

data are typically provided by a design

engineer or your local AERCO

representative.

4. Once the degree day is chosen go across
the chart to the desired supply header
temperature for the degree day chosen in
step three.

5. Now go up that column to the reset ratio row
to find the reset ratio.

6. Access the secondary menu of the
temperature controller and then scroll
through it until the display shows REFT. This
is the building reference temperature.

7. Use the ⇑ ⇓ arrow keys to set the desired
building reference temperature.

8. Press ENTER to accept any changes.

9. Now scroll through the secondary menu until
it displays RR. This is the reset ratio.

10. Use the ⇑ ⇓ arrow keys to set the desired
reset ratio.

11. Press ENTER to accept the change.

The unit is now ready to run. Go back to the
primary menu and start the unit

24

MODE OF OPERATION

5.2 CONSTANT SETPOINT MODE

Constant setpoint mode of operation is when a
non-changing, fixed, header temperature is
desired. Common uses of this mode of operation
include water source heat pump loops, and shell
and tube heat exchangers for potable hot water
systems or processes.

There are no external hookups, other than AC
power, necessary to operate in this mode. While
it is necessary to set the desired setpoint
temperature, it is not necessary to change any
other temperature-related functions. The unit is
factory preset with settings that work well in most
applications. Prior to changing any temperature­related parameters, other than the setpoint, it is
suggested that AERCO be contacted. For a
complete listing of factory, defaults and a
description of temperature related functions see
Appendices A and E.

5.2.1 SETTING THE SETPOINT

The setpoint of the unit is adjustable from 50 to
220 degrees. To set the setpoint do the
following:

1. While in the Primary menu, scroll through it
until "Setp" is displayed.

2. Use the ⇑ ⇓ keys to set the desired setpoint.

3. Press enter to accept any changes.

4. The unit is now ready to run.

5.3 4 to 20 MILLIAMP REMOTE

SETPOINT MODE

In this mode of operation a 4 to 20ma signal sent
to the unit changes it’s setpoint. The signal is
typically sent from an energy management
system that determines the appropriate setpoint
based on outside air temperature. In this mode a
4ma signal is equal to a 50-degree setpoint while
a 20ma signal is equal to a 220 setpoint. This
mode of operation can be used to drive single as
well as multiple units.

In this mode, the external interface board is
utilized. The interface board, located in the field
wiring box, is factory configured and converts the
4 to 20 ma signal to an RS-485 signal. The RS­485 signal is in turn sent to the temperature
controller. For the temperature controller to
recognize a signal, from an external source, the
following functions must be correctly set.

MENU FUNCTION SETTING

Secondary Lore re
Secondary FUNC Cont

Primary Auto ON

While it is possible to change the settings of
temperature related functions; the unit is factory
preset with settings that work well in most
applications. It is suggested that an AERCO
representative is contacted prior to changing any
temperature related function settings. For a
complete listing of factory, defaults and a
description of temperature related functions see
Appendices A and E.

5.3.1 4 to 20 MA REMOTE SETPOINT FIELD WIRING

The only wiring necessary is the 4 to 20ma
signal wires from the source, to terminals 13 and
14 in the field wiring box. The signal must be
floating (ungrounded), and the wire used must
be a two wire shielded cable of 22 gauge
minimum. Polarity must be observed and the
shield must be connected to terminal 1 in the
external field wiring box. The source end of the
shield must be left floating and not connected.
When driving multiple units, each unit’s wiring
must conform to the above.

5.3.2 4 to 20 MA REMOTE SETPOINT STARTUP

Since this mode of operation is factory preset
and the setpoint is being externally controlled, no
startup instructions are necessary. However the
unit must be taken out of remote mode, and set
to local mode, to manually run the unit. Once
finished with manual mode it is necessary to set
the unit back to remote mode for it to accept
signals from an external source. The
temperature controller must also be left in
manual and not automatic mode.

To set the unit to local mode, do the following:

1. Access the temperature controller’s
secondary menu.

2. Scroll through the menu until "lore" is
displayed.

3. Use the ⇑ ⇓ keys to set the temperature
controller to local. The yellow REM light, on
the temperature controller, should
extinguish.

4. Press ENTER to accept the change.

25

MODE OF OPERATION

5. Follow the above directions to change back
to remote mode.

NOTE:

The unit automatically defaults to remote

mode upon AC power being applied. This is

due to the presence of the external

interface board.

5.4 4 to 20MA DIRECT DRIVE MODE

In this mode of operation the 4 to 20ma signal
sent to the unit changes the unit’s percentage of
firing rate. The signal is typically sent from an
energy management system that, through PID
controls, determines the rate of change
necessary in the supply header. The 4 to 20ma
signal sent from the energy management system
equals a firing rate between 0 to 100%. In this
mode 4ma equals 0% firing rate and 20ma
equals 100% firing rate. The unit is a slave to the
energy management system and does not have
a role in temperature control. This mode of
operation can be used to drive single as well as
multiple units.

In this mode, the external interface board is
utilized. The interface board, located in the
external field wiring box, is factory configured
and converts the 4 to 20ma signal to an RS-485
signal. The RS-485 signal is in turn sent to the
temperature controller. For the temperature
controller to recognize a signal, from an external
source, the following functions must be correctly
set.

MENU FUNCTION SETTING

Secondary Lore re
Secondary FUNC Cont

Primary Auto OFF

5.4.1 4 to 20MA DIRECT DRIVE FIELD

WIRING

The only wiring necessary is the 4 to 20 ma
signal from the source, to terminals 13 and 14 in
the external field wiring box. The signal must be
floating, (ungrounded), and the wire used must
be a two wire shielded cable of 22 gauge
minimum. Polarity must be observed and the
shield must be connected to terminal 1 in the
external wiring relay box. The source end of the
end must be left floating and not connected.
When driving multiple units, each unit’s wiring
must conform to the above.

5.4.2 4 to 20 MA DIRECT DRIVE STARTUP

Since this mode of operation is factory preset
and the percentage of firing rate is being
externally controlled there are no startup
instructions necessary. However the unit must
be taken out of remote mode, and set to local
mode, to manually run the unit. Once finished
with manual mode, it is necessary to set the unit
back to remote mode for it to accept signals
from an external source. The temperature
controller must also be left in manual and not
automatic mode.

To set the unit to local mode do the following:

1. Access the temperature controller’s
secondary menu.

2. Scroll through the menu until "lore" is
displayed.

3. Use the ⇑ ⇓ keys to set the temperature
controller to local. The yellow REM light, on
the temperature controller, should extinguish

4. Press ENTER to accept the change.

5. Follow the above directions to change back
to remote mode.

NOTE:

The unit automatically defaults to remote

mode upon AC power being applied. This

is due to the presence of the external

interface board.

5.5 BOILER MANAGEMENT SYSTEM

(BMS)

The BMS mode of operation is used when it is
desired to operate multiple units in the most
efficient manner possible. A total of eight units
can be managed by a single AERCO BMS 168
system. In BMS mode, the Boiler Management
System modulates the units firing rate. All
temperature functions are monitored and
controlled by the BMS panel. For BMS
programming and operation see the BMS
Operations Guide.

In BMS mode, the external interface board is
utilized. The interface board, located in the field
wiring box, is factory configured, and converts
the pulse width modulation signal, sent from the
BMS, to an RS-485 signal. The RS-485 signal is
then sent to the temperature controller. For the
temperature controller to recognize a signal,

26

MODE OF OPERATION

from an external source, the following functions
must be correctly set.

MENU FUNCTION SETTING

Secondary Lore re
Secondary FUNC Cont

Primary Auto OFF

5.5.1 BOILER MANAGEMENT SYSTEM EXTERNAL FIELD WIRING

Wiring for this system is from the BMS panel to
terminals 2 and 3 in the unit’s external field
wiring box. Wire the units using a twisted pair of
22 gauge minimum wire. No shield is necessary.
When wiring multiple units, each unit’s wiring
must conform to the above. For a complete BMS
wiring diagram, see wiring schematic #18973
located in Appendix H.

5.5.2 BOILER MANAGEMENT SYSTEM SETUP AND STARTUP

This mode of operation is factory preset and the
firing rate is controlled by the AERCO BMS
Model 168. There are no setup instructions for
each individual unit. However the unit must be
taken out of remote mode, and set to local
mode, to manually run the unit. Once finished
with manual mode it is necessary to set the unit
back to remote mode for it to be controlled by
the BMS.

To set the unit in local mode do the following:

1. Access the temperature controller’s
secondary menu.

2. Scroll through the menu until "lore" is
displayed.

3. Use the ⇑ ⇓ keys to set the temperature
controller to local. The yellow REM light, on
the temperature controller, should extinguish

4. Press ENTER to accept the change.

5. Follow the above directions to change back
to remote mode.

NOTE:

The unit automatically defaults to remote

mode upon AC power being applied. This is

due to the presence of the external

interface board.

5.6 COMBINATION CONTROL SYSTEM (CCP)

A Combination Control System is when enough
units are installed to cover the space-heating
load on the design day. However one or more of
the units are used to heat domestic, water while
the remaining units take care of the heating load.
The units used for the domestic hot water are
designated as the combination units and are
referred to as the combo units. The combo units
heat water to a constant setpoint temperature
that is circulated through a heat exchanger in a
domestic hot water tank.

An AERCO BMS 168 panel, a Combination
Control Panel (CCP), and the units are
interfaced in this mode of operation. When the
space heating units are all at 100% firing rate,
the BMS asks the CCP to switch the Combo
boilers to space heating mode. If the domestic
load is satisfied, the aquastat on the domestic
tank is open, the combo units will switch over to
space heating. If the domestic load is not
satisfied, the combo units remain on the
domestic load. If the combo units switch over to
space heating but there is a call for domestic hot
water, the CCP switches the combo units back
to the domestic load.

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

In CCP mode, the external interface board is
utilized. The interface board, located in the field
wiring box, is factory configured, and converts
the pulse width modulation signal, sent from the
BMS, to an RS-485 signal. The RS-485 signal is
then sent to the temperature controller. For the
temperature controller to recognize a signal,
from an external source, the following functions
must be correctly set.

MENU FUNCTION SETTING

Secondary Lore re
Secondary FUNC Cont

Primary Auto ON

27

MODE OF OPERATION

5.6.1 COMBINATION CONTROL SYSTEM

FIELD WIRING

Wiring for this system is between the BMS
panel, the CCP and terminals 2 and 3 in the
unit’s field wiring box. Wire the units using a
twisted pair of 22 gauge minimum wire. No
shield is necessary. When wiring multiple units,
each unit’s wiring must conform to the above.
For a complete CCP system-wiring diagram, see
the AERCO CCP-1 literature.

5.6.2 COMBINATION CONTROL SYSTEM

SETUP AND STARTUP

Setup for the Combination mode unit is limited to
setting the desired setpoint of the unit when in
combination (constant setpoint mode).

The setpoint is adjustable from 50 to 220
degrees. To set the setpoint do the following:

1. While in either the primary or secondary
menus, scroll through until the display shows
"Setp".

2. Use the ⇑ ⇓ keys to set the desired setpoint.

3. Press enter to accept the changes.

While it is possible to change other temperature
related functions, when the unit is in combination
mode, the unit is factory preset with settings that
work well in most applications. It is suggested
that AERCO be contacted prior to changing
settings other than the unit’s setpoint. For a
complete listing and description of temperature
related functions see Appendix E.

When the unit switches to BMS mode, the firing
rate is controlled by the AERCO BMS Model

168. There are no setup requirements in this

mode. However when the unit is in BMS mode,
and it is desired to run the unit in manual mode,
it must be taken out of remote mode and set to
local mode. Once finished with manual mode it is
necessary to set the unit back to remote mode
for it to be controlled by the BMS.

To set the unit in local mode do the following:

1. Access the temperature controller’s
secondary menu.

2. Scroll through the menu until lore is
displayed.

3. Use the ⇑ ⇓ keys to set the temperature
controller to local. The yellow REM light, on
the temperature controller, should extinguish

4. Press ENTER to accept the change.

5. Follow the above directions to change back
to remote mode.

5.7. USING THE OUTSIDE AIR SENSOR

FEATURE

This feature allows the unit to be enabled or
disabled based on outside air temperatures. To
use this feature an outside air temperature
sensor must be installed, the feature must be
turned on, and a temperature setting must be
chosen.

To initiate this feature:

1. Access the secondary menu in the
temperature controller.

2. Scroll through the secondary menu until
OAST is displayed.

3. Use the ⇑ ⇓ keys to turn this feature on or
off.

4. Press ENTER to accept the change

5. Now scroll through the secondary menu until
OAT is displayed.

6. Use the ⇑ ⇓ keys to set the desired outside
air temperature the units are to begin
running.

7. Press ENTER to accept the change

28

SECTION 6-SAFETY DEVICE TESTING PROCEDURES

6.1 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.

NOTE:

It will be necessary to remove the sheet

metal covers and cap from the unit to

perform the following tests.

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.

6.2 GAS PRESSURE FAULT TEST

1. Shut off the gas supply to the unit.

2. Install a 0-16” W.C. manometer in the gas
pipe assembly below the low gas pressure
switch. (See Fig. 6.1)

3. Open the gas supply to the unit and reset
the low gas switch.

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 6.5” W.C.

6. Open the gas supply to the unit.

7. The unit should not start until the reset
button on gas pressure switch is depressed.

SAFETY DEVICE TESTING

1/4" NPT PLUG

(INSTALL
MANOMETER

HERE)

SSOV

Figure 6.1

1/8” Pipe Plug Position for Manometer

installation

NOTE:

After faulting the unit, the fault message will

be displayed and the fault indicator light will

flash until the CLEAR button is pressed.

6.3 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.

29

SAFETY DEVICE TESTING

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 once the shell is full.

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

6.4 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. 6.2).

6.5 FLAME FAULT TEST

1. Start the unit.

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.

6.3).

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

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 6.2

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
its prior setting.

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

Figure 6.3

Manual Leak Detection Valve

9. Reset the Combustion safeguard and
CLEAR the Annunciator.

10. Start the unit.

6.6 AIR PRESSURE FAULT TEST

WARNING!

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

BE REMOVED PRIOR TO PERFORMING

WIRE REMOVAL OR OTHER TESTING

PROCEDURES THAT CAN RESULT IN

ELECTRICAL SHOCK.

30

SAFETY DEVICE TESTING

1. Disconnect AC power from the unit.

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

6.4).

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 6.4

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 6.5

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.

6.6).

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.

6.7 PURGE INTERLOCKS FAULT TEST

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

2. Loosen the two setscrews that attach the
safety shut off valve actuator to the valve
body. (See Fig. 6.5).

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

4. Start the unit.

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

Figure 6.6

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. 6.7).

31

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.

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.

6.8 SAFETY PRESSURE RELIEF VALVE

TEST

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

Figure 6.7

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. 6.7).

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

17. Start the unit in manual mode.

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

19. Disconnect AC power from the unit.

20. Reconnect wire #62 to the ignition position
switch.

32

SECTION 7 - MAINTENANCE

7.1 MAINTENANCE SCHEDULE

The unit requires regular routine maintenance to
keep up efficiency and reliability. For best
operation and life of the unit, the following
routine maintenance procedures should be
carried out in the time periods specified.

Table 1 Maintenance Schedule

Sect Item

7.2 Spark

Ignitor

7.3 Flame

Detector

7.4 Combustion

Adj.

7.5 Testing of

Safety
Devices

7.6 *Manifold &

Tubes

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

TO AVOID PERSONAL INJURY, BEFORE

(A) DISCONNECT THE AC SUPPLY BY
TURNING OFF THE SERVICE SWITCH

AND AC SUPPLY CIRCUIT BREAKER

(B) SHUT OFF THE GAS SUPPLY AT THE

MANUAL SHUT-OFF VALVE PROVIDED

(C) ALLOW THE UNIT TO COOL TO A

SAFE TEMPERATURE TO PREVENT

BURNING OR SCALDING

7.2 SPARK IGNITOR

The spark ignitor assembly is located in the body
of the burner (see Fig. 7.1). 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.

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.

6 Mos. 12 Mos.

Inspect

Inspect

*Check Check 1 hr.

Test 20

Replace

Replace

24

Labor

Mos.

Time

15

mins.

15

mins.

mins.

Inspe

4 hrs.

ct &
clean
if
neces
sary

WARNING!

SERVICING:

WITH THE UNIT

MAINTENANCE

2. 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

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

4. 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.

5. The ignitor is gapped at 1/8-inch. If there is a
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).

6. Prior to reinstalling the ignitor, an anti-seize
compound must
threads.

The ignitor must be removed and installed using
the ignitor removal tool provided with the unit(s).

Damage to the burner due to using a socket for

removal and installation of the ignitor is not

covered under warranty.

7. 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.

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

7.3 FLAME DETECTOR

The flame detector assembly is located in the
body of the burner (see Fig. 7.1). The flame
detector may be HOT. Allow the unit to cool
sufficiently before removing the flame detector.

be applied to the ignitor

CAUTION!

33

Figure 7.1

Spark Ignitor and Flame Detector Location

To inspect or replace the flame detector:

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

2. Disconnect the plastic tubing from the
condensate cup to drain and remove the
rear covers from the unit. Access to the
flame detector may also be gained by
removing the unit’s left side panel

3. Disconnect the flame detector lead wire.
Unscrew the flame detector and remove it
from its guide tube. The detector is flexible
and may be bent to ease its removal.

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.

6. Reconnect the flame detector lead wire.

7. Replace the rear cover panels or left side
panel and reconnect the rear covers to the
unit. Replace the condensate cup to drain
tubing.

7.4 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.

7.5 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 CSD­1, require that these tests be performed on a

MAINTENANCE

scheduled basis. Test schedules must conform
to local jurisdictions. The results of the tests
should be recorded in a log book. See Section 6­Safety Device Testing Procedures.

7.6 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

*Not necessary to change but should be on hand
in case damage occurs during the inspection.

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. Remove the flame detector and ignition

cable wires from the flame detector and
ignitor contactor. Remove the flame detector
and ignitor as sections 7.2, and 7.3.

6. Remove the grounding terminal from the

burner by loosening the upper screw and
sliding the connector from the grounding rod.
(See Fig. 7.2)

34

Figure 7.2

Grounding Terminal Location

7. Using a 7/16” socket or open end wrench
remove the four 1/4”-20 nuts on the gas inlet
pipe flange at the burner (See Fig. 7.3).

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. 7.3).

9. Loosen the hose clamp nearest the air/fuel
valve outlet on the air/fuel valve to burner
adapter (See Fig. 7.3).

10. Using a 1/2” socket wrench remove six 5/16­18 hex nuts supporting the burner (See Fig.

7.3).

MAINTENANCE

Figure 7.4

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. 7.5).

Figure 7.3

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. 7.4).

Figure 7.5

Blower Proof Switch Wire Locations

15. Loosen the hose clamp on the air/fuel valve
inlet and slide the clamp back towards the
blower (See Fig. 7.6).

35

Figure 7.6

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. 7.7).

17. Using two 9/16” wrenches remove the two
3/8-16 hex nuts and bolts holding the air/fuel
valve to the differential pressure regulator
(See Fig. 7.7).

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

19. Remove the flue venting from the exhaust
manifold.

MAINTENANCE

insulation. 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.

7.8).

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:

The combustion chamber liner should be

installed prior to reinstalling the exhaust

manifold

Figure 7.7

Feedback Tube and Air/Fuel Valve to Differential

Regulator Bolts

20. To prevent damage to and for easier
handling of the exhaust manifold it will be
necessary to remove the exhaust manifold

Figure 7.8

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

.

36

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

7.6.1 PROPANE UNITS

For propane units it will be necessary to remove
the air mix assembly in addition to the
components outlined in Section 7.6. Proceed as
follows:

1. Follow steps 1 through 5 under Section 7.6.

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. 7.9).

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

4. Proceed back to Section 7.6 and continue at
Step # 6.

MAINTENANCE

Figure 7.9

Propane Unit Component Location

NOTE:

Older propane units have a 1/8” feedback

tube and 1/8” OD tube compression fittings.

37

SECTION 8- TROUBLESHOOTING GUIDE

This troubleshooting section is intended to serve
as a guideline to determining and solving faults
on the KC1000. Whenever a fault occurs,
proceed as follows:

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

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

3. Start the KC1000 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.

8.1 LOW GAS PRESSURE

8.1.1 Low Supply Gas Pressure

8.1.2 Gas Pressure Switches

A LOW GAS PRESSURE message indicates
that gas pressure has gone below 6.5” W.C.,
tripping the low gas pressure switch.

Recommended Troubleshooting Equipment

• 16.5” Manometer

• Analog or Digital Ohmmeter

8.1.1 LOW SUPPLY GAS PRESSURE

1. Install a manometer in the KC1000 Boiler
supply gas manifold as per Section 4.2.2.

2. Check the static pressure to the unit. It
should be between 10” to 14” W.C.

TROUBLESHOOTING

3. If the static pressure to the unit is lower than
10” W.C., readjust the supply regulator until
it’s output is between 10” to 14” W.C. If a
static supply pressure of 10” to 14” W.C.
cannot be obtained, proceed to step #8.

4. If static pressure is already 10” to 14” W.C.
or has been readjusted, start the unit. It may
be necessary to depress the reset button on
units having manual reset gas switches
before the unit will restart.

5. Observe the gas supply pressure during the
ignition cycle. If gas pressure drops below

6.5” W.C. during the ignition cycle try to
increase gas pressure at the gas supply
regulator then re-start the unit. If gas
pressure cannot be sufficiently increased,
proceed to Step #8.

6. If gas pressure does not drop below 6.5”
W.C. in any one of the above steps slowly
increase the input percentage in 10%
increments while monitoring gas pressure.

7. If gas pressure drops below 6.5” W.C. while
increasing the firing rate, tripping the gas
pressure switch, try to increase gas pressure
at the supply regulator then repeat step #6. If
gas pressure cannot be sufficiently raised,
proceed to step eight.

8. Not being able to reach a desired gas
pressure, while in a static or firing mode, is
an indication of one of the following. 1) The
gas supply regulator is not properly sized. 2)
The gas pressure to the gas supply regulator
is insufficient. 3) The gas supply piping has
too many pressure drops. It will be
necessary to contact one or more of the
following when troubleshooting these
conditions. Your local gas utility. The
regulator manufacturer. The local AERCO
representative.

8.1.2 LOW GAS PRESSURE SWITCH

1. If static pressure to the unit is correct,
disconnect AC power to the unit. Remove
wires #20 & #140 from the low gas pressure
switch.

2. Using an ohmmeter, check the gas pressure
switch for continuity. Be sure the gas supply
to the unit is on and that the static pressure
is above 6.5” W.C. and reset the manual
rest gas pressure by depressing the reset
button prior to checking continuity.

38

TROUBLESHOOTING

3. Replace the low gas pressure switch if it
does not show continuity.

4. If there is no continuity, check for loose
connectors at the switch end of the wires.
Check the pins in the connector on the
bottom of the control box for proper insertion
and/or signs of wear. Make any necessary
repairs.

5. If the wires and connectors are not
defective, reconnect them. Reconnect
electric power.

6. If the gas pressure fault still 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.

8.2 HIGH GAS PRESSURE

A HIGH GAS PRESSURE message indicates
that gas pressure has exceeded 20” W .C.,
tripping the high gas pressure switch.

Recommended Troubleshooting Equipment

• 16.5” Manometer

• Analog or Digital Ohmmeter

1. Install a manometer in the unit’s gas supply
manifold as per Section 4.2.2. of this
manual.

2. Check the static pressure to the unit. It
should be between 10” to 14” W.C.

3. If the static pressure to the unit is higher
than 14” readjust the supply regulator until
it’s output is less than 14” W.C.

4. Start the unit and raise the firing rate in 10%
increments. If gas pressure is less than 6.5”
W.C. after reaching 100% input percentage,
readjust the gas the gas pressure to 6.5”. (It
may be necessary to depress the high gas
pressure switches manual reset button prior
to restarting the unit.)

5. Next, lower the input percentage to shut the
unit down. Measure the static gas pressure.
If it is above 14” it is an indication that there
may be excessive pressure drops in the gas
supply piping or other components in the gas
supply system.

6. If gas pressure did not require adjustment
and is higher than 14” W.C, it may be

necessary to replace the gas supply
regulator with a lock up style. Consult your
local AERCO representative for more
information.

8.2.3 HIGH GAS PRESSURE SWITCH

1. If static pressure to the unit is correct,
disconnect AC power to the unit. Remove
wires #32 & #140 from the high gas
pressure switch.

2. Using an ohmmeter, check the gas pressure
switch for continuity. Be sure the gas supply
to the unit is on and that the static pressure
is less than 20” W.C. If the unit has a
manual reset gas pressure switch, be sure
to depress the reset button prior to checking
continuity.

3. Replace the high gas pressure switch if it
does not show continuity.

4. If there is no continuity, check for loose
connectors at the switch end of the wires.
Check the pins in the connector on the
bottom of the control box for proper insertion
and/or signs of wear.

8.2 EXHAUST TEMPERATURE FAULT

A HI EXHAUST TEMP. message indicates that
the exhaust temperature has exceeded 500
This fault is an indication only display. It WILL
NOT SHUT DOW N the unit. The fault LED will
indicate and the fault relay will trip.

A high exhaust temperature is an indication that
the unit has a carbon coating on the fireside of
the heat exchanger exhaust tubes. Carbon build­up in the heat exchanger exhaust tubes results
in a loss of heat transfer and therefore high
exhaust temperatures. Carbon build-up 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 first be combustion
calibrated. to determine which one of the above
are responsible. Refer to sections 4.2 and 4.3 for
combustion calibration, or contact your local
AERCO representative further assistance.

8.2.1 Exhaust Temperature Sensor

8.2.2 Wiring & Connections

Recommended Troubleshooting Equipment

Digital Ohmmeter

Digital Temperature Meter

o

F.

39

TROUBLESHOOTING

8.2.1 EXHAUST TEMPERATURE
SENSOR

Start the unit and wait for the HI EXHAUST

TEMP. message to display.

1. Using an accurate temperature
measurement device, measure the actual

flue gas temperature. If the measurement
taken from the exhaust sensor

o

F, and the fault message still does not

500
clear, shut the unit of
power

.

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

3. Check continuity between the sensor wires.
(ensure that the sensor has cooled below
400°) If there is continuity replace the
exhaust sensor.

4. If there is no continuity and the exhaust
temperature fault still will not clear, replace
the Annunciator board.

5. If the measured flue gas temperature is
greater than 500
calibration as per Sections 4.2 and 4.3.

f and remove AC

0

F, check combustion

, is less than

,

8.3. WATER LEVEL FAULT

A LOW W ATER LEVEL message indicates that
water level in the unit is too low. Check that the
shut-off 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 there is
sufficient water level). If there is 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.

8.3.1 Water Level Probe

8.3.2 Wiring & Connections

8.3.3 Water level Circuit

Recommended Troubleshooting Equipment

• Digital Volt/Ohmmeter

8.31 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.

WARNING!

THIS WIRE HAS A POTENTIAL OF 12
VAC. BE SURE TO REMOVE POWER

FROM THE UNIT BEFORE

DISCONNECTING OR HANDLING THE

WIRE.

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

4. Reapply AC 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 8.3.2.

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

6. Reconnect AC power to the unit. If the fault
still does not clear, proceed to section 8.3.3.

If the fault clears

8.3.2 WIRING AND CONNECTIONS

1. Disconnect AC power to the unit.

2. Remove the unit cap and disconnect wire
#25 from the water level probe and unplug
the 9 pin connector from the control box.

3. Referring to system schematic 161413 in
Appendix H, 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. Reconnect the 9 pin connector to the control
panel.

10. Reconnect electric power to the unit. If the
water level fault still does not clear, see
Section 8.3.3.

, replace the probe.

40

TROUBLESHOOTING

8.3.3 WATER LEVEL CIRCUIT

1. Remove AC power from the unit.

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

WARNING!

THE WIRES AND COMPONENTS IN THE

CONTROL PANEL USE 120VAC POWER.

DO NOT TOUCH ANY WIRES OR

COMPONENTS IN THE CONTROL BOX

WITH POWER APPLIED.

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

4. 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 panel and
the unit shell.

5. If there is no continuity repair as necessary.
If there is continuity replace the low water
level circuit board.

8.4 WATER TEMPERATURE FAULT

A HIGH WATER TEMPERATURE fault indicates
that the temperature of the discharge water has
exceeded the setpoint of the over temperature
switches. If the unit fires but displays the HIGH
WATER TEMP. message replace the
Annunciator. Try to reset the unit by pressing the
clear button to clear the fault message. If the

fault message cannot be cleared
does not fire

8.4.1 Determining the Cause

8.4.2 Over Temperature Limit Switches

8.4.3 Other Causes

Recommended Troubleshooting Equipment

, check the following.

• Digital Voltmeter

• Digital Ohmmeter

8.4.1 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

o

F higher than the setpoint of the unit. Make

of 20
adjustments if necessary.

, check continuity

, and

, and the unit

Often in a boiler system, supply water
temperatures can vary and may be higher than
the system design temperature. Check the
actual outlet water temperature of the unit and
ensure that the lower temperature switch is 20
or more above the actual discharge water
temperature. In a situation like this it may be
necessary to raise the lower limit setting to 40
above the system design temperature. If after
raising the lower limit switch setting the water
temperature the fault still persists, see Section

8.4.2.

It is sometimes common for a unit to over-temp
when it is being controlled by an external energy
management system that also controls the
system pump(s). The external energy
management system may not be interlocked to
the unit(s) to disable the unit(s) in the event that
the system pump or other system component
should fail. Typically in an over-temperature
situation of this nature the upper, manual reset,
temperature limit switch is tripped.
Reset the unit and, if necessary, the upper over

temperature limit switch. If the unit will not reset
proceed to section 8.4.2.

o

F

0

F

8.4.2 OVER TEMPERATURE LIMIT
SWITCHES

1. Disconnect AC power to the unit.

2. Raise the temperature limit switch setpoint a
minimum of 10
discharge water temperature.

3. Referring to system schematic 161413 in
Appendix H, 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 wire's #18, #19 and #33.

0

F above the actual

,

41

TROUBLESHOOTING

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

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

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

12. Reapply AC power to the unit.

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

8.4.3 OTHER CAUSES

Other over temperature related causes include:

1. Improper settings of PID control settings.

2. Improper flow rates through the unit.

3. PID settings require tuning to the loop

If one of the above is suspect contact your local
AERCO representative for further assistance

8.5 FLAME FAULT

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.

8.5.1 Flame Fault While Firing

8.5.2 Flame Fault During Ignition Cycle

8.5.3 Safety Shut-Off Valve

8.5.4 Spark Ignitor

8.5.5 Flame Detector

8.5.6 Ignition Circuit

8.5.7 Air Fuel Valve Ignition Position Switch

8.5.8 Flame Detector Voltage

8.5.9 Residual Flame

Recommended Troubleshooting Equipment

• Digital or Analog Voltmeter

• Combustion Analyzer

• 8” and 16.5” Manometers

8.5.1 FLAME FAULT WHILE FIRING

1. Install a DC voltmeter in the flame test jacks
located on the front of the combustion
safeguard and start the unit.

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

3. Fire the unit at various firing rates (i.e
30%, 50%, 100% etc

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

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

,).

, 16%,

8.5.2 FLAME FAULT DURING IGNITION

TRIAL

1. Check that all gas supply valves are open

2. If the gas supply valves were open, start 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 proceed to
Section 8.7.7.

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

NOTE:

At the ignition cycle, the low fire switch is

made, and the safety shut-off 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 8.5.3

5. If the safety shut-off valve opens check the
spark ignitor as per Section 8.5.4 and the
flame detector, as per Section 8.5.5.

6. If the spark ignitor and flame detector are
okay, or require replacement and the flame
fault still persists, check the ignition circuit as
per Section 8.5.6.

42

TROUBLESHOOTING

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

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

If the flame fault still persists after the above,
replace the combustion safeguard.

8.5.3 SAFETY SHUT-OFF VALVE

1. Start the unit.

2. When the starting sequence reaches the
ignition trial cycle, observe the response of
the safety shut-off valve through the window
in the actuator portion

3. At the ignition cycle, the OPEN disc should
slowly begin to descend down as the
hydraulic actuator opens the valve.

4. If the actuator does not open the valve,
disconnect AC power to the unit.

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

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

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

8. Referring to system schematic 161413 in
Appendix H, connect an AC voltmeter
across wires #14 and #28.

9. Reconnect AC power to the unit.

10. Start the unit.

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

12. If 120VAC is observed on the voltmeter,
replace the safety shut-off valve actuator.

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

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

15. Referring to system schematic 161413 in
Appendix H, locate wires #14, #28 and #27
and check each for continuity.

16. 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

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

18. Make any necessary repairs.

19. If all wires show continuity and all
connections are okay, reconnect wires #14,
#28 and #29 to the safety shut-off valve and
wires #28 and #29 to their proper locations
in the AC wiring box.

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

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

22. Reconnect AC power to the unit and Start
the unit.

23. If the safety shut-off valve still does not
open, proceed to section 8.7.8

24. Be sure to return the safety shut-off valve to
its original position and replace all electrical
cover plates.

8.5.4 SPARK IGNITOR

1. Disconnect AC power to the unit.

2. Remove the spark ignitor as per Section 7.2
of this manual.

3. Inspect the ignitor for signs of erosion.

4. Replace the ignitor if eroded.

5. Check for carbon build-up on the ignitor

.

6. If there is carbon 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.

43

TROUBLESHOOTING

8.5.5 FLAME DETECTOR

1. Disconnect AC power to the unit.

2. Remove the flame detector as per Section

7.3.

3. Check the detector for signs of erosion or
carbon build-up.

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

5. Carbon build-up on the flame detector
indicates that unit may require combustion
calibration.

6. Check the combustion calibration settings as
per Sections 4.2 and 4.3.

8.5.6 IGNITION CIRCUIT

1. Disconnect AC power to the unit.

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

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

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

5. Reconnect AC power to the unit.

6. Start 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 CIRCUIT COMPONENTS

WHILE TESTING.

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

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

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

10. Replace the cable if there is no continuity or
if there is a loose connection.

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

12. Referring to system schematic 161413 in
Appendix H, locate wires #12 and #29.

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

14. Reconnect AC power to the unit and start
the unit.

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

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

17. If 120VAC is not observed on the AC
voltmeter during the Ignition cycle,
disconnect AC 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 161413 in
Appendix H, check wires #12 and #29 for
continuity.

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. After 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.

44

TROUBLESHOOTING

29. Reconnect AC power to the unit and start
the unit.

30. If the flame fault still persists, replace the
combustion safeguard.

8.5.7 FLAME DETECTOR VOLTAGE

1. Disconnect AC power to the unit.

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

3. Connect an AC voltmeter from the flame
detector lead wire to the frame of the unit.

WARNING !

A SHOCK POTENTIAL EXISTS. THE

FLAME DETECTOR LEAD WIRE HAS A

POTENTIAL OF 345 VAC.

4. Reconnect AC 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

8.5.2, Step 8.

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

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

9. Referring to system schematic 161413 in
Appendix H, 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 9
pin 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. Reconnect AC power to the unit and start
the unit.

15. If the flame fault still persists, contact you’re
your local AERCO representative safeguard.

8.5.8 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 typically a leaking safety shut-off valve. To
check for a leaking safety shut-off 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 shut-off valve and the differential
pressure regulator.

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

4. Install an 8” or 16.5” 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.

8.6 AIR PRESSURE FAULT

A LOCKOUT RUN AIR FLOW indicates that the
air pressure, while firing, was too low for
operation. Oscillations or rumbling of the unit is
also a common cause this fault.

8.6.1 Determining the Cause of the Fault

8.6.2 Oscillations

8.6.3 Blower

8.6.4 Blower Proof Switch

8.6.5 Solid State Relay

Recommended Troubleshooting Equipment

AC Voltmeter

Ohmmeter

8.6.1 DETERMINING THE CAUSE OF

THE FAULT

1. Clear the Annunciator and start the unit.

2. If the unit does not fault after proving flame,
proceed to Section 8.6.2.

3. If the blower does not start
Section 8.6.3.

, proceed to

45

TROUBLESHOOTING

4. If the blower starts but the Annunciator
displays LOW AIR FLOW , proceed to
Section 8.6.4.

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

6. If combustion air is ducted into the room, or
brought in through a louver, be sure that the
size of the ducting or louver is adequate.
Ensure that the louvers are open while the
unit is firing.

8.6.2 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

off.

1. Start the unit.

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

3. If a rumbling sound is heard, at firing rates
above 75%, combustion calibrate the unit as
per sections 4.3 and 4.4.

8.6.3 BLOWER

1. Disconnect AC 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. Reconnect AC power to the unit.

7. Start the unit.

8. The AC voltmeter should measure 120VAC.

9. If 120VAC is not measured, proceed to
section 8.6.5

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

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

8.6.4 BLOWER PROOF SWITCH

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

2. Connect an ohmmeter across the blower
proof switch and start 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 in this section.

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

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

7. Referring to system schematic 161413 in
Appendix H, 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, 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. Reconnect AC power to the unit and start
the unit.

13. If the blower proof fault still persists, replace
the combustion safeguard.

46

TROUBLESHOOTING

8.6.5 SOLID STATE RELAY

1. Referring to Appendix I,Item #17, open the
control box and locate the solid state relay.

2. Locate wire 81 on terminal 3 of the relay.
Measure the AC voltage on terminal 3 when
the unit is attempting to start.

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

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

8.7 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 shut-off
valve proof of closure switch, the blower proof
switch, or the air/fuel valve open switch.

8.7.1 Determining the Cause

8.7.2 Blower

8.7.3 Combustion Air Supply and Blower

Proof Switch

8.7.4 Purge Interlocks

8.7.5 SSOV Proof of Closure Switch

8.7.6 Air/fuel Valve Open Proving Switch

8.7.7 Air/Fuel Valve not Rotating

8.7.8 Air/Fuel Valve Ignition Position Switch

Recommended Troubleshooting Equipment

AC Voltmeter
Ohmmeter

8.7.1 DETERMINING THE CAUSE

1. Clear the Annunciator and start the unit.

2. If the blower starts and the message
SYSTEM FAULT PURGE INTERLOCKS is
displayed proceed to section 8.7.4

3. If the blower does not start, and the
message SYSTEM FAULT LOW AIR
PRESSURE is displayed, proceed to section

8.7.2.

4. If the blower starts, and the message
SYSTEM FAULT LOW AIR PRESSURE is
displayed, proceed to section 8.7.3

5. If the unit does not fire, and the message
SYS FLT is displayed on the temperature
controller and the Annunciator, proceed to
section 8.7.8.

8.7.2. 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. Reconnect AC power to the unit.

7. Start the unit.

8. The AC voltmeter should display 120VAC.

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

10. If 120VAC 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.

8.7.3 COMBUSTION 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.

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

47

TROUBLESHOOTING

4. Connect an ohmmeter across the blower
proof switch and start 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 there is blockage, clean
the switch and retest.

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

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

9. Referring to system schematic 161413 in
Appendix H, 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 connector 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. Reconnect AC power to the unit and start
the unit.

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

8.7.4 PURGE INTERLOCKS

If the SSOV proof of closure switch or the air/fuel
valve open position switches fail to prove closed
during the start up 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 start the unit.

3. If the Annunciator displays the message
PURGE INTLK OPEN and the air/fuel valve
does not rotate, proceed to section 8.7.7.

4. If the air/fuel valve rotates to its full open
position and engages the air/fuel valve open
proving switch, and the Annunciator still
displays SYSTEM FAULT, PURGE
INTERLOCKS, proceed to section 8.7.6.

8.7.5 SSOV PROOF OF CLOSURE

SWITCH

1. Disconnect AC power to the unit.

2. Loosen the two set screws securing the
safety shut-off valve actuator to the safety
shut-off valve body.

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

4. Remove the electrical cover plate exposing
the control wiring

5. Referring to the system schematic 161413 in
Appendix H, 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
show continuity 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.

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 electrical cover
plate and reassemble the actuator to the
valve body.

48

TROUBLESHOOTING

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

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

16. Disconnect AC 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 161413 in
Appendix H, locate wires #21 and #22,
check each for continuity using an ohm
meter.

18. Check for loose connections.

19. Check wires #21 and #22 at the control
panel connector end 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. Reconnect AC power to the unit.

24. Start the unit. If the condition still persists
proceed to section 8.7.6.

8.7.6 AIR/FUEL VALVE OPEN, PROVING

SWITCH

1. Remove the air/fuel valve cover.

2. Start the unit.

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

4. If the air/fuel valve does not rotate, proceed
to 8.8.7.

5. Disconnect AC power to the unit.

6. Referring to system schematic 161413, in
Appendix H, 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 161413 in
Appendix H, 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,
reconnect wire #59 and #60 to the air/fuel
valve open switch. Reconnect the 12 pin
connector to the control panel and start 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.

8.7.7 AIR/FUEL VALVE NOT ROTATING

1. Disconnect AC 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.

49

TROUBLESHOOTING

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
161413 in Appendix H, 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. Referring to Appendix I, Item #4, 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 control.

12. Apply AC 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 volts ± 2 volts.

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, replace the stepper
motor driver board.

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

19. If the DC voltage is at 0 volts, replace the
temperature controller.

8.8.8 AIR/FUEL VALVE IGNITION
POSITION SWITCH

1. Disconnect AC power to the unit.

2. Remove the air/fuel valve cover

3. Referring to system schematic 161413 in
Appendix H, 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 161413 in
Appendix H, 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 start the
unit.

13. If the system fault still persists, contact your
local AERCO representative.

50

APPENDICES

APPENDIX A

Temperature Controller Menus

APPENDIX B

Temperature Controller Quick Programming Guide

APPENDIX C

APPENDIX

Temperature Sensor Resistance Chart

APPENDIX D

Indoor/Outdoor Reset Ratio Chart

APPENDIX E

Mode of Operation Factory Default Settings

APPENDIX F

Dimensional & Parts Drawings

APPENDIX G

Piping Draw ings

APPENDIX H

Wiring Schematics

APPENDIX I

Control Box Isometric Drawing

APPENDIX A

PRIMARY MENU ITEM DESCRIPTIONS

tout

pct

Auto

Setp

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

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 a 500,000
BTU gas input while a 75 % signal
equals approximately a 750,000 BTU
gas input and so on.

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

When set to automatic mode the
temperature controller receives and
processes 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 boiler. It is up to the operator who
put it into manual mode to control the
outlet temperature and firing rate.

i

SECONDARY MENU ITEM DESCRIPTIONS

FUNC

OSAT

Oat

LLT

Int

Hlt

Pb1

CONSTANT SETPOINT

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.

This menu item turns the outside air
enable\disable feature on or off. When
ON, an outside air temperature can be
chosen to enable or disable the unit.

This displays the outside air
temperature that the unit is enabled.
This parameter is displayed only when
OSAT is on.

This is Low Limit Temperature alarm.
This will put the temperature controller
into alarm if the outlet water
temperature goes below this setting.

This is High Limit Temperature alarm.
This will put the temperature controller
into alarm if the outlet water
temperature exceeds this setting.

This is the Proportional Band in 0F 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. It is
adjusted with the× and Ø. Press
ENTER to accept changes.

APPENDIX A

ii

APPENDIX A

Drt

Addr

LOre

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

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

This changes the local/remote status of
the controller. In local mode all external
computer write commands are ignored.
Read commands still function. In remote
both read and write comands from an
external computer will function.

iii

SECONDARY MENU ITEM DESCRIPTIONS

INDOOR-OUTDOOR RESET MODE

FUNC

REFT

RR

OSAT

Oat

LLT

Hlt

APPENDIX A

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

This is the building reference
temperature. It is the desired
temperature that the inside of the
building is to maintained.

Reset Ratio is the number of degrees
that the header temperature will
increase with each degree change in
outside air temperature

This menu item turns the outside air
enable\disable feature on or off. When
ON, an outside air temperature can be
chosen to enable or disable the unit.

This displays the outside air
temperature that the unit is enabled.
This parameter is displayed only when
OSAT is on.

This is Low Limit Temperature alarm.
This will put the temperature controller
into alarm if the outlet water
temperature goes below this setting.

This is High Limit Temperature alarm.
This will put the temperature controller
into alarm if the outlet water
temperature exceeds this setting.

iv

APPENDIX A

Pb1

Int

Drt

Addr

LOre

This is the Proportional Band in 0F 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. It is
adjusted with the× and Ø. Press
ENTER to accept changes.

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

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

This changes the local/remote status of
the controller. In local mode all external
computer write commands are ignored.
Read commands still function. In remote
both read and write commands from an
external computer will function.

v

APPENDIX B

TEMPERATURE CONTROLLER QUICK REFERENCE

PROGRAMMING GUIDE

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

their parameters, 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 the unit being serviced.

vi

APPENDIX B

NOTE:

The temperature controller defaults back to the PRIMARY 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

vii

• 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.

• SCROLLING THROUGH MENU ITEMS

APPENDIX B

To scroll through Menu items in a menu level, Press INDEX.
To scroll thru the PRIMARY, SECURE, or SECONDARY menus in reverse,

⇓

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

SECONDARY menu item, without scrolling, simultaneously press the INDEX and the
arrow key.

arrow key.

⇓

• CHANGING MENU ITEM VALUES

To change the value of a selected menu item press either the ⇑ arrow key, to increase

⇓

the item value, or the
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 decr ease the item value. Press, ENTER to accept

NOTE:

viii

APPENDIX C

ix

Air

Temp

50F
45F
40F
35F
30F
25F
20F
15F
10F

5F
0F

-5F

-10F

-15F

-20F

APPENDIX D

INDOOR\OUTDOOR RESET RATIO CHARTS

Header Temperature for a Building Reference Temperature of 50F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

50 50 50 50 50 50 50 50 50 50
53 54 55 56 57 58 59 60 60 62
56 58 60 62 64 66 68 70 72 74
59 62 65 68 71 74 77 80 83 86
62 66 70 74 78 82 86 90 94 98
65 70 75 80 85 90 95 100 105 110
68 74 80 86 92 98 104 110 116 122
71 78 85 92 99 106 113 120 127 134
74 82 90 98 106 114 122 130 138 146
77 86 95 104 113 122 131 140 149 158
80 90 100 110 120 130 140 150 160 170
83 94 105 116 127 138 149 160 171 182
86 98 110 122 134 146 158 170 182 194
89 102 115 128 141 154 167 180 193 206
92 106 120 134 148 162 176 190 204 218

Air

Temp

60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F

5F
0F

-5F

-10F

-15F

-20F

Header Temperature for a Building Reference Temperature of 60F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

60 60 60 60 60 60 60 60 60 60
63 64 65 66 67 68 69 70 71 72
66 68 70 72 74 76 78 80 82 84
69 72 75 78 81 84 87 90 93 96
72 76 80 84 88 92 96 100 104 108
75 80 85 90 95 100 105 110 115 120
78 84 90 96 102 108 114 120 126 132
81 88 95 102 109 116 123 130 137 144
84 92 100 108 116 124 132 140 148 156
87 96 105 114 123 132 141 150 159 168
90 100 110 120 130 140 150 160 170 180
93 104 115 126 137 148 159 170 181 192
96 108 120 132 144 156 168 180 192 204

99 112 125 138 151 164 177 190 203 216
102 116 130 144 158 172 186 200 214
105 120 135 150 165 180 195 210
108 124 140 156 172 188 204

Header Temperature for a Building Reference Temperature of 65F

x

Air

Temp

65
60
55
50
45
40
35
30
25
20
15
10

5
0

-5

-10

-15

-20

APPENDIX D

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

65 65 65 65 65 65 65 65 65 65
68 69 70 71 72 73 74 75 76 77
71 73 75 77 79 81 83 85 87 89
74 77 80 83 86 89 92 95 98 101
77 81 85 89 93 97 101 105 109 113
80 85 90 95 100 105 110 115 120 125
83 89 95 101 107 113 119 125 131 137
86 93 100 107 114 121 128 135 142 149
89 97 105 113 121 129 137 145 153 161
92 101 110 119 128 137 146 155 164 173
95 105 115 125 135 145 155 165 175 185

98 109 120 131 142 153 164 175 186 197
101 113 125 137 149 161 173 185 197 209
104 117 130 143 156 169 182 195 208
107 121 135 149 163 177 191 205 219
110 125 140 155 170 185 200 215
113 129 145 161 177 193 209
116 133 150 167 201 218

Air

Temp

70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F

5F
0F

-5F

-10F

-15F

-20F

Header Temperature for a Building Reference Temperature of 70F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

70 70 70 70 70 70 70 70 70 70

73 74 75 76 77 78 79 80 81 82

76 78 80 82 84 86 88 90 92 94

79 82 85 88 91 94 97 100 103 106

82 86 90 94 98 102 106 110 114 118

85 90 95 100 105 110 115 120 125 130

88 94 100 106 112 118 124 130 136 142

91 98 105 112 119 126 133 140 147 154

94 102 110 118 126 134 142 150 158 166

97 106 115 124 133 142 151 160 169 178
100 110 120 130 140 150 160 170 180 190
103 114 125 136 147 158 169 180 191 202
106 118 130 142 154 166 178 190 202 214
109 122 135 148 161 174 187 200 213
112 126 140 154 168 182 196 210
115 130 145 160 175 190 205
118 134 150 166 182 198 214
121 138 155 172 189 206
124 142 160 178 196 214

xi

Air

Temp

75F
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F

5F
0F

-5F

-10F

-15F

APPENDIX D

Header Temperature for a Building Reference Temperature of 75F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

75 75 75 75 75 75 75 75 75 75

78 79 80 81 82 83 84 85 86 87

81 83 85 87 89 91 93 95 97 99

84 87 90 93 96 99 102 105 108 111

87 91 95 99 103 107 111 115 119 123

90 95 100 105 110 115 120 125 130 135

93 99 105 111 117 123 129 135 141 17

96 103 110 117 124 131 138 145 152 159

99 107 115 123 131 139 147 155 163 171
102 111 120 129 138 147 156 165 174 183
105 115 125 135 145 155 165 175 185 195
108 119 130 141 152 163 174 185 196 207
111 123 135 147 159 171 183 195 207 219
114 127 140 153 166 179 192 205 218
117 131 145 159 173 187 201 215
120 135 150 165 180 195 210
123 139 155 171 187 203 219
126 143 160 177 194 211
129 147 165 183 201 219

Header Temperature for a Building Reference Temperature of 80F

RESET RATIO

Air

Temp

80F 80 80 80 80 80 80 80 80 80 80
75F 83 84 85 86 87 88 89 90 91 92
70F 86 88 90 92 94 96 98 100 102 104
65F 89 92 95 98 101 104 107 110 113 116
60F 92 96 100 104 108 112 116 120 124 128
55F 95 100 105 110 115 120 125 130 135 140
50F 98 104 110 116 122 128 134 140 146 152
45F 101 108 115 122 129 136 143 150 157 164
40F 104 112 120 128 136 144 152 160 168 176
35F 107 116 125 134 143 152 161 170 179 188
30F 110 120 130 140 150 160 170 180 190 200
25F 113 124 135 146 157 168 174 190 201 212
20F 116 128 140 152 164 176 188 200 212
15F 119 132 145 158 171 184 197 210
10F 122 136 150 164 178 192 206

5F 125 140 155 170 185 200 215
0F 128 144 160 176 192 208

-5F 131 148 165 182 199 216

-10F 134 152 170 188 206

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

xii

Header Temperature for a Building Reference Temperature of 90F

RESET RATIO

Air

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Temp

90F
85F
80F
75F
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F

5F
0F

90 90 90 90 90 90 90 90 90 90

93 94 95 96 97 98 99 100 101 102

96 98 100 102 104 106 108 110 112 114

99 102 105 108 111 114 117 120 123 126
102 106 110 114 118 122 126 130 134 138
105 110 115 120 125 130 135 140 145 150
108 114 120 126 132 138 144 150 156 162
111 118 125 132 139 146 153 160 167 174
114 122 130 138 146 154 162 170 178 186
117 126 135 144 153 162 171 180 189 198
120 130 140 150 160 170 180 190 200 210
123 134 145 156 167 178 189 200
126 138 150 162 174 186 198 210
129 142 155 168 181 194 207
132 146 160 174 188 202 216
135 150 165 180 195 210
138 154 170 186 202 218
141 158 175 192 209
144 162 180 198 216

APPENDIX D

xiii

BOILER DEFAULT SETTINGS

CONSTANT SET POINT MODE

APPENDIX E

MENU LEVEL

& CODE

PRIMARY MENU

tout OUTLET TEMPERATURE ACTUAL

pct PERCENTAGE OF FIRING RATE ACTUAL

setp UNIT’S SETPOINT TEMPERATURE 120

airt OUTSIDE AIR TEMPERATURE ACTUAL

auto AUTOMATIC\MANUAL MODE AUTO ON

SECONDARY MENU

func MODE OF OPERATION CONT

OAST OUTSIDE AIR SENSOR FEATURE OFF

OAT OUTSIDE AIR TEMP 0

LLT LOW LIMIT TEMPERATURE 40

HLT HIGH LIMIT TEMPERATURE 220

pb1 PROPORTIONAL GAIN 70

int INTEGRAL 1

drt DERIVATIVE 0 (off)

addr ADDRESS 32

lore LOCAL/REMOTE MODE LOC

SECURE

secr SECURITY LEVEL 3
func MODE OF OPERATION CONT
gain GAIN 1

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 0 SEC.

DFIL DISPLAY FILTER 5

ARUP ANTI RESET WINDUP ON

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

VAL VALLEY(Lowest Temp. Has Seen Since Reset) ACTUAL
INPC INPUT CORRECTION 0
INPT INPUT TIMER 0.2

FILT SENSOR FILTER 2

UNIT UNIT OF DISPLAY F

ADDR ADDRESS 32
BAUD BAUD RATE 9600

INP INPUT CAL

DESCRIPTION OF CODE FACTORY

DEFAULT

xiv

BOILER DEFAULT SETTINGS

INDOOR /OUTDOOR RESET MODE

APPENDIX E

MENU LEVEL

& CODE

PRIMARY MENU

tout OUTLET TEMPERATURE ACTUAL

Pct PERCENTAGE OF FIRE RATE ACTUAL

SEtP UNIT’S SETPOINT TEMPERATURE 120

Airt OUTSIDE AIR TEMPERATURE ACTUAL

Auto AUTO\MANUAL MODE AUTO ON

SECONDARY MENU

Func MODE OF OPERATION OART

rEFt BUILDING REFERENCE TEMPERATURE 70

rr RESET RATIO 1.5

OASt OUTSIDE AIR SENSOR FEATURE OFF

OAt OUTSIDE AIR TEMP 0

LLt LOW LIMIT TEMPERATURE 40
HLt HIGH LIMIT TEMPERATURE 220

Pb1 PROPORTIONAL GAIN 70

Int INTEGRAL 1

drt DERIVATIVE 0 (off)

Addr ADDRESS 32

LOrE LOCAL/REMOTE LOC

DESCRIPTION OF CODE DEFAULT

VALUE

SECURE MENU

SECr SECURITY LEVEL 3

Func MODE OF OPERATION OART

gAin GAIN 1

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 0 SEC.

dFiL DISPLAY FILTER 5

ArUP ANTI RESET WINDUP ON

PEA PEAK ACTUAL

VAL VALLEY ACTUAL

InPC INPUT CORRECTION 0

InPt INPUT TIMER 0.2

FiLt SENSOR FILTER 2

Unit UNIT OF DISPLAY F

Addr ADDRESS 32

bAUd BAUD RATE 9600

InP INPUT CAL

xv

APPENDIX F

xvi

APPENDIX F

H

(184)

72-1/2

1"NPT

DRAIN

TEST PRESS.

(PSIG)

3(8)

VALVE

MATERIALS OF CONSTRUCTION

1/4" CARBON STEEL HEADS, SA-455

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

PRESSURE

VESSEL

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

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

COMBUSTION

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

1/4" WALL CU-NI WELDED TUBE SB171, CDA-706

CHAMBER

22(56)

(FLOOR FLANGE)

HEAT EXCHANGER DESIGN STANDARDS

DIMENSIONAL DRAWING

MODEL KC

GK 2-1-95

CHKD

STYLE

AP-A-568

APPD

240 225

c.g.

TEMP. (°F)

INTERNATIONAL INC.

NORTHVALE, NEW JERSEY 07647

5-3/4(15)

150

(OPTIONAL O.A.

INLET ADAPTER

PRESS. (PSIG)

MAX. WORKING MAXIMUM

ASME B & PV CODE SECTION IV STAMP H

SHELL SIDE

PRESSURE

RELIEF

VALVE

SHELL CAP

AC SERVICE CONN.

3/4 CONDUIT

120VAC SINGLE PHASE

14-3/4(37)

20 AMP W/GRD

3/4" NPT GAS VENT

TRAIN OPTION" ONLY

CONN. FOR "IRI GAS

AVAIL. - 6" OD)

COMB. AIR INTAKE

(34.4)

13-9/16

29

77-1/8

(196)

1-1/4NPT GAS INLET

3-1/8

14-3/8

KC SERIES GAS FIRED BOILER

(37)

(TYP)

REMOTE ALARM & CONTROL

CONNECTION - 3/4 CONDUIT

30-1/8

(77)

35(89)

49(124)

57(145)

16-3/4

(59)

23-1/4

(43)

5/8" I.D

MALE HOSE

CONDENSATE

DRAIN

NOTES:

1) DRAIN VALVE AND RELIEF VALVE ARE INCLUDED SEPARATELY IN SHIPMENT

2) A 1/4" PER FOOT FLUE PITCH BACK TOWARDS THE HEATER MUST BE

MAINTAINED TO ALLOW THE FLOW OF ANY CONDENSATE FORMED IN THE

FLUE TO FLOW TO THE DRAIN

3) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS)

47(119)

6(15)I.D.

FLUE CONN.

19(48)

SYS. WATER SUPPLY

4-150# FLG'D

(OUTLET)

4-150# FLG'D

SYS. WATER RETURN

(INLET)

3/4(2)DIA.

15-1/2(39)

TYP.

)

4-PLCS

(

68-1/2

(174)

c.g.

22-1/4(57)

(ENCLOSURE)

xvii

APPENDIX F

xviii

APPENDIX F

xix

APPENDIX G

xx

APPENDIX G

xxi

APPENDIX H

xxii

APPENDIX H

xxiii

APPENDIX I

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

3

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

xxiv

APPENDIX I

18 123280-B_ TEMPERATURE CONTROLLER (NEED STYLE NUMBER )
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

xxv

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 [phone]

Visit Us at www.aerco.com