AERCO GF-109 User Manual version 3.04

Download

Instruction

GF-109

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

No.

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-10-1324 and above

Patent No. 4,852,524

Printed in U.S.A. REVISED, JUNE 24, 2010

Telephone Support

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

Friday) (800) 526-0288

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

www.aerco.com

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-109 - THE AERCO KC1000 GAS FIRED BOILER

Operating & Maintenance Instructions

FOREWARD A SECTION 1 – SAFETY PRECAUTIONS 1-1

Para. Subject Page

1.1 Warnings & Cautions 1-1

1.2 Emergency Shutdown 1-2

SECTION 2 – INSTALLATION PROCEDURES 2-1

Para. Subject Page

2.1 Receiving the Unit 2-1

2.2 Unpacking 2-1

2.3 Installation 2-2

2.4 Gas Supply Piping 2-4

2.5 Electrical Supply 2-5

2.6 Mode of Operation and Field Control Wiring

2-6

Para. Subject Page

1.3 Prolonged Shutdown 1-2

Para. Subject Page

2.7 I/O Box Connections 2-8

2.8 Auxiliary Relay Contacts 2-10

2.9 Flue Gas Vent Installation 2-10

2.10 Combustion Air 2-10

SECTION 3 – CONTROL PANEL OPERATING PROCEDURES 3-1

Para. Subject Page

3.1 Introduction 3-1

3.2 Control Panel Description 3-1

3.3 Control Panel Menus 3-3

3.4 Operating Menu 3-4

3.5 Setup Menu 3-4

Para. Subject Page

3.6 Configuration Menu 3-5

3.7 Tuning Menu 3-6

3.8 Start Sequence 3-7

3.9 Start/Stop Levels 3-9

SECTION 4 – INITIAL START-UP 4-1

Para. Subject Page

4.1 Initial Startup Requirements 4-1

4.2 Tools and Instrumentation for Combustion Calibration

4.3 Combustion Calibration

4-1 4-2

Para. Subject Page

4.4 Propane Combustion Calibration 4-5

4.5 Unit Reassembly 4-6

4.6 Over-Temperature Limit Switch Adjustments

4-6

Section 5 – MODE OF OPERATION 5-1

Para. Subject Page

5.1 Introduction 5-1

5.2 Indoor/Outdoor Reset Mode 5-1

5.3

5.4 Remote Setpoint Modes 5-2

5.5 Direct Drive Modes 5-3

Constant Setpoint Mode 5-2

Para. Subject Page

5.6 Boiler Management System (BMS)

5.7 Combination Control System (CCS)

5-4 5-5

CONTENTS

SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1

Para. Subject Page

6.1 Testing of Safety Devices 6-1

6.2 Low Gas Pressure Fault Test 6-1

6.3 High Gas Pressure Fault Test 6-1

6.4 Low Water Level Fault Test 6-2

6.5 Water Temperature Fault Test 6-2

6.6 Interlock Fault Tests 6-3

6.7 Flame Fault Test 6-3

Para. Subject Page

6.8 Air Flow Fault Test 6-4

6.9 SSOV Proof of Closure Switch 6-4

6.10 Purge Switch Open During Purge

6.11 Ignition Switch Open During Ignition

6.12 Safety Pressure Relief Valve Test

6-5 6-6 6-6

SECTION 7 – MAINTENANCE 7-1

Para. Subject Page

7.1 Maintenance Schedule 7-1

7.2 Spark Ignitor 7-1

7.3 Flame Detector 7-2

7.4 Combustion Calibration 7-2

Para. Subject Page

7.5 Safety Device Testing 7-2

7.6 Man if old and Exhaust Tubes 7-2

7.7 Heat Exchanger Water Side Injection

7.8 Condensate Drain Assembly 7-6

7-5

SECTION 8 – TROUBLESHOOTING 8-1

Para. Subject Page

8.1 Introduction 8-1

Para. Subject Page

SECTION 9 – RS232 COMMUNICATION 9-1

Para. Subject Page

9.1 Introduction 9-1

9.2 RS232 Communication Setup 9-1

Para. Subject Page

9.3 Menu Processing Utilizing RS232 Communication

9.4 Data Logging 9-2

9-1

APPENDICES

App Subject Page

A Boiler Menu Item Descriptions A-1 B

C Temperature Sensor Resistance D Indoor/Outdoor Reset Ratio

Startup, Status and Fault Messages

Chart Charts

B-1 C-1 D-1

App Subject Page

E Boiler Default Settings E-1 F Dimensional and Part Drawings F-1 G Piping Drawings G-1 H Wiring Schematics H-1 I KC10 00 Contr o l Pan el V ie ws I-1 J Recommended Spare Parts J-1

WARRANTIES W-1

FOREWORD

Foreword

The AERCO KC boiler is a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the load tracking capability relates energy input directly to fluctuating system loads through a 20:1 modulating turndown ratio for natural gas units and 14:1 for propane units. The boiler’s condensing capability offers extremely high efficiencies and makes the KC boiler ideally suited for modern low temperature, as well as, conventional heating systems.

The KC boiler can be used singular or in modular arrangements for inherent standby with minimum space requirements. Venting capabilities offer maximum flexibility and allow installation without normal restrictions. The advanced electronics of each boiler module offer selectable modes of operation and interface capabilities.

After prolonged shutdown, it is recommended that the startup procedures in Section 4 and test procedures in Section 6 of this manual be performed, to verify system operating parameters. If there is an emergency, turn off the electrical power supply to the Aerco boiler or close the manual gas valve located before the unit. The installer is to identify the emergency shut-off device. FOR SERVICE OR PARTS, contact your local sales representative or AERCO INTERNATIONAL.

NAME:

ORGANIZATION:

ADDRESS:

TELEPHONE:

INSTALLATION DATE: _____________________________________________

SAFETY PRECAUTIONS

SECTION 1 -- SAFETY PRECAUTIONS

1.1 WARNINGS & CAUTIONS

Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions 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 AERCO Instruction Manual, the installation of units 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 boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CGA B149, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

See pages 1-2 and 1-3 for important information regarding installation of units within the Commonwealth of Massachusetts.

IMPORTANT

This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.

WARNINGS!

MUST BE OBSERVED TO PREVENT SERIOUS INJURY.

WARNING!

BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.

WARNING

DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

WARNING!

THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THEREFORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES.

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. CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE.

WARNING!

ELECTRICAL VOLTAGES OF 120 VAC ARE USED IN THIS EQUIPMENT. THEREFORE THE COVER ON THE UNIT’S POWER BOX (LOCATED ON THE FRONT RIGHT SIDE OF THE UNIT UNDER THE HOOD AND SHEET METAL SIDE PANEL) MUST BE INSTALLED AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.

CAUTIONS!

Must be observed to prevent equipment damage or loss of operating effectiveness.

CAUTION!

Many soaps used for gas pipe leak testing are corrosive to metals. The piping 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.

1-1

SAFETY PRECAUTIONS

1.2 EMERGENCY SHUTDOWN

If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit.

IMPORTANT

The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 5 of this manual be performed, to verify all systemoperating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.

Figure 1-1

Manual Gas Shutoff Valve

IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS

Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements:

• Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.

• Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.

• If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed upstream of the Fill/Makeup Valve.

• The vent termination must be located a minimum of 4 feet above grade level.

• If side-wall venting is used, the installation must conform to the following requirements extracted

from 248 CMR 5.08 (2):

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

. At the time of installation of the

1-2

Extracted Information From 248 CMR 5.08 (2) – Continued

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

SAFETY PRECAUTIONS

2. APPROVED CARBON MONOXIDE DETECTORS. required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.

KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

(b) EXEMPTIONS

1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

. A metal or plastic identification plate shall be permanently mounted to the exterior

. The state or local gas inspector of the side wall horizontally vented gas fueled

: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

Each carbon monoxide detector as

When

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

_______________________________ [End of Extracted Information From 248 CMR 5.08 (2)]

1-3

SECTION 2 - INSTALLATION PROCEDURES

2.1. RECEIVING THE UNIT

Each KC1000 Boiler is shipped as a single crated unit. The crated unit shipping weight is approximately 1500 pounds. It must be moved with the proper riggin g equipment f or safety and to avoid unit 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 indic ator 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 s hipment. Request a freight claim and inspecti on by a claims adjus ter before proceeding or refuse delivery of the equipment.

2.2. UNPACKING

Carefully unpack the unit. Take care not to damage the unit jacket when cutting away packaging materials. An inspection of the unit should be made to deter mine if damage during shipment occurred th at was not indicated by the Tip-N-Tell. The freight c arrier should be notif ied

INSTALLATION

immediately if any damage is detected. The following accessories come standard with each unit and are packed separ ately within the unit’s packing container

• Spare Spark Ignitor

• Spare Flame Detector

• Manual 1-1/4" Gas Shu t of f Valve

• Drain Valve As s embly

• ASME Pressure Relief Valve

• Ignitor Removal Tool (One per Site)

• Temperature/Pressure Gauge and Fittings

• 2 Lifting Lugs

• Stainless Steel Condensate Cup

• Shell Cap

• Wing Nut for Shell Cap

Optional accessories ar e als o separatel y pack ed within the unit’s packing container. Sta ndard and optional accessories shipped with the unit should be identif ied and put in a s afe place until installation or use.

Figure 2.1. Boiler Clearances

2-1

INSTALLATION

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 m ust 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.

MASSACHUSETTS INSTALLATIONS

For boiler installations within the Commonwealth of Massachusetts, the boiler must be installed by a plumber or gas fitter who is licensed within the Commonwealth. In addition, the boiler installation must comply with all requirements specified in Section 1 (Safety Precautions), pages 1-2 and 1-3.

2.3.1. SETTING THE UNI T

Remove the unit from the wooden skid and place in position using a block and tackle or hoist attached to the lifting lugs, (see Figure

2.2). USE ONLY THE LIFTING LUGS TO MOVE THE UNIT.

The KC-1000 is U /L approved f or installation o n combustible flooring. A 4” to 6" high housekeeping concrete pad is recommended and allows for sufficient drainage of the condensate.

It is suggested that u nits 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.

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. T he supp l y connection is l ocated on the left side near the top of the unit’s shell.

Whether installin g single or m ultiple 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 AER CO 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 m aintenance. In multiple unit installations, the f lo w through eac h u nit must be balanced.

2-2

INSTALLATION

Every boiler plan t must have a so urce of makeup water to it. As with an y 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.

The relief piping must be full size without reduction. No valves, restrictions, or other blockages should be allowed in the discharge line. In multiple un it installations the relief val ve discharge lines must not (connected), together . Each m ust be individu ally run to a suitable discharge location. The drain valve provided should be installed on the right hand side of the unit towar ds the bottom of the shell. The valv e should be pointed in th e down position, (see Figure 2.4).

be manifolded,

Figure 2.3

Supply and Return Location

NOTE:

The maximum working pressure for installations within the Province of Alberta is 87 psig. Therefore a pressure relief valve with a setting of 75 psig (or lower) should be installed for these installations. See Drawing AP-A-863 in Appendix F.

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). T he pressure relief valve should be piped in the vertical position using the fittings supplied. A suitable pipe com pound should be used on the threaded connections, and excess should be wiped off to avoid getting any into the valve body. The discharg e from the relief valve shou ld be piped to within 12 inches of the floor to prevent injury in the event of a discharge.

psig as

Figure 2.4

Relief and Drain Valve Location

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 Figures. 2.5a and 2.5b). A suitable pipe compound should be used sparingly to the threaded connection.

2-3

INSTALLATION

PARTIAL TOP VIEW OF BOILER

FOR INSTALLATION OF PRESS./TEMP. GAUGE PART NO. 122994-1 (PRESS. RANGE 0 – 75 PSI)

SHELL

CAP

SYSTEM

SUPPLY

REDUCING BUSHING

PRESS./TEMP. GAUGE

Pressure /Temperature Gauge Installation

1/2" x 1 /4"

Figure 2.5a

route it to a floor drain. If a floor drain is not available, a condensate pump can be used to remove the condensate to drain. The condensate drain line must be removable for routine maintenance. Therefore, DO NOT hardpipe.

4. Replace the rear cover and side panel on the unit.

Figure 2.5b

Pressure/Temperature Gauge Installation

2.3.5 CONDENSATE PIPING

The KC Boiler is designed to condense. Therefore, the installation site must include suitable provisions for condensate drainage or collection. A stainless steel condensate cup is separately packed within the unit’s shipping container. To install the condensate cup, proceed as follows:

1. Remove the l eft side panel and only the lef t half of the rear cover to provi de acces s to the exhaust manifold and burner (Figure 2.6).

2. Insert the 1-3/4 inc h manifold drai n hose into the condensate cup. A llow the cup to rest on the floor directly beneath the manifold drain hole (Figure 2.6).

3. Attach a length of 3/4 inch I.D. polyprop ylene tubing to the condensate c up drain tube and

Figure 2.6

Condensate Drain System Location

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.

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.

2-4

INSTALLATION

The location of the 1-1/4 " inlet gas connect ion is on the right side of the unit as s hown 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 s hould be installed. Piping should be supported f rom floor or wal ls onl y and must not be secured to the unit.

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

To avoid damage to the unit, when pressure testing gas piping, isolate the unit from the 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 pres sure 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 tim e when firing. Proper sizing of the gas supply regulat or in delivering the correct gas flow and outlet pressure is mandator y. The gas supply pres sure 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 suff icient capacity volume, (1000 cfh), for the unit and shoul d have no mor e 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 supp l y pressur e will not ex cee d 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.

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 g as shut-of valve must be installed upstream of the supply regulator in a readily accessible location.

Figure 2.7

Gas Supply Regulator and Manual Shut -Off

Valve Location

2.4.3 IRI GAS TRAIN KIT

The IRI gas train is an optional gas train required in some ar eas by code or f or insurance purposes. The IRI gas tra in is factory pre-piped and wired. (Refer to Appendix F, Drawing No. SD-A-584).

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. AC power connection to the unit are made at the Power Box.This box is loc ated on the fr ont right side of the unit as shown in Figure 2.8. Condu it should

2-5

INSTALLATION

be run from the knockouts in the side of the box in such a manner th at it does not interfere with the removal of an y s heet metal covers. A f lex ib le electrical connecti on ma y be utilized t o allow th e covers to be easily removed.

POWER BOX

FRAME

SSOV ACTUATOR

Figure 2.8

AC Power Box Location

BLOWER

Figure 2.9

AC Power Wiring Diagram

2.6 MODE OF OPERATION and FIE L D CONTROL WIRING

The KC Boiler is available in several different modes of operation. While each unit is factory configured and wired f or the mode specified on the equipment order, som e field wiring may be required to complete th e installation. This wir ing is typically routed to the Input/Output (I/O) Box located on the left side of the unit beneath the removable side panel (see Figure 2.10). Field wiring for each particular mode of operation is described in the following paragraphs. For additional information concerning modes of operations, refer to Section 5.

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 KC1000 unit. A means for disconnecting AC power from the unit (such as a service switch) must be installed near the unit for normal operation and maintenanc e. All electrical connections should be made in accorda nce with the Natio nal Electrical Code and/ or with any applicable local codes.

The AC power wiring di agram is shown in F igure

2.9.

Figure 2.10

Input/Output (I/O) Box Location

2-6

INSTALLATION

2.6.1 CONSTANT SETPOINT MODE 2.6. 2 INDOOR/OUTDOOR RESET MODE

The Constant Setpoi nt Mode is used when it is desired to have a fixed setpoint that does not deviate. No wiring connections other than electrical supply connections are required for this mode. However, if des ired, fault monitoring or enable/disable in terlock wiring c an be utilized (see paragraphs 2.7.9 and 2.7.10).

This mode of operation increases supply water temperature as outdoor te mperatures decrease. An outside air tem perature sensor (AERCO PN

122790) is required. The sensor MUST BE wired to the I/O Box wiring term inals (see Figure

2.11). For more information concerning the outside air sensor ins talla tion, ref er to paragra ph

2.7.1. For programming and setup instructions concerning the indoor/outdoor-reset mode of operation, refer to Section 5, paragraph 5.1. .

Figure 2.11

I/O Box Terminal Strip

2.6.3 BOILER MANAGEMENT SYSTEM

(BMS) MODE

NOTE

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

When using an AERCO Boiler Management System (BMS), the field wiring is connected between the BMS Panel and each Boiler’s I/O Box terminal strip (Figure 2-11). Twisted shielded pair wire f rom 18 to 22 AWG must be utilized for the connections. The BMS Mode can utilize either pulse width modulation (PWM) signaling, or RS485 Modbu s s ignaling. F or PWM

signaling, connections are made from the AERCO Boiler Management System to the B.M.S. (PWM) IN terminals on the I/O Box terminal strip. For RS485 Modbus signaling, connections are made from the BMS to the RS485 COMM term inals on the I/O Box ter minal strip. Polarity m ust be maintain ed and the shie ld must be connected only at the AERCO BMS. The boiler end of the shi eld m ust be left f loating. For additional instructions, refer to Chapter 5, paragraph 5.6 in t his manual. Also, ref er to GF108M (BMS Model 168) and GF-124 (BMS II Model 5R5-384), BMS -Operations Guides.

2-7

INSTALLATION

2.6.4 REMOTE SETPOINT and DIRECT

DRIVE MODES

The KC1000 Boiler c an accept several types of signal formats from an Energy Management System or other source to control either the setpoint (Remote Setpoint Mode) or valve position (Direct Dr ive Mode ) of the Boi ler. Thes e formats are:

4 to 20 mA/1 to 5 Vdc 0 to 20 mA/0 to 5 Vdc PWM – (Pulse Width Modulated signal. See

paragraph 2.7.4) Network – (RS485 Modbus. See para. 2.7.7) While it is possib le to control one or m or e boi lers

using one of the above modes of operation, it may not be the method best suited for the application. Prior to s electing one of the above modes of operation, it is recommended that you consult with your loca l AERCO representa tive or the factory for the mode of operation that will work best with your application. For more information on wiring th e 4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5 VDC, see paragraph

2.7.3.

2.6.5 COMBINATION MODE

NOTE

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

With a Combination Mode unit, field wiring is between the unit’s I/O Box, the CCP (Combination Control Panel), and the BMS Model 168 (Boiler Management System). The wiring must be done using a shielded twisted pair of 22 AWG wire. Polarity must be maintained between the unit, the CCP, and the BMS. For further instructions and wiring diagrams, refer to the GF-108 Boiler Management System Operations Guide and the CCP-1 data sheet.

2.7 I/O BOX CONNECTIONS

The types of input and output/signals and devices to be connecte d to the I/O Box terminals shown in Figure 2.11 are described in the following paragraphs.

CAUTION!

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

2.7.1 OUTDOOR SENSOR IN

An outdoor air temperature sensor (AERCO Part No. 122790) will be required mainly for the Indoor/Outdoor Reset m ode of operation. It can also be used with anoth er m ode if it is desired to use the outdoor sensor enable/disable feature. This feature allows the boiler to be enabled or disabled based on the outdoor air tem perature. The factory default for the outdoor sensor is DISABLED. To enable the sensor and/or select an enable/disable o utdoor temperature, see the Configuration menu in Section 3.

The outdoor sensor m ay be wired up t o 200 feet from the boiler and is connected to the OUTDOOR SENSOR IN and the SENSOR COMMON terminals in the I/O box (see Figures

2.10 and 2.11). W ire the sensor using a twisted shielded pair cabl e of 18-22 AW G wire. There is no polarity when terminating the wires. The shield is to be connected only to the terminals labeled SHEILD in t he I/O Box. The sensor end of the shield must be left free and ungrounded.

When mounting the sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be shield ed f orm dir ec t sunli ght as well as impingement by the elements. If a shield is used, it must allow for free air circulation.

2.7.2 AUX SENSOR IN

The AUX SENSOR IN terminals can b e used to add an additional temperature sensor for monitoring purposes. This input is always enabled and is a view only input that can be seen in the operating m enu. The sensor m us t be wired to the AUX SENSOR IN and SENSOR COMMON and must be similar to AERCO BALCO wire sensor P/N 12449. A resistance chart for this sensor can be found in Appendix C.

2-8

INSTALLATION

2.7.3 ANALOG IN

The ANALOG IN + and – terminals are used when an external signal is used to drive the valve position (Direc t Drive Mode) or change the setpoint (Remote Setpoint Mode) of the Boiler.

Either a 4 to 20 mA / 1 to 5 VDC or a 0 to 20 mA / 0 to 5 VDC signal may be used to vary the setpoint or valve position. The factory default setting is 4 to 20 mA / 1 to 5 VDC, however this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu described in Section 3. If voltage rather than current is selected as the dr ive signal, a DIP switch mus t be set on the PMC Board located inside the Control Box. Contact the AERCO factory for information on setting DIP switches.

All supplied signals must be floating (ungrounded) signals . Connectio ns bet ween the source and the Boiler’s I/O Box must be made using twisted shie lded pair of 18 –22 AW G wire such as Belden 9841(se e Figure 2.11). Polarit y must be maintained and the shield must be connected only at the source end and must be left floating (not connected) at the Boiler’s I/O Box.

Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F setpoint or a 0% to 100% valve position. No scaling for these signals is provided.

2.7.4 B.M.S. (PWM) IN

NOTE

Only BMS Model 168 can utilize Pulse Width Modulation (PW M), not the BMS II (Model 5R5-384).

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

2.7.5 SHIELD

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

2.7.6 mA OUT

These terminals provide a 4 to 20 mA output that can be used to monitor setpoint ( 40°F to 220°F), outlet temperature (30°F to 245°F), or valve position (0% to 100%). This function is enabled in the Configuration Menu (Section 3, Table 3-4).

2.7.7 RS-485 COMM

These terminals are used for RS-485 MODBUS serial communication between the unit and an external “Master”, s uch as a Boiler M anagement System or other suitable device.

2.7.8 EXHAUST SWITCH IN

These terminals permit an external exhaust switch to be connected to the exhaust manifold of the boiler. The exhaust sensor should be a normally open t ype sw itch (such as AERCO Par t No. 123463) that closes (trips) at 500

2.7.9 INTERLOCKS

The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers. These interlock s are called the Rem ote Interlock and Delayed Interlock (Figure 2.11). The wiring terminals for these interlocks are located inside the I/O Box on the lef t side of the unit. The I/O Box cover contains a wiring diagram which s hows th e ter m inal str ip locat ions for these interlock s which are labeled R EMOTE INTL’K IN and DELAYED INTL’K IN. Both interlocks, described in the following paragraphs, are factory wired in the closed position.

NOTE:

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

2.7.9.1 REMOTE INTERLOCK IN

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

2-9

INSTALLATION

2.7.9.2 DELAYED INTERLOCK IN

The delayed interl ock circuit (DELAYED INTL’K IN) is typically used in conjunction with the auxiliary rela y described in paragraph 2.8. This interlock circuit is located in the pur ge section of the start string. It can be connected to the proving device (end switch, flow switch etc.) of an auxiliary piece of equipment started by the boiler’s auxiliary relay. The delayed interlock must be closed for the boiler to fire. If the delayed interlock is connected to a proving device that requir es tim e to clos e (mak e), a tim e delay (Aux Start On Dly) that holds the start sequence of the boiler long enough for for a proving switch to make can be programmed. Should the proving switch not prove within the programmed time frame, the boiler will shut down. The Aux Start On Dly can be programmed from 0 to 120 sec onds . This optio n is locate in the Configuration Menu (Section 3).

2.7.10 FAULT RELAY

The fault relay is a single pole double throw (SPDT) relay having a normally open and normally close set of relay contacts that are rated for 5 amps at 12 0 VAC and 5 amps at 30 VDC. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed. The fault relay connections are shown in Figure 2.11.

2.8 AUXILIARY RELAY CONTACTS

Each Boiler is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and deenergized after the dem and for heat is satisf ied. The relay is prov ided for the control of auxiliary equipment, such as pumps and louvers, or can be used as a Boiler status indictor (firing or n ot firing). Its contacts are r ated for 120 VAC @ 5 amps. Refer to Figure 2.11 to locate the AUX RELAY terminals for wiring connections.

2.9 FLUE GAS VENT INSTALLATION

The AERCO Venting a nd Combustion Air Gu id e, GF-1050, must be cons ulted before any flue or inlet air venting is designed or installed. Suitable, U/L approved, positive pressure, water-tight vent materials as specified in AERCO’s GF-1050, m ust be used for safety and UL certification. Because the unit is capable of discharging low tem perature exhaust gas es, the flue must be pitched bac k to the un it a minimum of 1/4" per foot to avoid an y condensate pooli ng and to allow for proper drainage.

While there is a positive flue pressure during operation, the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet of 0.81” W.C.. Fittings as well as pipe lengths m ust 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 properl y or reliably.

For Massachusetts boiler installations, the Heatfab Division of the Selkirk Corporation provides vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts. Contact information for this supplier is as follows:

Selkirk Corporation Heatfab Division 130 Industrial Blvd. Turners Falls, MA 01376 Phone: 1-800-772-0739

www.heat-fab.com

2.10 COMBUSTION AIR

The AERCO Venting a nd Combustion Air Gu id e, GF-1050, MUST be co nsulted before any flue or combustion supply air venting is designed or started. Combustion air supply is a direct requirement of ANSI 223.1, NF PA-54, and local codes. These codes sh ould be consulted before a permanent design is determined.

The combustion air must be free of chlorine, halogenated hydrocarbons, or other chemicals that can become ha zardous when used in gasfired equipment. Common sources of these compounds are swimming pools, degreasing compounds, plastic proc essing and refrigerants. Whenever the env ironment c ontains thes e t ypes 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 suppl y from ducting, consult the AERCO GF-1050, Venting and Combustion Air Guide.

2-10

INSTALLATION

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 open ings 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 mus t take into account restrictions such as louvers and bird screens.

2.10.2 COMBUSTION AIR FROM INSIDE

THE BUILDING

When combustion air is provided f rom 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 BT UH of total input or 1000 square inches of f ree area. The free area must take into account any restrictions such as louvers.

2.10.3 SEALED COMBUSTION

The KC Boiler is UL a pproved for 100% sealed combustion application when installed properly. When a sealed combustion air application is installed, the se aled combustion air pipi ng must be deducted from the maximum allowable discharge piping amounts . Each unit must have a minimum 6" diam eter connection made to th e special Inlet Air Adapter # GP-18917 available from AERCO. This adapter bolts directly on to the air inlet of the unit ’s blower. See installati on instructions with adapt er. All inlet air ducts m ust be sealed air tight.

2-11

CONTROL PANEL OPERATING PROCEDURES

SECTION 3 - CONTROL PANEL OPERATING PROCEDURES

3.1. INTRODUCTION

The information in this Section provides a guide to the operation of the KC1000 Boiler using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel will void the equipment warranty. In addition, the following WARNINGS and CAUTIONS must be observed at all times.

CAUTION:

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

WARNING:

ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC. IT MUST NOT BE SERVICED OR ACCESSED BY OTHER THAN FACTORY CERTIFIED SERVICE TECHNICIANS.

WARNING:

DO NOT ATTEMPT TO DRY FIRE THE BOILER. 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.

3.2. CONTROL PANEL DESCRIPTION

The KC1000 Control Panel shown in Figure 3-1 contains all of the controls, indicators and displays necessary to operate, adjust and troubleshoot the KC1000 Boiler. These operating controls, indicators and displays are listed and described in Table 3-1. Additional information on these items are provided in the individual operating procedures provided in this Section.

Figure 3-1. Control Panel Front View

3-1

CONTROL PANEL OPERATING PROCEDURES

Table 3-1. Operating Controls, Indicators and Displays

ITEM

NO.

CONTROL, INDICATOR

OR DISPLAY

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

follows:

COMM

MANUAL

REMOTE

DEMAND

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

OUTLET

TEMPERATURE

Display

RS-232 Port

READY Indicator

ON/OFF Switch

LOW WATER LEVEL

TEST/RESET Switches

FAULT Indicator Red FAULT LED indicator lights when a boiler alarm

CLEAR Key

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

BACK

Lights when RS-232 communication is occurring Lights when the unit is being controlled using the front panel

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

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

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

Startup Messages Alarm Messages Operating Status Messages Menu Selection

3–Digit, 7–Segment LED display continuously displays the

outlet water temperature. The °F or °C LED next to the

display lights to indicate whether the displayed temperature is in degrees Fahrenheit or degrees Celsius.

Port permits a Laptop Computer or External Modem to be connected to the boiler Control Panel.

Lights when all Pre-Purge conditions have been satisified.

Enables and disables boiler operation.

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

Pressing TEST opens the water level probe circuit and

simulates a Low Water Level alarm.

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

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

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

the Control Panel Menus: Steps through the main menu categories shown in Figure 3-2.

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

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

FUNCTION

3-2

ITEM

NO.

(Cont.)

CONTROL PANEL OPERATING PROCEDURES

Table 3-1. Operating Controls, Indicators and Displays - Continued

CONTROL, INDICATOR

OR DISPLAY

▲ (Up) Arrow When in one of the main menu categories (Figure 3-2),

pressing this key will select the displayed menu category. If

the CHANGE key was pressed and the menu item is flashing,

pressing the ▲ arrow key will increment the selected setting.

▼ (Down) Arrow When in one of the main menu categories (Figure 3-2),

pressing this key will select the displayed menu category. If

the CHANGE key was pressed and the menu item is flashing,

pressing the ▼ (Down) arrow key will increment the selected setting.

FUNCTION

CHANGE

ENTER

AUTO/MAN Switch

VALVE POSITION

Bargraph

Permits a setting to be changed (edited). When the

CHANGE key is pressed, the displayed menu item will begin

to flash. Pressing the ▲ or ▼ arrow key when the item is flashing will increment or decrement the displayed setting.

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

This switch toggles the boiler between the Automatic and

Manual modes of operation. When in the Manual (MAN) mode, the front panel controls are enabled and the MANUAL

status LED lights.

When in the Automatic (AUTO) mode, the MANUAL status

LED will be off and the front panel controls disabled.

20 segment red LED bargraph continuously shows the Air/Fuel Valve Position (% open) in 5% increments from 0 to 100%

3.3. CONTROL PANEL MENUS

The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of four major menu categories as shown in Figure 3-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by a password to prevent unauthorized use.

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

Once the valid password (159) is entered, the options listed in the Setup, Configuration and

Tuning menus can be viewed and changed, if desired.

3.3.1. Menu Processing Procedure

Accessing each menu and option is accomplished using the Menu Keys shown in Figure 3-1. Therefore, it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures.

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

2. Press the MENU key. The display will show

the Setup Menu which is the next menu category shown in Figure 3-2. This menu contains the Password option which must be entered if other menu options will be changed.

3-3

CONTROL PANEL OPERATING PROCEDURES

3. Continue pressing the MENU key until the

desired menu is displayed.

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

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

6. To change the value or setting of a displayed

menu option, press the CHANGE key. The

displayed option will begin to flash. Continue to press the ▲ or ▼ arrow key for the option to be changed. The available menu option choices will be displayed. The menu option choices do not wrap around.

7. To select and store a changed menu option,

press the ENTER key.

OPERATION

PASSWORD

SETUP

CONFIGURATION

NOTE:

The following paragraphs provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of

displayed startup, status and error messages.

3.4. OPERATING MENU

The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any of the displayed items. Since this menu is “ReadOnly”, it can be viewed at any time without entering a password. Press the ▲ arrow key to display the menu items in the order listed (TopDown). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up).

3.5. SETUP MENU

The Setup Menu (Table 3-3) permits the operator to set the unit password which is required to change any of the menu options. To prevent unauthorized use, a previously entered password entry will time-out after 1 hour. Therefore, the password must be reentered when required. In addition to permitting password entries, the Setup Menu is also used to enter date and time, language to be used for display messages, units of temperature measurements and entries required for external communication and control of the unit via the RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version.

3-4

TUNING

Figure 3-2. Menu Structure

CONTROL PANEL OPERATING PROCEDURES

NOTE

The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4).

Table 3-2. Operating Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Menu Item

Status Message

Active Setpoint 40°F 240°F

AIR Temp -70°F 245°F

Outdoor Temp* -70°F 130°F

Valve Position In 0% 100% Valve

Flame Strength 0% 100%

Run Cycles 0 999,999,999

Display

Position

Run Hours 0 999,999,999

Fault Log 0 19 0

Table 3-3. Setup Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Passsword 0 9999 0

Language English English

Time 12:00 am 11:59 pm

Date 01/01/00 12/31/99

Unit of Temp Fahrenheit or Celsius Fahrenheit

Comm Address 0 127 0

Baud Rate 2400, 4800, 9600, 19.2K 9600

Software Ver 0.00 Ver 9.99

3-5

CONTROL PANEL OPERATING PROCEDURES

3.6. CONFIGURATION MENU

The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the Constant Setpoint mode. The remaining options in this menu require the valid password to be entered, prior to changing existing entries. This menu contains a number of other configuration settings which may or may not be displayed, depending on the current operating mode setting.

Table 3-4. Configuration Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Internal Setpt Lo Temp Limit Hi Temp Limit 130°F

Unit Type KC Boiler, KC Boiler LN,

BMK Boiler, BMK Boiler LN,

BMK Boiler Dual, KC Water

Heater, KC Water Heater LN,

Water Heater 2010

Unit Size 0.5 MBTU, 1.0 MBTU

1.5 MBTU, 2.0 MBTU

3.0 MBTU, 3.5 MBTU

4.0 MBTU, 5.0 MBTU

Fuel Type Natural Gas, Propane Natural Gas

Boiler Mode Constant Setpoint,

Remote Setpoint,

Combination

Outdoor Reset

Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination)

Bldg Ref Temp (If Mode = Outdoor Reset)

Reset Ratio (If Mode = Outdoor Reset)

Outdoor Sensor Enabled or Disabled Disabled

System Start Tmp (If Outdoor Sensor = Enabled)

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (BMS)

40°F 230°F 70°F

0.1 9.9 1.2

30°F 100°F 60°F

NOTE:

The Configuration Menu settings shown in Table 3-4 are Factory-Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be

required.

KC Boiler

1.0 MBTU

6.0 MBTU

Constant

Setpoint

Direct Drive

4 – 20 mA,

1-5V

Network

3-6

CONTROL PANEL OPERATING PROCEDURES

Table 3-4. Configuration Menu - Continued

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Setpt Lo Limit 40°F Setpt Hi Limit 60°F

Setpt Hi Limit Setpt Lo Limit 220°F 200°F

Temp Hi Limit 40°F 240°F 210°F

Max Valve Position 40% 100% 100%

Pump Delay Timer 0 min. 30 min. 0 min.

Aux Start On Dly 0 sec. 120 sec. 0 sec.

Failsafe Mode Shutdown or Constant Setpt Shutdown

*Analog Output

(See CAUTION at end of Table 3-4 )

Low Fire Timer 2 sec. 600 sec. 2 sec.

Setpt Limiting Enabled or Disabled Disabled

Setpt Limit Band 0°F 10°F 5°F

Network Timeout 5 Sec 999 Sec 30 Sec

HI DB Setpt EN 0% 100% 30%

Demand Offsert 0 25 10

Deadband High 0 25 2

Deadband Low 0 25 2

Off, Setpoint, Outlet Temp,

Valve Position 4-20 mA,

Valve Position 0-10V

*CAUTION:

DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V).

3.7. TUNING MENU

The Tuning Menu items in Table 3-5 are Factory set for each individual unit.

Table 3-5. Tuning Menu

Available Choices or Limits Menu Item Display Minimum Maximum Default

Prop Band 1°F 120°F 70°F Integral Gain 0.00 2.00 1.00 Derivative Time 0.0 min 2.0 min 0.0 min Reset Defaults? Yes

*Valve

Position

0-10V

Do not change these menu entries unless specifically requested to do so by FactoryTrained personnel.

Are You Sure?

3-3-7

CONTROL PANEL OPERATING PROCEDURES

3.8. START SEQUENCE

When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge safety

switches to ensure they are closed. These switches include:

• Safety Shut-Off Valve Proof of Closure (POC) switch

• Low Water Level switch

• High Water Temperature switch

• High Gas Pressure switch

• Low Gas Pressure switch

If all of the above switches are closed, the

READY light above the ON/OFF switch will light

and the unit will be in the Standby mode.

When there is a demand for heat, the following events will occur:

NOTE:

If any of the Pre-Purge safety device switches are open, the appropriate fault message will be displayed. Also, the appropriate fault messages will be displayed throughout the start sequence,

if the required conditions are not observed.

3. With all required safety switches closed, a purge cycle will be initiated and the following events will occur:

(a) Blower relay energizes and turns on

blower.

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

purge position and closes purge position switch. The dial on the Air/Fuel Valve (Figure 3-4) will read 100 to indicate that the valve is full-open (100%).

STEPPER

MOTOR

DIAL (DETAIL “A”)

1. The DEMAND LED status indicator will light.

2. The unit checks to ensure that the proof of closure switch in the Safety Shut-Off Valve (SSOV) is closed (Figure 3-3).

100

DETAIL "A"

Figure 3-4.

Air/Fuel Valve In Purge Position

4. Next, the blower proof switch (Figure 3-5)

closes and the display will show Purging and

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

3-8

Figure 3-3.

Safety Shut-Off Valve

CONTROL PANEL OPERATING PROCEDURES

AIR/FUEL VALVE

BLOWER PROOF

SWITCH

154

155

TO FRAME

HARNESS

Figure 3-5.

Blower Proof Switch

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

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

ignition position and closes the ignition switch. The dial on the Air/Fuel Valve (Figure 3-6) will read between 25 and 35 to indicate that the valve is in the lowfire position.

(b) The igniter relay is activated and

provides ignition spark.

STEPPER

MOTOR

BLOWER

DETAIL "A"

DIAL (DETAIL “A”)

BURNER

Figure 3-6.

Air/Fuel Valve In Ignition Position

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

Standby will be displayed.

is energized (opened) allowing gas to flow into the Air/Fuel Valve.

6. Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected.

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

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

8. With the unit firing properly, it will be controlled by the temperature controller

circuitry. The VALVE POSITION will be

continuously displayed on the front panel bargraph.

3.9. START/STOP LEVELS

The start and stop levels are the valve position percentages that start and stop the unit, based on load. These levels are Factory preset as follows for natural gas and propane units:

• Start Level: 20% (All units)

• Stop Level: 13% (Natural Gas)

• Stop Level: 16% (Propane)

Normally, these settings should not require adjustment.

Note that the energy input of the boiler is not linearly related to the valve position percentage (Air/Fuel Valve Position). Refer to Table 3-6 for the relationship between the energy input and valve position percentage for a unit running on natural gas.

3-9

CONTROL PANEL OPERATING PROCEDURES

Table 3-6.

Relationship Between Air/Fuel Valve Position and Energy Input of a Unit Running on Natural Gas

Valve position,

Air/Fuel Valve

Position

(% Open)

0 0 0

10 0 0

(Stop Level)

20 89,000 9%

30 191,000 19%

40 311.000 31%

50 460,000 46%

60 600,000 60%

70 699,000 70%

80 836,000 84%

90 955,000 96%

100 1,000,000 100%

Energy Input

(BTU/Hr)

50,000 5 %

Boiler Energy Input (% of Full Capacity)

3-10

SECTION 4 - 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 perform ing initial star t-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 system s can be dangerous and void the product’s warranty. These start-up instructions should be precisely followed in order for the unit to operate saf ely, at a high thermal efficiency, and with low flue gas emissions.

Initial unit start-up is to be perform ed 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 com plete the initial unit start-up.

An AERCO Gas Fired Startup Sheet included with each KC-1000 must be com pleted 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. THIS 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 star t the unit.

INITIAL START-UP

4.2 TOOLS AND INSTRUMENTATION

FOR COMBUSTION CALIBRATION

To properly perform com bustion calibration, the proper instruments and tools must be used and correctly installed on the unit. The following paragraphs 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. One 1/4” and two 1/8” NPT-to-barbed fittings for use with manometers.

4. A flat-tip screwdriver for adjusting the AERCO differential gas pressure regulator.

5. Small and large flat blade screwdrivers.

6. 7/16" open end wrench and small adjustable wrenches.

7. Tube of silicone adhesive

*For propane fired units: an additional 8" W .C. manometer and 1/2" NPT to barbed fitting is needed.

4.2.2 INSTALLING THE SUPPLY GAS

MANOMETER

1. Close the main manual gas supply valve up stream of the unit.

2. Remove the 1/4" NPT pipe plug from the port on the inlet side of the safety shut off valve (see Figure 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.

4-1

INITIAL START-UP

Figure 4.1

1/8” Gas Plug Location

4.2.3 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 cover s vent section connections must be loosened and moved 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.

Figure 4.2

Analyzer Probe Hole Location

4-2

IMPORTANT

The unit is shipped from the factory set up for either natural gas or propane, as specified by the Style No. on the Sales Order.

For propane units, refer to paragraph 4.4 for some additional setup procedures unique to propane units. The oxygen and carbon monoxide levels in Tables 1, 2 and 3 apply to both natural gas and propane. However, it should be noted that in Table 2 the ox ygen and carbon monoxide levels are measured at 13% for natural gas and 16% for propane.

4.3 NATURAL GAS COMBUSTION CALIBRATION

The KC-1000 is shipped combustion calibrated from the factor y. Recalibration as part of a startup 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.

The following combustion calibration procedure closely follows the factory procedure. By following this procedure, readjustment of the combustion settings will be kept to a minimum.

1. Open the water 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.

3. If a lockup style regulator is installed as a gas supply regulator, adjust the gas supply until a reading of 12” W .C. s tatic press ure is obtained.

4. Set the ON/OFF switch to the OFF position. Turn on AC power to the unit. The display will show LOSS OF POWER and the time and date.

5. Set the unit to the Manual Mode by pressing the AUTO/MAN switch. A flashing Manual Valve Position message will be displayed with the present Air/Fuel Valve position in % open. Also, the MANUAL LED will light.

NOTE:

For a review of control panel operating procedures, refer to Section 3.

6. Adjust the Valve Position to 0% by pressing the ▼ arrow key.

7. Set the ON/OFF switch to the ON position.

8. Change the Valve Pos ition to 25% using the ▲ arrow key. This will put the unit into the starting sequence.

INITIAL START-UP

NOTE:

On initial start-up, or return to service from a fault condition, the unit will remain at a 29% valve position for two-minutes, although the control signal may indicate a greater input.

9. Following the warm-up period, increase the valve position in 20% increments while monitoring the gas pressure after each increase. If gas pressure dips below 8.5” W.C. for F M gas trains and 8.9” for IRI gas trains at any valve position 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 trains or 8.9” W.C. for IRI gas trains cannot be obtained at the 100% valve position, 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% valve position, change the valve position to 30% and insert the combustion analyzer probe into the stack.

NOTE:

Always go to a percentage of valve position from the same direction, (i.e., 100% to 30% or 30% to 20%). W henever going to a valve position from below (i.e., 20% to 30%), first go above then back down to the desired valve pos ition. This is necessary due to hysteresis in the air/fuel valve stepper motor. Hysteresis causes the air/fuel valve to stop in a slightly different position if the valve position percentage is approached from below or above. This results in a difference in oxygen readings for the same valve position percentage causing unnecessary recalibration.

11. Allow enough time for the combustion analyzer to settle. Compare the measured oxygen level to the oxygen range for the existing intake air temperature in Table 1.

12. If the measured oxygen level is within the range listed in Table 1, no adjustment is necessary. Proceed to step 19.

13. If the measured oxygen level is not within the range listed in Table 1, remove the regulator cap and cap gasket from the differential pressure regulator (see Figure 4.3) and proceed to step 14.

Table 1

Combustion Oxygen Levels for a 30%

Valve Position

Inlet Air

Temp

Oxygen

(+0.2/-1.0)

Carbon

Monoxide

-20°F 7.5 % <50 ppm 0°F 7.3 % <50 ppm

10°F 7.2 % <50 ppm 30°F 6.8 % <50 ppm

50°F 6.4 % <50 ppm 60°F 6.2 % <50 ppm 70°F 6.0 % <50 ppm 80°F 5.8 % <50 ppm 90°F 5.6 % <50 ppm

100°F 5.4 % <50 ppm

Figure 4.3

Differential Regulator

14. Use a flat-tip screwdriver to adjust the differential pressure regulator. Turn the screwdriver:

• counterclockwise to increase the

oxygen level

• clockwise to decrease the oxygen level

15. Replace the regulator cap and cap gasket and wait for the analyzer reading to settle.

16. W hen the analyzer reading settles, compare the new oxygen reading to Table 1.

17. If necessary, repeat the adjustment until the oxygen level is within the range specified in Table 1.

18. Replace the regulator cap and cap gasket.

NOTE:

Adjust only the differential regulator at 30% control signal; Do Not adjust the air shutter.

4-3

INITIAL START-UP

NOTE:

In the following step, adjust the valve position to 13% for natural gas, or 16% for propane.

19. When the oxygen level is within the specified range at 30%, change the valve position to 13% for natural gas (or 16% for propane).

20. The oxygen levels at the 13% valve position (or 16% for propane) should be as s hown in Table 2. No adjustment should be necessary. Contact the factory if the oxygen or carbon monoxide levels ar e not within the specified range.

Table 2

Combustion Oxygen Levels for a 13%

(Natural Gas) or 16% (Propane) Valve

Position

Inlet Air

Temp

-20°F <12 % <50 ppm 0°F <12 % <50 ppm

10°F <12 % <50 ppm 30°F <12 % <50 ppm

50°F <11 % <50 ppm 60°F <11 % <50 ppm 70°F <11 % <50 ppm 80°F <11 % <50 ppm 90°F <10 % <50 ppm

100°F <10 % <50 ppm

21. Change the valve position to 100%. After the combustion analyzer has settled, compare the measured oxygen level with the levels in Table 3.

Oxygen

(+0.2/-1.0)

Carbon

Monoxide

22. If the meas ured 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.

23. Wait f or 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.

24. If the m eas ured oxygen reading is above the oxygen range in Table 3, loosen the two 7/16" locking nuts securing the inlet air shutter.

REMINDER:

At 30% valve position, adjust only the differential pressure regulator. At 100% valve position, adjust only the inlet air shutter.

Table 3

Combustion Oxygen Levels for a 100%

Valve Position

Inlet Air

Temp

-20°F 6.5 % <150 ppm 0°F 6.3 % <150 ppm

10°F 6.2 % <150 ppm 30°F 5.8 % <150 ppm

50°F 5.4 % <150 ppm 60°F 5.2 % <150 ppm 70°F 5.0 % <150 ppm 80°F 4.8 % <150 ppm 90°F 4.6 % <150 ppm

100°F 4.4 % <150 ppm

4-4

Oxygen

(+0.2/-1.0)

Carbon

Monoxide

Figure 4.4

Air Shutter Locking Nut Location

25. Close the air shutter 1/4” to 1/2” to decrease the oxygen level and tighten the two nuts.

26. Allow the analyzer to settle then compare the new oxygen reading to Table 3.

27. Repeat the adjustment until the oxygen is within the specified range. Firmly tighten the inlet air shutter locking nuts when finished.

INITIAL START-UP

NOTE:

Adjust the inlet air shutter only at 100% valve position. Do not adjust the differential pressure regulator.

28. Change the valve position 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.

29. Continue this procedure until all oxygen levels are within the ranges specified in Tables 1, 2 and 3.

30. Record all readings on the AERCO s tart-up sheet provided with each unit. Proceed to paragraph 4.5.

4.4 PROPANE COMBUSTION

CALIBRATION

For propane units it will be necessary to install an additional 8” W.C. This manometer will be used to measure the pressure drop across the air/propane mixing orifice. After performing the setup procedures in paragraphs 4.2.2 through

4.2.4, install the 8” W.C. manometer as

described in steps 1, 2 and 3 which follow.

1. Refer to Fig. 4.5 and remove the 1/8” NPT plug from the gas inlet pipe ahead of the burner. 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. manom eter to the barbed fittings installed in steps 1, and 2.

NOTE:

The combustion calibration data in Tables 1, 2 and 3 apply to both natural gas and propane units. Therefore, refer to these Tables when performing propane combustion calibration. Note that Table 2 checks the oxygen and carbon monoxide levels at a valve position of 16% for propane instead of the 13% used for natural gas.

4. W hile perform ing the combustion calibra tion procedure in paragraph 4.3, measure the pressure drop across the air/propane m ixing orifice using the 0-8” W.C. manometer.

5. This reading should rem ain constant at 3.8” to 4.0” W.C. throughout the operating range.

6. If the pressure dr op 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” to 4.0” W.C. is obtained. Clockwise will increase the reading and counterclockwise will decrease the reading.

8. It adjustments are made to this regulator, it will be necessary to recheck oxygen readings at 16%, 30%, and 100% valve positions.

NOTE:

After an adjustment is made to the air r egulator, the cap must be replaced and securely tightened 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 reassembled for permanent operation as follows:

1. Set the ON/OFF switch to the OFF position. Disconnect the AC power supply from the unit.

2. Shut off the gas supply to the unit.

3. Remove the differential pressure regulator cap and cap gasket (see Figure 4.3).

4. Apply a drop of silicone adhesive to the regulator adjusting screw to lock its setting.

5. Reinstall the regulator cap and gasket on the regulator. Tighten the cap using a screwdriver or wrench.

4-5

INITIAL START-UP

fittings and reinstall the pipe plugs using a suitable thread compound.

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

8. Replace the unit’s panels and hood.

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 s witch is adjustable and s hould be adjusted 20 header temperature. The upper overtemperature limit s witch is a manual reset device and is not adjustable. It will shut off the unit if the water temperature reaches 240°F. DO NOT attempt to adjust its setpoint.

To adjust the lower over-tem perature switch lim it

switc

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

2. The two over-temper ature limit switches are located at the top of the shell (see Fig. 4.6). Do not attempt to adj ust the upper switch. It has been factory preset.

to 40o F above the operating

6. Remove all of the manometers and barbed

Figure 4.6

Over Temperature Limit Switch Location

3. Adjust the lower switch between 20°F to 40°F higher than the maximum header temperature the unit may see.

4. Replace the shell cap and wing nut.

4-6

MODE OF OPERATION

SECTION 5 - MODE OF OPERATION

5.1 INTRODUCTION

The following paragraphs provide detailed descriptions of the six different modes of operation for the KC1000 Boiler. Each unit is shipped from the factory tested and configured for the ordered mode of operation. 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 descriptions of the temperature related parameters are included in Appendix A. Factory defaults are listed in Appendix E. After reading this section, parameters can be customized to suit the needs of the specific application.

5.2 INDOOR/OUTDOOR RESET MODE

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

5.2.1 RESET RATIO

Reset ratio is an adjustable number from 0.1 to

9.9. Once it is 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.

5.2.2. BUILDING REFERENCE

TEMPERATURE

This is a temperature from 40°F to 240°F. Once selected, it is the temperature that the system references to begin increasing its temperature. For instance, if a reset ratio of 1.6 is used and we select a building reference temperature of 70°F, then at an outside temperature of 69°F, the supply header temperature will increase by

1.6° to 71.6°F.

5.2.3 OUTDOOR AIR TEMPERATURE

SENSOR INSTALLATION

The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature

is expected. The sensor must be shielded from the sun's direct rays, as well as from 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 200 feet from the unit. Sensor connections are made inside the Input/Output (I/O) Box on the left side of the KC1000 Boiler. Connections are made at the terminals labeled OUTDOOR SENSOR IN and SENSOR COMMON inside the I/O Box using shielded 18 to 22 AWG wire. A wiring diagram is provided on the cover of the I/O Box. Refer to Section 2, paragraph 2.6.2 for additional wiring information.

5.2.4 INDOOR/OUTDOOR STARTUP

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

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

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

NOTE:

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

4. Once the design outdoor air temperature is chosen, go across the chart to the desired supply header temperature for the design temperature chosen in step 3.

5. Next, go up that column to the Reset Ratio row to find the corresponding reset ratio.

6. Access the Configuration Menu and scroll

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

7. Press the CHANGE key. The display will begin to flash.

8. Use the ▲ and ▼ arrow keys to select the desired building reference temperature.

9. Press ENTER to save any changes.

10. Next, scroll through the Configuration Menu

until the display shows Reset Ratio.

5-1

MODE OF OPERATION

11. Press the CHANGE key. The display will begin to flash.

12. Use the ▲ and ▼ arrow keys to select the reset ratio determined in step 5.

13. Press ENTER to save the change.

Refer to paragraph 3.3 for detailed instructions on menu changing.

5.3 CONSTANT SETPOINT MODE

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

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

5.3.1 SETTING THE SETPOINT

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

MENU OPTION SETTING

Boiler Mode Constant Setpoint Internal Setpt Select desired setpoint

using ▲ and ▼ arrow

keys (40°F to 240°F)

Refer to paragraph 3.3 for detailed instructions on changing menu options.

5.4 REMOTE SETPOINT MODES

The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges:

4-20 mA/1-5 Vdc

0-20 mA/0-5 Vdc

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

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

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

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the CPU Board in the Control Box. Contact your local AERCO representative for details.

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

MENU OPTION SETTING

Boiler Mode Remote Setpoint

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

0-20mA/0-5V, or

Network

Refer to paragraph 3.3 for detailed instructions on changing menu options.

5-2

MODE OF OPERATION

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

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

5.4.1 REMOTE SETPOINT FIELD WIRING

The only wiring connections necessary for the Remote Setpoint mode are connection of the remote signal leads from the source to the unit’s I/O Box. The I/O Box is located on the front panel of the Benchmark Boiler. For either a 420mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.4.2 REMOTE SETPOINT STARTUP

Since this mode of operation is factory preset and the setpoint is being externally controlled, no

startup instructions are necessary. In this mode,

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

5.5 DIRECT DRIVE MODES

The unit’s air/fuel valve position can be changed by a remote signal which is typically sent from an Energy Management System (EMS) or from a Building Automation System (BAS). The Direct Drive mode can be driven by a current or voltage signal within the following ranges:

4-20 mA/1-5 Vdc

0-20 mA/0-5 Vdc

The factory default setting for the Direct Drive mode is 4-20 mA/1-5 Vdc. With this setting, a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0% to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to a 100% valve position. When a 0-20 mA/0-5 Vdc signal is used, zero is equal to a 0% valve position.

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

When in a Direct Drive mode, the unit is a slave to the EMS or BAS and does not have a role in temperature control. Direct Drive can be used to drive single, or multiple units.

NOTE:

If a voltage, rather t t signal is used to han curren control the valve position, a DIP switch adjustment must be made on the PMC Board in the Control Box. Contact your local AERCO representative for details.

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

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

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

MENU OPTION SETTING

Boiler Mode Direct Drive

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

0-20mA/0-5V, or

Network

Refer to paragraph 3.3 for instructions on changing menu options.

5-3

MODE OF OPERATION

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

5.5.1 DIRECT DRIVE FIELD WIRING

The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.5.2 DIRECT DRIVE STARTUP

Since this mode of operation is factory preset and the valve position is being externally

controlled, no startup instructions are necessary.

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

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

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

5.6 BOILER MANAGEMENT SYSTEM

(BMS) MODE

NOTE

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

The BMS mode of operation is used in conjunction with an AERCO Boiler Management System. The BMS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, a BMS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant’s supply water

header. The BMS can control up to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS485) network communication. For BMS programming, operation and Header Sensor installation details, see GF-108M (BMS Model 168) and GF-124 (BMS II Model 5R5-

384), BMS Operations Guides. For operation via an RS485 Modbus network, refer to Modbus Communication Manual GF-114.

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

MENU OPTION SETTING

Boiler Mode Direct Drive Remote Signal BMS (PWM Input)

or Network (RS485)

Refer to paragraph 3.3 for instructions on changing menu options.

5.6.1 BMS EXTERNAL FIELD WIRING

Wiring connections for BMS control using PWM signaling are made between connector JP2 on the BMS panel (boilers 1 through 8), and the B.M.S. (PWM) IN terminals in the I/O Box on the front of the Benchmark Boilers. Refer to the wiring diagram provided on the cover of the I/O Box.

Wiring connections for RS485 Modbus control are made between connector JP11 on the BMS (boilers 9 through 40) and the RS485 COMM terminals in the I/O Box on the front of the unit.

Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper polarity for the B.M.S. (PWM) IN and/or RS485 COMM wiring connections. Shields should be terminated only at the BMS and the boiler end must be left floating. Each unit’s wiring must conform to the above.

5.6.2 BMS SETUP AND STARTUP

This mode of operation is factory preset and the AERCO BMS controls the air/fuel valve position. There are no setup instructions for each individual unit.

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

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

5-4

MODE OF OPERATION

5.7 COMBINATION CONTROL SYSTEM

(CCS)

NOTE

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

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

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

When the space-heating load is such that all the space-heating boilers are at 100% valve position, the BMS will then ask the Combination Control Panel for the domestic boilers to become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become space-heating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the CCP switches the combo units back to the domestic load.

5.7.1 COMBINATION CONTROL SYSTEM FIELD WIRING

Wiring for this sy Model 168 panel, the CCP and the B.M.S. (PWM) IN terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above. For a complete CCP system-wiring diagram see the AERCO CCP-1 literature.

stem is between the BMS

5.7.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP

Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode, remote signal type and setpoint. The setpoint is adjustable from 40°F to 240°F.

Enter the following settings in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Combination

Remote Signal BMS (PWM Input)

Internal Setpt 40°F to 240°F

Refer to paragraph 3.3 for instructions on changing menu options.

While it is possible to change other temperaturerelated functions for combination mode, these functions are preset to their factory default values. These default settings 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 of temperature related function defaults, see Appendix E.

To set the unit to the manual mode, press the AUTO/MAN switch. The MANUAL LED will light.

To set the unit back to the auto mode, press the AUTO/MAN switch. The MANUAL LED will go off and the REMOTE LED will light.

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

When the boiler is switched to BMS mode, the AERCO BMS controls the valve position. There are no setup requirements to the boiler(s) in this mode.

5-5

SECTION 6-SAFETY DEVICE TESTING PROCEDURES

6.1 TESTING OF SAFETY DEVICES

Periodic testing of all controls and s afety devices is required to insure that they are operating as designed. Precautions must be tak en 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 c omponent has been serviced or replaced. All testing must conf or m to local jurisdictions or c odes s uc h 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 test s.

WARNING!

ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC. POWER MUST BE REMO VED PRI OR TO PERFORMING WIRE REMOVAL OR OTHER TESTING PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.

6.2 LOW 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 depress the CLEAR button to clear any fault messages..

4. Place the unit in Manual Mode and fire the unit at a valve position between 25% and 30%.

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.

SAFETY DEVICE TESTING

6. Open the gas supply to the unit and press the CLEAR button on the Control Box.

7. The unit should restart.

Figure 6.1

1/8” Pipe Plug Position for Manometer

Installation

NOTE:

After faulting the unit, the fault m essage will

be displayed and the fault indicator light will

flash until the CLEAR button is pressed.

6.3 HIGH GAS PRESSURE TEST

1. Start the unit in manual mode and fire between 25% and 30%.

2. Rem ove either wire # 150 or wire #151 from the high gas pressure switch. See Fig. 6.2.

3. The unit should shut down on a HIGH GAS PRESSURE FAULT.

4. Reconnect the wire previously removed from the high gas pressure switch and depress the CLEAR button.

5. The unit should restart.

6-1

SAFETY DEVICE TESTING

Figure 6.2

High Gas Pressure Switch

6.4 LOW WATER LEVEL FAULT TEST

1. Set 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 m essage will be displayed and the FAULT LED will flash after the water level has gone below the level of the probe.

6. Set the ON/OFF switch to ON. The READY light should remain off and the unit should not start. If the unit does start, shut the unit off immediately and refer fault to qualified service personnel.

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

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

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

10. After the shell is full, press the LOW WATER LEVEL RESET button to reset the low water cutoff. Press the CLEAR button to reset the FAULT LED and clear the error message.

11. Set the ON/OFF switch to the ON position. The unit is now ready for operation.

6.5 WATER TEMPERATURE FAULT

TEST

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

2. Lower the adjustable temperature limit switch setting to match the outlet water temperature. (See Fig. 6.3).

Figure 6.3

Temperature Limit Switch Setting

3. Once the switch setting is approximately at the actual water temperature, the unit should shutdown. The FAULT LED should be flashing and the message HIGH WATER TEMP SWITCH OPEN should be displayed. The unit should not start.

4. Reset the tem perature limit switch setting to its prior setting.

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

6-2

SAFETY DEVICE TESTING

6.6 INTERLOCK TESTS

The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Term inal connections for these circuits are located in the I/O Box and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumped (closed). However, each of these interlocks may be utilized in the field as a remote stop and start, an emergency cut-off, or to prove that a device such as a pump gas booster, or louver is operational.

6.6.1 REMOTE INTERLOCK

1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals.

2. Start the unit in the manual mode and fire at a 25% to 30% valve position.

3. If there is a jumper across the REMOTE INTL’K IN term inals, remove one s ide of the jumper. If the inter lock is being controlled by an external device, either open the interlock via the external device or disconnect one of the wires leading to the external device.

4. The unit should shut down and display INTERLOCK OPEN.

5. Once the interlock connection is reconnected, the INTERLOCK OPEN message should automatically clear and the unit should resume running.

6.6.2 DELAYED INTERLOCK

1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals.

2. Start the unit in the manual mode and fire at a 25% to 30% valve position.

3. If there is a jumper across the DELAYED INTL’K IN term inals, remove one s ide of the jumper. If the interlock is connected to a proving switch of an external device, disconnect one of the wires leading to the proving switch.

4. The unit should shut down and display DELAYED INTERLOCK OPEN. The FAULT LED should be flashing.

5. Once the interlock connection is reconnected, depress the CLEAR button. The unit should start.

6.7 FLAME FAULT TEST

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

2. Place the unit in the Manual Mode and set the valve position between 25% and 30%.

3. Close the manual leak detection valve located between the safety shut-off valve and the differential regulator (see Fig. 6.4).

4. Start the unit.

5. The unit should shut down after reaching the Ignition cycle and display FLAME LOSS

DURING IGN.

6. Open the valve previously closed in step 3 and depress the CLEAR button.

7. Restart the unit and allow it to prove flame.

8. Once flame is proven, clos e the m anual leak detection valve located between the safety shut-off valve and the differential regulator.

9. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps:

(a) The unit will execute a shutdown purge

cycle for a period of 15 seconds and display WAIT FAULT PURGE.

(b) The unit will execute a 30 second re-

ignition delay and display WAIT RETRY PAUSE.

ignition sequence and display WAIT IGNITION RETRY.

10. Since the manual gas shutoff valve is still closed, the unit will shut down and display FLAME LOSS DURING IGNITION following the IGNITION RETRY cycle.

11. Open the valve previously closed in step 8 and depress the CLEAR button. The unit should restart and fire.

6-3

SAFETY DEVICE TESTING

Figure 6.4

Manual Leak Detection Valve

6.8 AIR FLOW FAULT TEST

1. Start the unit in manual mode and set the valve position between 25% and 30%.

2. Once the unit has proved flame, remove either wire #154 or #155 from the blower proof switch (see Fig. 6.5) located on the air/fuel valve.

3. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps:

(a) The unit will execute a 30 second re-

ignition delay and display WAIT RETRY PAUSE.

(b) The unit will then execute a standard

ignition sequence and display WAIT IGNITION RETRY.

4. The unit should perform two IGNITION RETRY cycles and then shut down on the third successive ignition attempt. The unit will display AIRFLOW FAULT DURING PURGE.

5. Replace the wire previously removed from the blower-proof switch and depress the CLEAR button. The unit should restart.

WARNING!

ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC. POWER MUST BE REMO VED PRI OR TO PERFORMING WIRE REMOVAL OR OTHER TESTING PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.

Figure 6.5

Blower Proof Switch Location and Wiring

6.9 SSOV PROOF OF CLOSURE SWITCH

1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the valve position between 25% and 30%.

2. Remove the Safety Shut-Off Valve (SSOV) cover to access the terminal connections. See Fig. 6.6. For units with IRI gas trains, access the terminals of the downstream SSOV (see drawing SD-A-584 in Appendix F).

3. Remove either wire #149 or #148 from the SSOV.

4. The unit should fault and display SSOV SWITCH OPEN.

5. Replace the wire previously removed and depress the CLEAR button.

6. Start the unit.

7. Remove the wire again when the unit reaches the purge cycle.

8. The unit should shut down and display SSOV FAULT DURING PURGE.

9. Replace the wire on the SSOV and depress the CLEAR button. The unit should restart.

6-4

Figure 6.6

SSOV Actuator Cover Screw Location

6.10 PURGE SWITCH OPEN DURING PURGE

1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the valve position between 25% and 30%.

2. Remove the air/fuel valve cover by rotating the cover counterclockwise to unlock it and then pulling it towards you. See Figure 6.7.

3. Remove one of the two wires from the purge switch (Figuire 6.8) and start the unit.

4. The unit should begin to start, then shut down and display PRG SWITCH OPEN DURING PURGE.

5. Replace the wire on the purge switch and depress the CLEAR button. The unit should restart.

SAFETY DEVICE TESTING

Figure 6.7

Air/Fuel Valve Cover Location

Figure 6.9

Air/Fuel Valve Purge and Ignition Switch

Locations

6-5

SAFETY DEVICE TESTING

6.11 IGNITION SWITCH OPEN DURING

IGNITION

1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the valve position between 25% and 30%.

2. Remove the air/fuel valve cover (Fig. 6.7) by rotating the cover counterclockwise to unlock it then pulling it towards you.

3. Remove one of the two wires from the ignition switch (Fig. 6.8) and start the unit.

4. The unit should begin to start then shut down and display IGN SWITCH OPEN DURING IGNITION.

5. Replace the wire on the ignition switch and depress the CLEAR button. The unit should restart.

6.12 SAFETY PRESSURE RELIEF VALVE

TEST

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

6-6

SECTION 7 - MAINTENANCE

7.1 MAINTENANCE SCHEDULE

The unit requires regular routine m aintenance 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 in Table 7-1.

Appendix J contains recommended spare parts lists for maintenance of the KC1000 Boiler.

Table 7-1. Maintenance Schedule

Sect

7.2 Spark

7.3 Flame Detector

7.4 Combustion

7.5 Testing of

7.6 *Manifold &

7.7 Water Side

7.8 Condensate

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

TO AVOID PERSONAL INJURY, BEFORE SERVICING: (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 WITH THE UNIT (C) ALLOW THE UNIT TO COOL TO A SAFE TEMPERATURE TO PREVENT BURNING OR SCALDING

7.2 SPARK IGNITOR

The spark ignitor assembly (part no. GP-122435-S) is located in the body of the burner (see Figure 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.

Item

Ignitor (GP-122435-S)

(GM-123428)

Adj.

Safety Devices

Tubes

Inspection

Drain

WARNING!

Mos.

Inspect Replace

Check Check

Test

Inspect

Mos.

Inspect

& Clean

Mos.

Inspect

& clean

neces-

Inspect 2 hr.

Labor

Time

mins.

1 hr.

mins.

4 hrs.

sary

mins.

MAINTENANCE

To inspect/replace the Ignitor :

1. Set the ON/OFF switch on the control panel to the OFF position and disconnect AC power from the unit.

2. For access to the spark ignitor (GP-122435-S), rem ove the unit’s right side panel. Access can also be gained by removing the rear panels and condensate drainage system

3. Disconnect the ignitor cable fr om the ignitor extension. Remove the silicone ignitor plug from the burner shell by simultaneously twisting and pulling downward.

4. Insert the ignitor rem oval tool into the burner shell, where the ignitor plug 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 ther e 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 Section 4 for Combustion Calibration).

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

The ignitor must be r emoved and installed using the ignitor removal tool provided with the unit(s). Damage to the burner due to using a sock et for removal and installation of the ignitor is not covered under warranty.

7. Reinstall the ignitor assembly using the ignitor removal tool. Do not over tighten the ignitor. A slight snugging up is sufficient.

8. Reinstall the ignitor plug into the burner shell by simultaneously twisting and pushing it into the shell.

9. Reattach the ignitor cable to the extension and verify that it “clicks” into place.

be applied to the ignitor

CAUTION!

7-1

MAINTENANCE

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

SPARK IGNITOR

ASSEMBLY

BURNER

SHELL

SILICONE

PLUG

FLAME DETECTOR

Figure 7.1

Spark Ignitor and Flame Detector Locations

7.3 FLAME DETECTOR

The flame detector assembly (part no. GM 123428) is located in the body of the burner (see Figure 7.1). The flame detector may be HOT. Allow the unit to cool sufficiently before removing the flame detector.

To inspect or replace the flame detector (part no. GM 123428):

1. Set the ON/OFF s witch on the control panel to the OFF position and disconnect AC power from the unit.

2. Remove the left side panel from the unit.

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 7-1 as part of the maintenance requirements. Refer to Section 4 for the 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 CSD-1, require that these tests be perfor med on a scheduled basis. Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a log book. See Section 6-Safety Device Testing Procedures.

7.6 MANIFOLD AND EXHAUST TUBES

The presence of even trace amounts of chlorides and/or sulf ur , 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

*Change only if 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. Rem ove the condensate cup fr om under the

unit and the condensate drainage tubing from the manifold.

7-2

MAINTENANCE

5. Remove the flame detector and ignition cable wires from the flame detector and ignitor contactor. Remove the ignitor and flame detector per paragraphs 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 Figure 7.2).

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 Figure 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 Figure 7.3).

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

10. Using a 1/2” socket wrench remove six 5/16-18 hex nuts supporting the burner (See Fig. 7.3).

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 7.4

Exhaust Sensor Connector Loc ation

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 Figure 7.5).

Figure 7.3

Burner Disassembly Diagram

Figure 7.5

Blower Proof Switch Wire Locations

15. Loos en the hose clamp on the air/f uel valve inlet and slide the clamp back towards the blower (See Figure 7.6).

7-3

MAINTENANCE

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 diffe rential pressure regulator. Remove the feedback tube (See Figure 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 Figure 7.7).

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

19. Remove the flue venting from the exhaust manifold.

20. To prevent damage to and for easier handling of the exhaust manifold it will be necessary to remove the exhaust manifold insulation. Using a 7/16” wrench or sock et, 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 Figure 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 cham ber 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

7-4

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

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

MAINTENANCE

7.6.1 PROPANE UNITS

For propane units it will be necess ary to remove the air mix assembly in addition to the components outlined in Sec tion 7.6. Proceed as follows:

1. Follow steps 1 through 5 in paragraph 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 Figure 7.9).

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

4. Go back to paragraph 7.6 and continue at Step # 6.

7.7 HEAT EXCHANGER WATER SIDE INSPECTION

Per CSD-1, the water side of the heat exchanger requires an inspection. To inspect the heat exchanger, proceed as follows:

1. Shut off AC power to the unit.

2. Close the supply and return valves to the

unit (Fig 7.10).

3. Open the drain valve and allow the unit to

fully drain. The 1/4 inch plug in the top of the shell may be removed to aid in drainage or the relief valve may be opened (Fig 7.10).

4. Remove the 2 ½ inch plug located in the

shell at the rear of the unit (Fig. 7.11).

5. Remove the relief valve, drain valve

(Fig. 7.10) and any reducing bushings.

6. Perform the inspection and reassemble the

unit once the inspection is completed.

7. Open the supply and return valves and

reconnect AC power to the unit.

Figure 7.9

Propane Unit Component Location

NOTE:

Older propane units have a 1/8” feedback

tube and 1/8” OD tube compression fitt ings.

Figure 7.10

Heat Exchanger Supply and Return

Locations

7-5

MAINTENANCE

Figure 7.11

Heat Exchanger 2 ½ Inch Inspection Plug

Location

7.8 CO NDENSATE DRAIN ASSEMBLY

KC Boilers contain a condensate drain cup (Figure 2.6) which should be inspected and cleaned annually to ensure proper operation.

To inspect and clean the assembly, proceed as follows:

1. Remove the left side panel and left rear

cover to provide access to the condensate drain components (see Figure 2.6).

2. Disconnect the drain hose attached to the

exhaust manifold.

3. Disconnect the plastic tubing from the

condensate cup drain tube to the drain

4. Rem ove the condensate cup fr om under the

unit. Thoroughly clean the cup and inspect drain tube for blockage.

5. Check to ensure that the condensate drain

opening in the exhaust manifold is not blocked.

6. Flush out the drain hose and plastic tubing.

7. After the above items have been cleaned

and inspected, reassemble the condensate drain components by reversing the previous steps.

7-6

Section 8 - TROUBLESHOOTING GUIDE

8.1 INTRODUCTION

This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a f ault in a KC1000 Boiler. T he troubleshooting procedures contained in this section are presented in tabular form in T able 8-1 on the following pages This table is compr ised of three columns labeled: Fault Indication, Probable Cause and Corrective Action. The numbered items in the Probable Cause and Corrective Action columns correspond to each other. For example, Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.

NOTE:

The front panel of the C-More Control Box contains an RS232 port which can be interfaced to a laptop computer or other suitable device. This RS232 communication feature permits service personnel to view menu item s and data logs which can be useful in isolating faults. Refer to Section 9 of this manual for detailed RS232 communication set-up and procedures.

TROUBLESHOOTING

When a fault occurs in the KC1000 Boiler, proceed as follows to isolate and correct the fault:

1. Observe the fault messages displayed in the

Control Box display.

2. Refer to the Fault Indication column in the

following troubleshooting table and locate the Fault that best describes the existing conditions.

3. Proceed to the Probable Cause c olumn and

start with the first item (1) lis ted for the Fault Indication.

4. Per form the chec ks and procedures listed in

the Corrective Action column for the first Probable Cause candidate.

5. Continue checking each additional Probable

Cause for the existing fault until the fault is corrected.

6. If the fault cannot be corrected using the

information provided in the Troubleshooting Tables, contact your local AERCO Representative.

8-1

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

AIRFLOW FAULT

DURING IGNITION

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING RUN

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

1. Blower not running or running too slow

2. Defective Air Flow Switch

3. Blocked Air flow Switch

4. Blocked Blower inlet or inlet ductwork.

5. No voltage to switch from control box.

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

5. Combustion oscillations

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

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

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

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

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

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

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

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

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

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

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

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

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

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

8-2

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

DELAYED

INTERLOCK OPEN

DIRECT DRIVE

SIGNAL FAULT

FLAME LOSS

DURING IGN

1. Delayed Interlock Jumper not installed or removed.

2. Device proving switch hooked to interlocks is not closed

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

2. Signal is not isolated (floating).

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

1. Burner Ground Screw not installed or loose.

2. Worn flame detector

3. No spark from Spark Plug

4. Defective Ignition Transformer

5. Defective Ignition/Stepper (IGST) Board

6. Defective SSOV

7. Defective Differential Pressure Regulator.

8. Carbon or other debris on Burner.

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

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

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

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

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

1. Inspect and install/retighten Burner Ground Screw.

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

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

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

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

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

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

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

8-3

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

FLAME LOSS

DURING RUN

HEAT DEMAND

FAILURE

HIGH EXHAUST TEMPERATURE

HIGH GAS

PRESSURE

1. Worn Flame Detector or cracked ceramic.

2. Defective Differential Regulator.

3. Poor combustion calibration.

4. Debris on burner.

5. Blocked condensate drain.

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

2. Relay is activated when not in Demand

1. Defective exhaust sensor.

2. Carboned heat exchanger due to incorrect combustion calibration

1. Incorrect supply gas pressure.

2. Defective Supply Regulator or Wrong Style Regulator

3. Defective High Gas P r essure Switch

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

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

3. Check combustion calibration. Adjust as necessary.

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

5. Remove blockage in condensate drain.

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

2. Defective relay. Replace IGST Board.

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

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

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

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

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

F, check

8-4

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

HIGH WATER TEMP

SWITCH OPEN

HIGH WATER

TEMPERATURE

IGN BOARD

COMM FAULT

1. Faulty Water temperature switch.

2. Incorrect PID settings.

3. Faulty shell temperature sensor.

4. Unit in Manual mode

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

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

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

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

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Temp HI Limit setting is too low.

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

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

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

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

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

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

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

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

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

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Check Temp HI Limit setting.

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

8-5

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

IGN SWTCH CLOSED

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

INTERLOCK

OPEN

1. Air/Fuel Valve not rotating

2. Defective or shorted switch

3. Switch wired incorrectly

4. Defective Power Supply Board or fuse

5. Defective IGST Board

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

2. Defective ignition switch

3. Defective Power Supply Board or fuse

4. Defective IGST Board

1. Interlock jumper not installed or removed

2. Energy Management System does not have boiler enabled.

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

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

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

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

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

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

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

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

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

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

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

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

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

8-6

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

LINE VOLTAGE

OUT OF PHASE

LOW GAS

PRESSURE

LOW WATER

LEVEL

MODBUS COMM

FAULT

PRG SWTCH CLOSED

DURING IGNITION

1. Line and Neutral switched in AC Power Box.

2. Incorrect power supply transformer wiring.

1. Incorrect supply gas pressure.

2. Defective or incorrect ly sized Gas Supply Regulator.

3. Defective Low Pressure Gas Switch

1. Insufficient water level in system

2. Defective water level circuitry.

3. Defective water level probe.

1. Boiler not seeing information from Modbus network

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

2. Defective or shorted switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

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

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

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

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

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

1. Check system for sufficient water level.

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

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

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

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

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

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

8-7

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

continued 5. Defective IGST Board 5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace IGST Board.

PRG SWTCH OPEN

DURING PURGE

OUTDOOR TEMP

SENSOR FAULT

REMOTE SETPT

SIGNAL FAULT

RESIDUAL

FLAME

1. Defective purge switch.

2. No voltage present at switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Loose or broken wiring.

2. Defective Sensor.

3. Incorrect Sensor.

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

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

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

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

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

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

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

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

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

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

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

3. Ensure that the correct sensor is installed.

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

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

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

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

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

8-8

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 2. Defective Flame Detecto 2. Replace Flame Detector.

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING RUN

SSOV RELAY

FAILURE

SSOV

SWITCH OPEN

STEPPER MOTOR

FAILURE

See SSOV SWITCH OPEN

1. SSOV switch closed for 15 seconds during run.

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

1. Actuator not allowing for full closure of gas valve

2. SSOV powered when it should not be

3. Defective Switch or Actuator

4. Incorrectly wired switch.

1. Air/Fuel Valve out of calibration.

2. Air/Fuel Valve unplugged.

3. Loose wiring connection to the stepper motor.

4. Defective Air/Fuel Valve stepper motor.

5. Defective Power Supply Board or fuse

6. Defective IGST Board

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

Ignition/Stepper (IGST) Board.

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

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

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

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

1. Refer to GF-112 and perform Stepper Test (para. 6.3.5) to ensure stepper motor rotates properly between the 0% (fully closed) and 100% (fully open) positions. Verify that the VALVE POSITION bargraph and the dial on the Air/Fuel Valve track each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (GF-112, para. 6.2.1).

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

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

4. Replace stepper motor.

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

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

8-9

Section 9 - RS232 COMMUNICATION

9.1 INTRODUCTION

The RS232 port on the fron t panel of the C-More Control Box (Figure 3-1) c an be interfaced to a laptop computer or other suitable terminal using a RS232 adapter cable. RS232 communication can be accomplished using any “Dumb Terminal” emulation, such as “Hyper Terminal” which is included with Microsoft Windows. The RS232 communication feature permits viewing or changing of Control Panel menu optio ns and also provides ac ces s to dat a lo gs s ho w ing E ven t Time Line, Fault and Sensor log displays.

9.2 RS232 COMMUNICATION SETUP

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

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

2400 4800 9600 (Default)

19.2K

2. Data Format – The program must be set for:

8 data bits, 1 stop bit, no parity and either Xon/Xoff or No flow control.

9.3 MENU PROCESSING UTILIZING RS232

COMMUNICATION

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

1. Start the emulator software program and

ensure that the specif ied baud rat e and data formats have been entered.

2. Press the Enter key on the laptop. An

asterisk (*) prompt should appear.

3. At the prompt, enter the valid RS232

password (jaguar) in lower case letters and press Enter.

4. “W elcome to Aerco” will appear in th e laptop

or “dumb terminal” display with a listing of the following available entry choices:

RS232 COMMUNICATION

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

NOTE:

The Level 1 passw ord (159) must be enter ed to change options in the Setup, Conf iguration and Tuning Menus. The Level 2 password (6817) must be entered to view or change opti ons in the Calibration and Diagnostics Menus.

With the exception of the password entry, all other keyboard entries c an be m ade us ing either upper or lower case.

5. To view the availa bl e menus in the top-do wn sequence shown in Figure 3-2, enter M <Rtn>. The Menu title and first 10 options will be displayed.

6. When viewing menus containing more than 10 options, enter N <Rtn> to display the remaining options.

7. Shortcut keys are also avai lab le to g o d irec tly to a specific menu. These shortcut keys are:

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

8. To change a value or setti ng for a dis played menu option, proceed as follows:

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

right of the displayed option to be changed, and then press <Rtn>.

(b) Enter the desired value or setting for the

option and press <Rtn>. Refer to Section 3, Tables 3-2 through 3-5 for allowable entry ranges and settings for the Operating, Setup, Configurati on and Tuning Menus. (The Calibration and Diagnostic Menus should only be used by Factory-Trained service personnel).

9-1

RS232 COMMUNICATION

volatile memory.

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

10. To display the Faul t (F) Log, Sensor (S) Log or Time (T) Line Log, press F, S or T followed by <Rtn>. Refer to paragraph 9.4 for descriptions and samples of these data logs.

11. To log off and terminate the RS232 communication link, press L followed by <Rtn>.

9.4 DATA LOGGING

During operation, the C-More Control Panel continuously monitors and logs data associated with operational events, faults and sensor readings associated with the boiler or water heater system. Descriptions of these data logs are provided in the following paragraphs. The basic procedure f or accessing each data log is described in paragraph 9.3, step 7.

within the C-More Control Panel. Events such as power-up, ignition and turn-off are time stamped. Data logged while the unit is running are run-length encoded. Data is logged or the run-length incremented every 30 seconds. For a new run record to be logged, the fire rate or flame strength must change by more than 5%, or the run mode mus t change. At steady-state, the run-length is allowed to reach a max imum of 30 minutes before the record is logged. This means that no more than 3 0 minutes of data can be lost if the unit loses po wer. Table 9-2 shows a sample Operation Time Log for a boiler:

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

9.4.1 Fault Log

The C-More Control Pane l logs th e last 20 f aults (0 – 19) starting with th e most recent (#0). T hey can be viewed in the front panel display or via the RS232 port. The Fault Log cannot be cleared. If the Fault Log already contains 10 faults, the earliest fault is overwritten when a new fault occurs. A sam ple Fault Log display is shown in Table 9-1.

NOTE:

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

9.4.2 Operation Time Log

NOTE:

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

9.4.3 Sensor Log

The sensor values c an be logged at a different rate if needed b y setting th e Sensor L og Inter val in the Diagnostics Menu. The log interval can vary from once ever y minute to once every day. Table 9-3 shows a sample Sensor Log ever y 5 minutes for a boiler running in Constant Setp oint mode.

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

9-2

RS232 COMMUNICATION

Table 9-1. Sample Fault Log Display

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

Table 9-2. Sample Operation Time Log Display

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

Table 9-3. Sample Sensor Log Display

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

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

9-3

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS

MENU LEVEL & OPTION DESCRIPTION

OPERATING MENU Active Setpoint This is the setpoint temperatur e t o which the

control is set when operating in the Constant Setpoint, Remote Setpoint or O utdoor Reset Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint sett ing in the Configuration Menu. When in the Remote Setpoint Mode, this value is the setpoint equivalent to the remote analog signal supplied t o t he unit. When in the O ut door Reset Mode, this is the

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

enabled. Valve Position In Desired input valve position. This would normally

be the same as the fire valve position shown on

the bargraph (valve position out) when the boiler is

operating. Flame Strength Displays flame strength from 0% to 100%. Run Cycles Displays the total number of run cycles fr om 0 to

999,999. Run Hours Displays tot al run time of unit in hours f r om 0 to

9,999,999. Fault Log Displays information on the last 20 faults (0 – 19).

A-1

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED

MENU LEVEL & OPTION DESCRIPTION

SETUP MENU

Password Allows password to be entered.

Language Permits selection of English, Spanish or French for Time Displays time from 12:00 am to 11:59 pm .

Date Displays dates from 01/01/00 to 12/31/ 99 Unit of Temp Permits selection of temper ature displays in

Comm Address For RS-485 communications (0 to 127). Default

Baud Rate Allows communications Baud Rate to be set (2400 Software Version Identifies the current software version of t he control CONFIGURATION MENU

Internal Setpoint Allows internal setpoint to be set . Default is 130°F. Unit Type Allows selection of KC Boiler, KC Boiler LN, BMK

Unit Size Sets unit size from 0.5 to 6. 0 MBTUs. Default is 1.0 Fuel Type Allows selection of Natural Gas or Propane

Boiler Mode It allows selection of: Constant Setpoint , Remote

Remote Signal Used to set the type of external signal which will be

Bldg Ref Temp

Once the valid password (159) is entered, options in the Setup, Configurat ion and Tuning Menus can be modified.

displayed messages. Default is English.

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

address is 0. RS-232 should have its own (programmable) password.

to 19.2K). Default is 9600. box (Ver 0.0 to Ver 9.9).

Boiler, BMK Boiler LN, BMK Boiler Dual, KC Water Heater, KC Water Heater LN, Water Heater 2010

MBTU.

Setpoint, Direct Drive, Combinat ion, or Outdoor Reset Mode. Default is Constant Setpoint Mode.

used when operating in the Remote Setpoint, Direct Drive or Combination Mode. The factory def ault is 4-20 mA/1-5V. Allows the building reference temperat ur e to be set when operating a boiler in the Outdoor Reset Mode. Default is 70°F.

A-2

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU (Cont.)

Reset Ratio Permits setting of Reset Ratio when operating boiler

Outdoor Sensor Allows outdoor sensor function to be enabled or System Start Tmp If outdoor sensor is enabled, this m enu item allows

Setpoint Lo Limit Used to set t he minimum allowable setpoint (40°F to Setpoint Hi Limit Used to set the m aximum allowable setpoint Temp Hi Limit This is the maximum allowable outlet temperat ur e

Max Valve Positon Sets the maximum allowable valve position for the Pump Delay Timer Specifies the amount of t im e ( 0 t o 30 m in. ) to keep

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

Failsafe Mode Allows the Failsafe mode to be set to either

Analog Output Must be set to Valve Pos 0-10V. Lo Fire Timer Specifies how long (2 to 600 sec.) to remain in the

Network Timeout Specifies the timeout value (seconds) bef ore a

in the Outdoor Reset Mode. Reset Ratio is adjustable from 0.1 to 9.9. Default is 1.2.

disabled. Default is disabled. the system start temperature to be set from 30 to

100°F. Default is 60°F. Setpoint Hi Limit). Default is 60°F (Setpoint Lo Limit to 240°F). Default is 200°F. (40 to 240°F). Any temperature above this setting

will turn off the unit. The temperature must then drop 5° below this setting to allow the unit to run. Default Hi Limit is 210°F.

unit (40% to 100%). Default is 100%. the pump running after t he unit turns off. Default is

zero. between activating the Aux Relay (due to a

demand) and checking the pre-purg e st r ing to start the boiler. Default is 0 sec.

Constant Setpoint or Shutdown. Default is Shutdown.

low fire position after ig nit ion, before going to the desired output. Default is 2 sec.

Modbus fault is declared. Available settings range from 5 to 999 seconds. Default is 30 seconds.

A-3

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU (Cont.)

HI DB Setpt EN Oper at ing at a Valve Position below this value will

Demand Offset This entry will reduce excessive ON/OFF cycling in

Deadband High Deadband Low

inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH. Setting range is fr om 0 to 100. (Default is 30)

AUTO mode. When this entry is a non-zero value, the unit will not turn on again until Valve Position In reaches the Start Level value AND the Outlet Temperature goes below the Active Setpoint – Demand Offset. In addition, the boiler will fire at the 29% Valve Position level or below for a period of one minute. When this ent r y is set t o zero, t he unit will turn on again as soon as the Valve Position in reaches the Start Level value. There will not be a one minute delay when firing at the 29% Valve Position level. Setting range is 0 to 25. (Default is 10) Deadband High and Deadband Low settings create an “Outlet Temperatur e” Zone. In which no Valve Position corrections will be attempted. The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint + Deadband High and Active Setpoint – Deadband Low. When the Out let Temperature reaches Active Setpoint and remains there for a per iod of 15 seconds, the unit will go into a DEADBAND MODE at which point no Valve Position corrections will be attempted while the Outlet Temper at ur e remains anywhere within the Deadband ZONE. When the unit is in the DEADBAND MODE, the °F or °C LED will flash on and off. When the Outlet T em perature drifts out of the Deadband ZONE, the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections. Setting range is 0 to 25. (Default is 2 for both Deadband High and Deadband Low)

A-4

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED

MENU LEVEL & OPTION DESCRIPTION

TUNING MENU

Prop Band Generates a valve position based on the error that

Integral Gain This sets the fract ion of the output, due to setpoint

Derivative Time This value (0.0 to 20.0 min.) responds to the rate of

Reset Defaults? Allows Tuning Menu options to be reset to their

exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F) , the valve position will be less than 100%. If the error is equal to or greater t han t he pr oportional band setting, the valve position will be 100%.

error, to add or subtract from the output each minute to move towards the setpoint. Gain is adjustable from 0.00 to 1.00 (Default is 0.10).

change of the setpoint err or . This is the time that this action advances the output.

Factory Default values.

A-5

APPENDIX B

APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES

TABLE B-1 . STARTUP AND STAT US MES SAGES

MESSAGE DESCRIPTION

DEMAND DELAY

XX sec

DISABLED

HH:MM pm, pm

MM/DD/YY

FLAME PROVEN

IGNITION TR IAL

XX sec

PURGING

XX sec

STANDBY Displayed when ON/OFF switch is in the ON position, but

WAIT Prompts the operator to wait.

WARMUP

XX sec

Displayed if Demand Delay is active. Displayed if ON/OFF switch is set to OFF. The display also

shows the time (am or pm) and date that the unit was disabled. Displayed after flame has been detected for a period of 2 seconds. Initially, the flame strength is shown in %. After 5 seconds has elapsed, the time and date are shown in place of flame strength. Displayed during ignition trial of startup sequence. The duration of cycle counts up in seconds. Displayed during the purge cycle during startup. The duration of the purge cycle counts up in seconds.

there is no demand for heat. The time and date are also displayed.

Displayed for 2 minutes during the initial warm-up only.

B-1

APPENDIX B

FAULT MESSAGE FAULT DESCRIPTION

TABLE B-2. FAULT MESSAGES

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING IGN

AIRFLOW FAULT

DURING RUN

DELAYED

INTERLOC K OPEN

DIRECT DRIVE SIGNAL FAULT

FFWD TEMP

SENSOR FAULT

FLAME LOSS

DURING IGN

FLAME LOSS

DURING RUN

HEAT DEMAND

FAILURE HIGH EXHAUST TEMPERATURE

HIGH GAS

PRESSURE

HIGH WATER

TEMPERATURE

HIGH WATER TEMP

SWITCH OPEN

IGN BOARD

COMM FAULT

IGN SWTCH CLOSED

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

INTERLOCK

OPEN

LINE VOLTAGE

OUT OF PHASE

LOW GAS

PRESSURE

LOW WATER

LEVEL

NETWORK COMM

FAULT

The Blower Proof Switch opened during purge, or air inlet is blocked.

The Blower Proof Switch opened during ignition. The Blower Proof Switch opened during run. The Delayed Interlock is open. The direct drive signal is not present or is out of range. The temperature measured by the Feed Forward (FFWD)

Sensor is out of range. The Flame signal was not seen during ignition or lost within 5 seconds after ignition. The Flame signal was lost during run.

The Heat Demand Relays on the Ignition board failed to activate when commanded. The High Exhaust Temperature Limit Switch is closed.

The High Gas Pressure Limit Switch is open. The temperature measured by the Outlet Sensor exceeded

the Temp Hi Limit setting. The High Water Temperature Limit Switch is open.

A communication fault has occurred between the PMC board and Ignition board. The Ignition Position Limit switch on the Air/Fuel Valve closed during purge. The Ignition Position Limit switch on the Air/Fuel Valve opened during ignition. The Remote Interlock is open.

The Line (Hot) and Neutral wires are reversed. The Low Gas Pressure Limit Switch is open. The Low Water Cutoff board is indicating low water level. The RS-485 network information is not present or is

corrupted.

B-2

FAULT MESSAGE FAULT DESCRIPTION

OUTDOOR TEMP

SENSOR FAULT

OUTLET TE MP

SENSOR FAULT

PRG SWTCH CLOSED

DURING IGNITION

PRG SWTCH OPEN

DURING PURGE REMOTE SETPT

SIGNAL FAULT

RESIDUAL

FLAME

SSOV

SWITCH OPEN

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING IGN

SSOV FAULT DURING RUN SSOV RELAY

FAILURE

STEPPER MOTOR

FAILURE

APPENDIX B

TABLE B-2. FAULT MESSAGES - Continued

The temperature measured by the Outdoor Air Sensor is out of range. The temperature measured by the Outlet Sensor is out of range:

• OUTLET TEMPERATURE display = SHt Indicates sensor is shorted

• OUTLET TEMPERATURE display = OPn indicates sensor is open-circuited

The Purge Position Limit Switch on the Air/Fuel Valve closed during ignition. The Purge Position Limit Switch on the Air/Fuel Valve opened during purge. The Remote Setpoint signal is not present or is out of range.

The Flame signal was seen for more than 60 seconds during standby. The SSOV switch opened during standby.

The SSOV switch opened during purge. The SSOV switch closed or failed to open during ignition. The SSOV switch closed for more than 15 seconds during

run. A failure has been detected in one of the relays that control the SSOV. The Stepper Motor failed to move the Air/Fuel Valve to the desired position.

B-3

Temperature Sensor Resistance Chart

(Balco)

APPENDIX C

C-1

Air

Temp

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

5F 0F

-5F

-10F

-15F

-20F

Air

Temp

60F 55F 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

Header Temperature for a Building Reference Temperatrure 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

D-1

APPENDIX D

Header Temperature for a Building Reference Temperature of 65F

Air

Temp

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

5 0

-5

-10

-15

-20

Air

Temp

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

5F 0F

-5F

-10F

-15F

-20F

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

Header Temperature for a Building Reference Temperature of 70F

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

RESET RATIO

D-2

APPENDIX D

Header Temperature for a Building Reference Temperature of 75F

RESET RATIO

Air

Temp

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

5F 0F

-5F

-10F

-15F

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

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

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

D-3

APPENDIX D

Header Temperature for a Building Reference Temperature of 90F

RESET RATIO

Air

Temp

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

5F 0F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

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

D-4

APPENDIX E

MENU & OPTION FACTORY DEFAULT

BOILER DEFAULT SETTINGS

Setup Menu

Password 0 Language English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600

Configuration Menu

Internal Setpt 130°F Unit Type KC Boiler Unit Size 1.0 MBTU Boiler Mode Constant Setpoint Remote Signal

(If Mode = Remote Setpoint, Direct Drive or Combination)

Bldg Ref Temp (If Boiler Mode = Outdoor Reset)

4 – 20 mA / 1-5V

70°F

Reset Ratio (If Boiler Mode = Outdoor Reset)

Outdoor Sensor Disabled System Start Tmp

(If Outdoor Sensor = Enabled) Setpt Lo Limit 60°F Setpt Hi Limit 200°F

Temp Hi Limit Max Fire Rate 100% Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Position 0-10V

CAUTION: DO NOT Change Lo Fire Timer 2 sec Setpt Limit Band (If Setpt Limiting = Enabled) 5°F

1.2

60°F

215°F

E-1

APPENDIX E

MENU & OPTION FACTORY DEFAULT

BOILER DEFAULT SETTINGS - Continued

Configuration Menu --Continued

Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2

Tuning Menu

Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min

E-2

APPENDIX F

F-1

APPENDIX F

F-2

TEST PRESS.

(PSIG)

APPENDIX F

REV.

(184)

72-1/2

1"NPT

DRAIN

3(8)

VALVE

HEAT EXCHANGER DESIGN STANDARDS

TEMP. (°F)

PRESS. (PSIG)

MAX. WORKING MAXIMUM

DIMENSIONAL DRAWING

(PROVINCE OF ALBERTA INSTALLATIONS)

AP-A-863

CZ 100206

DWN.BY

APPD

250 130.5

SHELL CAP

AC SERVICE CONN.

3/4 CONDUIT

120VAC SINGLE PHASE

ASME B & PV CODE SECTION IV STAMP H

SHELL SIDE

VALVE

PRESSURE

RELIEF

14-3/4(37)

20 AMP W/GRD

COMB. AIR INTAKE

TRAIN OPTION" ONLY

CONN. FOR "IRI GAS

3/4" NPT GAS VENT

c.g.

NORTHVALE, NEW JERSEY 07647

INTERNATIONAL INC.

5-3/4(15)

(OPTIONAL O.A.

INLET ADAPTER

AVAIL. - 6" OD)

(34.4)

13-9/16

(196)

77-1/8

1-1/4NPT GAS INLET

3-1/8

(37)

(TYP)

14-3/8

KCGWB-DP GAS FIRED BOILER

47(119)

6(15)I.D.

FLUE CONN.

22(56)

c.g.

22-1/4(57)

REMOTE ALARM & CONTROL

5/8" I.D

MALE HOSE

49(124)

CONDENSATE

CONNECTION - 3/4 CONDUIT

57(145)

DRAIN

MAINTAINED TO ALLOW THE FLOW OF ANY CONDENSATE FORMED IN THE

NOTES:

FLUE TO FLOW TO THE DRAIN

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

3) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS)

(FLOOR FLANGE)

(77)

19(48)

SYS. WATER SUPPLY

4-150# FLG'D

(OUTLET)

4-150# FLG'D

SYS. WATER RETURN

(INLET)

15-1/2(39)

)

(ENCLOSURE)

TYP.

4-PLCS

3/4(2)DIA.

(

(174)

68-1/2

30-1/8

23-1/4

(59)

35(89)

(43)

16-3/4

F-3

APPENDIX F

HEAT EXCHANGER

PART NO.

ITEM

GM-20881

PART NO.

GM-20844-2

GM-123352

GP-18532

GP-122551

GP-161151

GP-122537

GP-20885

GP-122540

GP-123337

GP-122849

GP-18900

GP-18899

QTYITEM PART NO. DESCRIPTION

1 SHELL GASKET

***

XX GP -123050

8-22

GP-9-428

GP-122789

GM-122743

GP-5130-

9-308

69087-

XX NOT SHOWN IN THE DRAWING * SEE DR AWING PL-A-136 F OR INSTALLATION DET AIL

** INDICATE P RESSURE RELIEF VALVE SETTING

(30, 50, 75, 100, OR 150 PSI)

*** -2 (30 AND 50 PSI RELIEF VALVE SETTING)

38 39

-3 (75 AND 100 PSI RELIEF VALVE SETT ING)

-4 (150 PSI RELIEF VALVE SETTING)

DESCRIPTION

HEAT EXCHANGER ASS'Y

EXHAUST MANIFOLD

TEFLON RELEASE GASKET

BURNER FLANGE GASKET

COMBUSTION CHAMBER LINER

EXH. MANIFOLD TO COMB. CHAMB. GASKET

DESCRIPTION

EXHAUST MANIFOLD

EXHAUST MANIFOLD INSULATION

EXHAUST MANIFOLD DRAIN HOSE

HOSE CLAMP 13/16" - 1-3/4"∅ RANGE

CONDENSATE CUP ASSEMBLY

VENT MOUNTING FLANGE

GASKETS

EXH. MANIFOLD TO LOWER HEAD SEAL

OTHER ACCESSORIES

DESCRIPTIONQTYITEM PART NO.

1-1/2" X 1" REDUCING BUSHING18

1" NPT X 4" LG. NIPPLE - RED BRASS

1" NPT 90° ELBOW - BRONZE

DRAIN VALVE ASSEMBLY

1" NPT PRESSURE RELIEF VALVE

1" NPT CLOSE NIPPLE - RED BRASS

TEMP./PRESS. GAUGE

EXTERNAL GAS SHUT-OFF VALVE

ITEM

PART NO.

GM-18997

181182

181123

181191

PART NO.

ITEM

12493523

65029

124936

GP-122553

GP-16115225

GP-122669

GP-122835

8500328

ITEM29PART NO.

GP-161146

GP-18894

123581

GP-122614

201211

201222

GP-161147

GM-20934

GM-20874

36 1

GM-20933

ITEM

PART NO.

161559

GP-122464

GP-122569

161560

181198

161450

61002-14

GP-122403

123536

GP-122821

123448

122843

123463

123711

161569

124334

GP-122412

123863

PART NO.ITEM

GP-122406

GAS TRAIN

QT Y

QTY

BLOWER MOTOR CAP. (FOR BLOWERS WITH AMETEK/A.O. SM ITH MOTOR)

2SPACER

BURNER AND AIR/FUEL VALVE

QTY

1 1/8" NPT BALL VALVE

QTY

DESCRIPTION

GAS TRAIN ASSEMBLY (FM; NAT. GAS)

GAS TRAIN ASSEMBLY (IRI; NAT. GAS)

GAS TRAIN ASSEMBLY (FM; PROPANE)

GAS TRAIN ASSEMBLY (IRI; PROPANE)

BLOWER

BLOWER (INCLUDES CAPACITOR 65029)

BLOWER MOTOR CAPACITOR (FOR BLOW ERS WITH BALDOR MOTOR)

3/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.

1/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.

DESCRIPTION

BLOWER M OTOR CAPACITOR (FOR ACI BLOWERS)

BLOWER AIR INLET SHUTTER

AIR INLET SCREEN

DAMPER TO BLOWER INLET HOSE

DESCRIPTION

BLOWER TO AIR VA. INLET HOSE

GAS PRESS. CONTROL TUBE

AIR/FUEL VALVE (NATURAL GAS)

AIR/FUEL VALVE (PROPANE)

VALVE TO BURNER AIR HOSE

GAS INLET PIPE1

BURNER ASSEMBLY (NATURAL GAS)

BURNER ASSEMBLY (PROPANE)

CONTROLS

DESCRIPTION

POWER BOX ASSEMBLY

IGNITION TRANSFORMER

IGNITION CABLE ASSEMBLY

INPUT/OUTP UT (I/O) BOX ASS EMBLY

CONTROL BOX ASSEMBLY

GAS TRAIN WIRING HARNESS

BLOWER PROOF SWITCH1

LOW PRESSURE GAS SWITCH

1/4" MNPT x 1/8" FNPT RED. BUSHING

TEMPERATURE SWITCH

SHELL SENSOR

LOW WATER CUT-OFF

EXHAUST TEMPERATURE SWITCH

TEMPERATURE SWITCH THERMOWELL

SHELL WIRING HARNESS

EXHAUST TEMP. SWITCH HARNESS

HIGH PRESS. GAS SWITCH

OTHER PARTS

DESCRIPTION

BURNER & AIR/FUEL VALVE O-RING

F-4

AERCO

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

KC1000 WATER BOILER

44 45

DWN.BY SCALE APPD.

PARTS LIST

041304

DATE

PL-A-139

(SH. 1 OF 2)

APPENDIX F

27 28

CPLG. W/PLUG

SIGHT PORT

AERCO

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

KC1000 WATER BOILER

DWN.BY SCALE APPD.

DATE

PARTS LIST

041304

PL-A-139

(SH. 2 OF 2)

F-5

APPENDIX F

F-6

APPENDIX F

F-7

APPENDIX G

G-1

APPENDIX G

G-2

APPENDIX H

H-1

APPENDIX H

REVDWG. NO.:

161613

SHEET 2 OF 2

CONTROL BOX CONNECTORS

16-PIN CONNECTOR

24-PIN CONNECTOR

OUT

211

212

213

214

215

216

9687 5 4 3 12

219

220

221

LS1

LS2

OUT

N.C.

N.O.

N.C.

N.O.

6 7

REMOTE INTLK

EXHAUST TEMP

DELAYED INTLK

NOT USED

RELAY

FAULT

RELAY

AUX

NOT USED

INTERNATIONAL INC.

061302MD

159 PARIS AVE, NORTHVALE, N.J.

GAS FIRED BOILER SYSTEM

(KC 1000)

WIRING SCH EMATIC

MAT'L SPEC.:

TITLE

DATE:CHECKED BY:

12 437865 9 10 1211

LS3

LS4

226

J3 J2

87654321

253

252 254

247

246 250

245 251

244

243

1210 11 13 14 1615 17 18 19 2120 22 23 24

241

240 242

854679123 1116 1415 13 12 10

238236

876543211211109131415

235 237 239

234232

233

4 3

231

OUT

LONWORKS

GND

RS-485 IN

ANALOG OUT

SHIELD

BMS (PWM) IN

ANALOG IN

SENSOR EXCIT. (12 VDC)

OXYGEN SENSOR IN

FLOW SENSOR IN

CO SENSOR IN

AUX SENSOR IN

SENSOR COMMON IN

OUTDOOR AIR SENSOR IN

INPUT/OUTPUT BOX

DRAWN BY: DATE:

ORIGINAL

DWG. SIZE

THIRD ANGLE PROJECTION

.005 TOTAL

AS FOLLOWS UNLESS OTHERWISE SPECIFIED

ALL DIMENSIONS ARE AFTER FINISH OR PLATING

DIAMETERS ON A COMMON AXIS

PERPENDICULARITY/PARALLELISM/FLATNESS .003 TOTAL

XX ±.015 XXX ± .005 FRACTIONS 1/32± ANGLES ±1°

ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE

CK'D

DATE BY

REVISIONS

SEE SHEET ONE

H-2

THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPER TY OF AERCO INTERNATIONAL, INC. THEY ARE ISSUED IN STRICT CONFIDENCE AND

SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR M ANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER.

REV ECO

AERCO GF-109 User Manual version 3.04

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

SECTION 2 – INSTALLATION PROCEDURES 2-1

SECTION 3 – CONTROL PANEL OPERATING PROCEDURES 3-1

SECTION 4 – INITIAL START-UP 4-1

Section 5 – MODE OF OPERATION 5-1

SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1

SECTION 7 – MAINTENANCE 7-1

SECTION 8 – TROUBLESHOOTING 8-1

APPENDICES

WARRANTIES W-1

SECTION 2 - INSTALLATION PROCEDURES

2.1. RECEIVING THE UNIT

2.2. UNPACKING

2.3 INSTALLATION

2.3.1. SETTING THE UNI T

2.3.2 SUPPLY AND RETURN PIPING

2.3.3 PRESSURE RELIEF AND DRAIN VALVE INSTALLATION

2.3.4 TEMPERATURE/PRESSURE INDICATOR

2.3.5 CONDENSATE PIPING

2.4. GAS SUPPLY PIPING

2.4.2 MANUAL GAS SHUTOFF VALVE

2.5 ELECTRICAL SUPPLY

2.6 MODE OF OPERATION and FIE L D CONTROL WIRING

2.6.1 CONSTANT SETPOINT MODE 2.6. 2 INDOOR/OUTDOOR RESET MODE

2.6.5 COMBINATION MODE

2.7 I/O BOX CONNECTIONS

2.7.1 OUTDOOR SENSOR IN

2.7.2 AUX SENSOR IN

2.7.3 ANALOG IN

2.7.4 B.M.S. (PWM) IN

2.7.5 SHIELD

2.7.6 mA OUT

2.7.7 RS-485 COMM

2.7.8 EXHAUST SWITCH IN

2.7.9 INTERLOCKS

2.7.10 FAULT RELAY

2.8 AUXILIARY RELAY CONTACTS

2.9 FLUE GAS VENT INSTALLATION

2.10 COMBUSTION AIR

SECTION 3 - CONTROL PANEL OPERATING PROCEDURES

3.1. INTRODUCTION

3.2. CONTROL PANEL DESCRIPTION

3.3. CONTROL PANEL MENUS

3.3.1. Menu Processing Procedure

3.4. OPERATING MENU

3.5. SETUP MENU

3.6. CONFIGURATION MENU

3.7. TUNING MENU

3.8. START SEQUENCE

3.9. START/STOP LEVELS

4.1 INITIAL START- UP REQUIREMENTS

4.2.1 REQUIRED TOOLS AND INSTRUMENTATION

4.2.3 PREPARING THE FLUE VENT PROBE HOLE

4.5 UNIT REASSEMBLY

SECTION 5 - MODE OF OPERATION

5.1 INTRODUCTION

5.2 INDOOR/OUTDOOR RESET MODE

5.2.1 RESET RATIO

5.2.4 INDOOR/OUTDOOR STARTUP

5.3 CONSTANT SETPOINT MODE

5.3.1 SETTING THE SETPOINT

5.4 REMOTE SETPOINT MODES

5.4.1 REMOTE SETPOINT FIELD WIRING

5.4.2 REMOTE SETPOINT STARTUP

5.5 DIRECT DRIVE MODES

5.5.1 DIRECT DRIVE FIELD WIRING

5.5.2 DIRECT DRIVE STARTUP

5.7.1 COMBINATION CONTROL SYSTEM FIELD WIRING

5.7.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP

SECTION 6-SAFETY DEVICE TESTING PROCEDURES

6.1 TESTING OF SAFETY DEVICES

6.3 HIGH GAS PRESSURE TEST

6.4 LOW WATER LEVEL FAULT TEST

6.6 INTERLOCK TESTS

6.6.1 REMOTE INTERLOCK

6.6.2 DELAYED INTERLOCK