AERCO GF-111 User Manual
AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-768-7789
KC Series Gas Fired Water Heater
GF-111
Operation and Maintenance Manual
Applicable to Serial Numbers G-10-1232 and above
KC Series
Gas Fired
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
Patent No. 4,852,524
1,000,000 BTU/HR Input
Printed in U.S.A. REVISED 12/10
AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-768-7789
KC Series Gas Fired Water Heater
GF-111
Operation and Maintenance Manual
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
© AERCO International, Inc., 2010
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.
Printed in U.S.A. REVISED 12/10
CONTENTS
Para.
Subject
Page
1.1
Warnings & Cautions
1-1
1.2
Emergency Shutdown
1-2
Para.
Subject
Page
1.3
Prolonged Shutdown
1-2
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
Para.
Subject
Page
2.6
Field Control W iring
2-6
2.7
Flue Gas Vent Installation
2-8
2.8
Combustion Air
2-8
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
3-6
3.7
Tuning Menu
3-7
3.8
Start Sequence
3-7
3.9
Start/Stop Levels
3-9
Para.
Subject
Page
4-1
Initial Startup Requirements
4-1
4-2
Tools and Instrumentation for
Combustion Calibration
4-1
4-3
Natural Gas Combustion
Calibration
4-2
Para.
Subject
Page
4-4
Propane Combustion Calibration
4-5
4.5
Unit Reassembly
4-5
4.6
Temperature Control Calibration
4-6
4.7
Over-Temperature Limit Switch
Adjustments
4-7
Para.
Subject
Page
5.1
Testing of Safety Devices
5-1
5.2
Low Gas Pressure Fault Test
5-1
5.3
High Gas Pressure Test
5-1
5.4
Low Water Level Fault Test
5-2
5.5
Water Temperature Fault Test
5-2
5.6
Interlock Tests
5-3
5.7
Flame Fault Test
5-3
5.8
Air Flow Fault Test
5-4
Para.
Subject
Page
5.9
SSOV Proof of Closure Switch
5-4
5.10
Purge Switch Open During
Purge
5-5
5.11
Ignition Switch Open During
Ignition
5-5
GF-111 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER
Operating & Maintenance Instructions
FOREWARD A
Section 1 – SAFETY PRECAUTIONS 1-1
Section 2 – INSTALLATION PROCEDURES 2-1
Section 3 – CONTROL PANEL OPERATING PROCEDURES 3-1
Section 4 – INITIAL START-UP 4-1
Section 5 – SAFETY DEVICE TESTING PROCEDURES 5-1
5.12 Safety Pressure Relief Valve
Test
5-6
i
CONTENTS
Para.
Subject
Page
6.1
Maintenance Schedule
6-1
6.2
Spark Ignitor
6-1
6.3
Flame Detector
6-2
6.4
Combustion Calibration
6-2
6.5
Safety Device Testing
6-2
6.6
BTU Transmitter Pump
Lubrication
6-2
Para.
Subject
Page
6.7
BTU Transmitter Assembly
6-3
6.8
Manifold and Exhaust Tubes
6-5
6.9
Heat Exchanger Inspection
6-8
6.10
Condensate Drain Assembly
6-9
Para.
Subject
Page
7.1
Introduction
7-1
Para.
Subject
Page
Para.
Subject
Page
8.1
Introduction
8-1
8.2
RS232 Communication Setup
8-1
Para.
Subject
Page
8.3
Menu Processing Utilizing
RS232 Communication
8-1
8.4
Data Logging
8-2
App
Subject
Page
Descriptions
Messages
Chart
D
Water Heater Default Settings
D-1
App
Subject
Page
E
Dimensional and Parts Drawings
E-1
F
Piping Drawings
F-1
G
Wiring Schematics
G-1
H
KC1000 Control Panel Views
H-1
I
Recommended Spare Parts
I-1
Section 6 – MAINTENANCE 6-1
Section 7 – TROUBLESHOOTING 7-1
Section 8 – RS232 COMMUNICATION 8-1
APPENDICES
A Water Heater Menu Item
B
C
Startup, Status and Fault
Temperature Sensor Resistance
A-1
B-1
C-1
WARRANTIES W-1
ii
FOREWORD
Foreword
The AERCO KC Water Heating System is a true industry advance that meets the needs of
today's energy and environmental concerns. Designed for use in any domestic water heating
system, it provides constant temperature water, regardless of flow rate. It’s small space
requirements and venting capabilities allow maximum installation flexibility. The KC Heater’s
load tracking controls modulate over a 20:1 turndown ratio for natural gas units and a 14:1
turndown ratio for propane units to match fluctuating system loads and yield high thermal
efficiencies.
With it’s compact design and direct or chimney venting, the KC Water Heating System is
adaptable to any installation. Efficiency, reliability and longevity make the KC Water Heating
System a true step forward in Water Heating System design.
After prolonged shutdown, it is recommended that the startup procedures in Section 4 and test
procedures in Section 5 of this manual be performed to verify system operating parameters. If
there is an emergency, turn off the electrical power supply to the KC Heater 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: ____________________________________________________
A
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