AERCO KC1000 User Manual
KC Series Low NOx Gas-Fired Water Heater
USER MANUAL
Applicable to Serial Numbers G-11-0694 and Above
KC Series
Low NOx
Gas Fired
GF-111LN
OMM-0029_0C
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
1,000,000 BTU/HR Input
Patent No. 4,852,524
REVISED FEBRUARY 16, 2012
GF-111LN
KC Series Low NOx Gas-Fired Water Heater
USER MANUAL
OMM-0029_0C
Telephone Support
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through Friday)
(800) 526-0288
AERCO International, Inc.
100 Oritani Drive
Blauvelt, NY 10913
www.aerco.com
© AERCO International, Inc., 2009
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.
REVISED FEBRUARY 16, 2012
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
3-5
3.7
Tuning Menu
3-7
3.8
Start Sequence
3-8
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
4-7
4.6
Temperature Control Calibration
4-8
4.7
Over-Temperature Limit Switch
Adjustments
4-10
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
Test
GF-111LN - AERCO KC1000 GAS FIRED LOW NOx WATER HEATER
Operating & Maintenance Instructions
FOREWORD 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
5-6
i
CONTENTS
Para.
Subject
Page
6.1
Maintenance Schedule
6-1
6.2
Spark Ignitor
6-1
6.3
Flame Detector
6-3
6.4
Combustion Calibration
6-3
6.5
Safety Device Testing
6-3
6.6
BTU Transmitter Pump
Lubrication
6-3
6.8
Manifold Exhaust Tubes
6-7
Para.
Subject
Page
6.9
Heat Exchanger Inspection &
Cleaning
6-12
6.10
Condensate Drain Assembly
6-15
6.13
Flame Strength Measurement
6-18
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
A
Water Heater Menu Item
Descriptions
A-1
B
Startup, Status and Fault
Messages
B-1
C
Temperature Sensor Resistance
Chart
C-1
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
KC1000 Low NOx Dual-Fuel
Switch-Over Instructions
I-1
J
Recommended Spare Parts
J-1
Section 6 – MAINTENANCE 6-1
6.7
BTU Transmitter Assembly
6-4
6.11
6.12
Low Water Cutoff Probe
Inspection and Cleaning
Hydraulic Zero Needle Valve
Adjustment (C-More Control
Box)
6-16
6-17
Section 7 – TROUBLESHOOTING 7-1
Section 8 – RS232 COMMUNICATION 8-1
APPENDICES
ii
WARRANTIES W-1
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 heaters and ANSI/NFPASB for
LP gas-fired heaters. Where applicable, the
equipment shall be installed in accordance with
the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149.1, 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 through 1-4 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.
IMPORTANT
Read the following restrictions prior to
installing the water heater:
1. The water heater can only be used for
applications where the chlorine concentrations Do Not Exceed 4 mg/L which is the
Environmental Protection Agency limit for
chlorine concentrations in drinking water.
2. Do Not use this heater for a pool heating
application.
3. If this heater was ordered with the optional
copper-lined, carbon steel shell, items 1 and
2 Do Not Apply. (Contact your local AERCO
representative to verify heater shell material.
WARNINGS!
MUST BE OBSERVED TO PREVENT
SERIOUS INJURY.
WARNING
A DOUBLE-POLE SWITCH MUST BE
INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNIT. THE
SWITCH MUST BE INSTALLED IN
AN EASILY ACCESSIBLE POSITION
TO QUICKLY AND SAFELY DISCONNECT ELECTRICAL SERVICE.
DO NOT AFFIX SWITCH TO UNIT
SHEET METAL ENCLOSURES.
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.
1-1
SAFETY PRECAUTIONS
MANUAL GAS SHUTOFF VALVE
VALVE OPEN
VALVE CLOSED
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
rinsed thoroughly with clean water after leak
checks have been completed.
be
CAUTION!
DO NOT use this heater if any part has been
under water. Call a qualified service
technician to inspect and replace any part
that has been under water.
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 heater and close the manual gas valve
located upstream the unit. The installer must
identify the emergency shut-off device.
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.
The Installer must identify and indicate the
location of the emergency shutdown manual
gas valve to operating personnel.
Water heater Installations within the Commonwealth of Massachusetts must conform to the following
requirements:
• Heater must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
• Prior to unit operation, the complete gas train and all connections must be leak tested using a
• 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
IMPORTANT
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Massachusetts.
non-corrosive soap.
from 248 CMR 5.08 (2):
Figure 1-1
Manual Gas Shutoff Valve
1-2
SAFETY PRECAUTIONS
(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. At the time of installation of the 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.
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.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in
accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior 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. The state or local gas inspector of the side wall horizontally vented gas fueled
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: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
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. When
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:
1-3
SAFETY PRECAUTIONS
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.
(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)]
1-4
SECTION 2 - INSTALLATION
2.1 RECEIVING THE UNIT
Each KC1000 Heater is shipped as a single
crated unit. The crated shipping weight is
approximately 1500 lb. and must be moved with
the proper rigging equipment for safety and to
avoid damage. The unit should be completely
inspected at the time of receipt from the carrier
before the bill of lading is signed. Each unit has
Tip-N-Tell indicator on the outside of the crate.
This indicates if the unit has been turned on its
side. If the Tip-N-Tell indicator is tripped, do not
sign for the shipment. Note the information on
the carrier’s paperwork and request a freight
claim and inspection by a claims adjuster before
proceeding. Any other visual damage to the
packaging materials should also be fully
explained to the delivering carrier.
2.2 UNPACKING
Carefully unpack the unit. Take care not to
damage the unit jacket when cutting away
packaging materials. A close inspection of the
unit should be made to determine if there has
been any damage incurred during shipment that
was not indicated by the Tip-N-Tell indicator.
INSTALLATION
The freight carrier should be notified
immediately if any damage is detected. The
following standard accessories are included with
each unit and are packed separately within the
unit’s packing container
• Spare Spark Igniter
• Spare Flame Detector
• Differential Regulator Spring:
P/N 122548 (Propane) or
P/N 124803 (Natural Gas)
• Manual 1-1/4" Gas Shutoff Valve
• Drain Valve Assembly
• ASME Pressure/Temperature
Relief Valve
• 2 Lifting Lugs
• Stainless Steel Condensate Cup
• Flue Clamps (2 Pieces)
• Shell Cap
• Wing Nut for Shell Cap
Optional accessories are also separately packed
within the unit’s packing container. Standard and
optional accessories shipped with the unit
should be identified and put in a safe place until
installation/use.
Figure 2.1 Heater Clearance
2-1
INSTALLATION
2.3 INSTALLATION
The unit must be installed with the prescribed
clearances for service as shown in Figure 2.1.
These are the minimum
required by AERCO. Local building codes may
require more clearance and take precedence.
WARNING !
KEEP UNIT AREA CLEAR AND FREE
FROM COMBUSTIBLE MATERIALS AND
FLAMMABLE VAPORS AND LIQUIDS.
MASSACHUSSETTS INSTALLATIONS
For water heater installations within the
Commonwealth of Massachusetts, the heater
must be installed by a plumber or a gas fitter
who is licensed within the Commonwealth. In
addition, the installation must comply with all
requirements specified in Section 1 (Safety
Precautions), pages 1-2 to 1-4.
2.3.1 SETTING THE UNIT
Locate the lifting lugs, shipped with the unit, and
attach them to the 5/8” x 11 studs at the top of
the unit. Remove the unit from the wooden skid
and place in position using a block and tackle or
hoist attached to the lifting lugs (Figure 2.2).
USE THE LIFTING LUGS TO MOVE THE
UNIT.
The KC-1000 is U/L approved for installation on
combustible flooring. A 4 to 6 inch high housekeeping concrete pad is recommended and
allows for sufficient drainage of the condensate.
The unit must be secured using only the holes
provided in the frame base. Do not use piping to
secure the unit in place. See drawing AP-A-804
in Appendix E for the base frame dimensions.
In multiple unit installations, it is important to
plan the position of each unit. Sufficient space
for piping connections and maintenance requirements must be given. All piping must include
ample provision for expansion.
clearance dimensions
Figure 2.2
Lifting Lug Location
3
2.3.2 WATER INLET AND OUTLET
PIPING
The locations of the 2" NPT cold water inlet and
hot water outlet piping connections are shown in
Figure 2.3. Flow rates through the unit are
limited to 30 gpm continuous and 40 gpm
intermittent.
The heater is shipped with a 2” NPT x 12” long
stainless steel flex connector. It is important that
this flex connector be installed at the hot water
outlet as mentioned in the installation diagrams
to ensure compliance with the AERCO warranty.
If it is desired to install the flex connector
elbowed towards the rear or top of the unit, two
additional parts (not supplied with heater) are
required. These parts are a 2”NPT x 6” long 304
or 316 stainless nipple and a 2” NPT 304 or 316
stainless elbow. Both of these parts must be
capable of withstanding up to 155 psig @ 210°F.
These parts may be added between the heater
outlet connection and the flex connector.
However, if this heater was ordered with the
optional copper-lined carbon steel shell (contact
your local AERCO Representative to verify), it is
not shipped with, and does not require a flex
connector.
2-2
INSTALLATION
Shut-off valves and union conections must be
installed in the inlet and outlet lines for
maintenance. The use of dielectric unions is
recommended. Install the piping and accessories as per the following drawings, located in
Appendix F of this manual.
• SD-A-705 for single units
• SD-A-706 for multiple units
• SD-A-707 for single units with a stratified
tank
• SD-A-708 for multiple units with a stratified
storage tank
• SD-A-709 for single units with a stratified
tank for 2 temperature zones
NOTE:
All piping must be arranged so that it does not
interfere with removal of any cover, inhibit
service or maintenance, or prevent access
between the unit and walls, or another unit.
Figure 2.4
Hose Bib Location
NOTE:
The maximum working pressure for installations
within the Province of Alberta is 87 psig.
Therefore, a pressure & temperature relief valve
with a setting of 75 psig/210°F is supplied with
Alberta shipments. See Drawing AP-A-863 in
Appendix E.
2.3.4 PRESSURE/TEMPERATURE
RELIEF & DRAIN
An ASME rated Pressure/Temperature Relief
Valve is supplied with each unit. With the
exception of Alberta installations (see above
Note), the valve setpoint is 150 psig/210°F.
Install the relief valve as shown in Figure 2.5. A
suitable pipe compound should be used on the
Figure 2.3
Inlet and Outlet Location
2.3.3 TEST HOSE BIB
A Test Hose Bib connection, upstream of the
shut off valve on the hot water outlet, is required
for startup and testing (Figure 2.4). It should be
a minimum of 3/4". The Test Hose Bib cannot
be omitted.
threaded connections. Any excess should be
wiped off to avoid getting any into the valve
body. The relief valve should be pipied to within
12 inches of the floor to prevent injury in the
event of a discharge. The relief piping must be
full size, 1-1/2”, without reduction. No valves,
restrictions, or other blockages are allowed in
the discharge line. In multiple unit installations
the discharge lines must not
together. Each must be individually run to a
suitable discharge location.
VALVE INSTALLATION
be manifolded
2-3
INSTALLATION
TEMPERATURE SENSOR
EXHAUST
MANIFOLD
CONDENSATE
DRAIN
BURNER
HOSE CLAMP
1-3/4" O.D. x 8-1 /2 “ LG.
SILICONE HOSE
5/8" O.D. TUBE CONN.
CONDENSATE CUP
PLACED ON FLOOR
A 1” drain valve assembly is furnished with each
unit. The drain valve assembly should be installed as shown in Figure 2.5. and hard piped to
a suitable drain.
2.3.5 SYSTEM RECIRCULATION
The system recirculating line ties into the unit at
the recirculating tee fitting provided in the drain
valve assembly (Figure 2.5). Shut off valves and
union connections are recommended for maintenance. Recirculation flow rates must be kept to
8 gpm or less. In a multiple unit installation, each
unit must be tied into the system recirculation
system.
3. Attach a length of 3/4 inch I.D. polypropylene
tubing to the condensate cup drain tube and
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 main-tenance. Therefore, DO NOT
hard-pipe.
4. Replace the rear cover and side panel on the
unit.
Figure 2.5
Pressure/Temperature Relief and Drain
Valve Installation Location
2.3.6 CONDENSATE PIPING
The KC Heater 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 unit’s shipping container. To install the condensate cup, proceed as
follows:
1. Remove the left side panel and only the left
half of the rear cover to provide access to the
exhaust manifold and burner (Figure 2.6).
2. Insert the 1-3/4 inch manifold drain hose into
the condensate cup. Allow the cup to rest on
the floor directly beneath the manifold drain
hole (Figure 2.6).
Figure 2.6
Condensate Drain Assembly Location
2.4 GAS SUPPLY PIPING
AERCO Gas Fired Equipment Gas Components
and Supply Design Guide (GF-1030) should be
consulted before any gas piping is designed or
started.
WARNING !
DO NOT USE MATCHES, CANDLES,
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS LEAKS
.
CAUTION !
Many soaps used for gas pipe leak testing
are corrosive to metals. The piping 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 the removal of any cover,
inhibit service, maintenance, or prevent access
between the unit and walls, or another unit.
2-4
INSTALLATION
The location of the 1-1/4" inlet gas connection
on the right side of the unit is shown in Figure
2.7.
All pipe should be de-burred and internally
cleared of any scale or iron chips before
installation. No flexible connectors or nonapproved gas fittings should be installed. Piping
should be supported from floor or walls only and
must not be secured to the unit.
A suitable piping compound approved for use
with gas should be used sparingly. Any excess
must be wiped off to prevent clogging of
components.
To avoid damage to the unit when pressure
testing gas piping, isolate the unit from the gas
supply piping. At no time should there be more
than 1 psig maximum to the unit. Bubble test all
external piping thoroughly for leaks using a soap
and water solution or suitable equivalent. The
gas piping must meet all applicable codes.
Figure 2.7
Gas Supply Regulator and Manual Shut -
Off Valve Location
2.4.1 GAS SUPPLY PRESSURE
REGULATOR
A mandatory external, in-line, supply gas
regulator (supplied by others) must be installed
upstream of each KC1000 and positioned as
shown in Figure 2.7. Union connections should
be placed in the proper locations to allow
maintenance of the regulator if required. The
regulator must be capable of providing the
required gas pressures for natural gas and
propane units as described in the paragraphs
which follow.
Natural Gas:
The maximum static inlet pressure to the unit
must be no more than 14” W.C. Minimum gas
pressure is 8.8” W.C. for FM gas trains and
9.2” W.C. for IRI gas trains when the unit is
firing at maximum input. Gas pressure should
not exceed 11.5” W.C. at any time when firing.
Proper sizing of the gas supply regulator in
delivering the correct gas flow and outlet
pressure is mandatory. The gas supply
pressure regulator must maintain the gas
pressure at a regulated 8.8” W.C. minimum
for FM gas trains and 9.2” W.C. for IRI gas
trains at maximum BTU input (970,000
BTU/HR) for natural gas installations. The
supply gas regulator must be of sufficient
capacity volume, (1000 cfh), for the unit and
should have no more than 1" droop from
minimum to full fire.
Propane:
The maximum static inlet pressure to the unit
must be no more than 14” W.C. Minimum gas
pressure is 7.7” W.C. for FM gas trains and
8.1” W.C. for IRI gas trains when the unit is
firing at maximum input. Gas pressure should
not exceed 11.5” W.C. at any time when firing.
Proper sizing of the gas supply regulator in
delivering the correct gas flow and outlet
pressure is mandatory. The gas supply
pressure regulator must maintain the gas
pressure at a regulated 7.7” W.C. minimum
for FM gas trains and 8.1” W.C. for IRI gas
trains at maximum BTU input (1,000,000
BTU/HR) for propane installations. The supply
gas regulator must be of sufficient capacity
volume, (400 cfh), for the unit and should have
no more than 1" droop from minimum to full
fire.
The supply gas regulator must be rated to
handle the maximum incoming supply gas
pressure. When the gas supply pressure will not
exceed 14” W.C. a non-lock up or flow through
style regulator may be used. When supply gas
pressure will exceed 14” W.C., a lock up style
regulator must be used. The gas supply
regulator must be propery vented to outdoors.
Consult the local gas utility for exact
requirements concerning venting of supply gas
regulators.
CAUTION!
A lockup style regulator must be used when gas
supply pressure exceeds 14” W.C.
2-5
INSTALLATION
POWER BOX
BLOWER
SSOV
ACTUATOR
FRAME
USE COPPER CONDUCTORS ONLY FOR FIELD WIRING
60 HZ
DISCONNECT POWER BEFORE SERVICING
DANGER: HIGH VOLTAGE
20 AMP
120 VAC,
NEUTRAL
GROUND
LINE
POWER BOX
AERCO INTERNATIONAL INC.
INPUT POWER
2.4.2 MANUAL GAS SHUTOFF VALVE
A 1-1/4” manual gas shutoff valve is furnished
with each unit and should be positioned as
shown in Figure 2.7. The valve must be installed
upstream of the gas supply regulator in a readily
accessible location.
2.4.3 IRI GAS TRAIN KIT
The IRI gas train is an optional gas train
required in some areas by code or for insurance
purposes. The IRI gas train comes preassembled and wired from the factory. See
Appendix E, Drawing SD-A-661.
The IRI gas train may be ordered pre-assembled
or as separate components. If either IRI gas
train option is ordered a complete instructional
package, detailing field installation will be
included. To obtain a copy of an IRI instructional
package prior to the equipment shipping, contact
your local representative or AERCO.
2.5 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 located on the front right side of
the unit as shown in Figure 2.8.
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 double-pole switch must be installed on the
electrical supply line in an easily accessible
location to quickly and safely disconnect
electrical service. DO NOT attach the switch to
sheet metal enclosures of the unit.
After placing the boiler in service, the ignition
safety shutoff device must be tested. If an
external electrical power source is used, the
installed boiler must be electrically bonded to
ground in accordance with the requirements of
the authority having jurisdiction. In the absence
of such requirements, the installation shall
conform to National Electrical Code (NEC),
ANSI/NFPA 70 and/or the Canadian Electrical
Code (CEC) Part I, CSA C22.1 Electrical Code.
The electrical wiring diagram is shown in Figure
2.9. Conduit should be run from the knockouts in
the side of the box in such a manner that it does
not interfere with the removal of any sheet metal
covers. A flexible electrical connection may be
utilized to allow the covers to be easily removed.
AC Power Box Location
Figure 2.8
2-6
Figure 2.9
AC Power Wiring Diagram
2.6 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an
internal operating control system. No field
control wiring is required for normal operation.
However, the KC1000 control system does allow
for some control and monitoring features.
INSTALLATION
GAS SHUT-OFF VALVE
I/O BOX
BLOWER
Wiring for these features can be accomplished
in the I/O Box behind the left side panel (Figures
2.10 and 2.11). The I/O Box is common to both
KC1000 water heaters and boilers. While some
of the inputs and outputs are common to both
water heaters and boilers, some are not
applicable to both. These are noted in the
following paragraphs.
Figure 2.10
Input/Output (I/O) Box Location
CAUTION!
DO NOT make any connections to the I/O
Box terminals labeled “NOT USED”.
Attempting to do so may cause equipment
damage.
2.6.1 OUTDOOR AIR SENSOR IN
Not applicable to Water Heaters.
2.6.2 AUX SENSOR IN
The AUX SENSOR IN terminals can be 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 menu. The sensor must 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 is located in APPENDIX C.
2.6.3 ANALOG IN
The ANALOG IN + and – terminals are used
when an external signal is used to change the
setpoint (Remote Setpoint Mode) of the heater.
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 air/fuel valve position. The factory
default setting is for 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
drive signal, a DIP switch must 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. Connections between the source
and the Heater’s I/O Box must be made using
twisted shielded pair of 18–22 AWG wire such
as Belden 9841(see Figure 2.11). Polarity must
be maintained and the shield must be connected
only at the source end and must be left floating
(not connected) at the Heater’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% air/fuel valve
position. No scaling for these signals is provided
2.6.4 B.M.S. (PWM) IN
Not applicable to Water Heaters.
2.6.5 SHIELD
The SHIELD terminals are used to terminate any
shields used on sensor wires connected to the
unit. Shields must only be connected to these
terminals.
2.6.6 mA OUT
These terminals provide a 4 to 20 mA output
that can be used to monitor setpoint ( 40°F to
240°F), outlet temperature (30°F to 240°F), or
air/fuel valve position (0% to 100% open). This
function is enabled in the Configuration Menu
(Section 3, Table 3.4).
2.6.7 RS-485 COMM
These terminals are used for RS-485 serial
communication between the unit and an external
“Master” such as an Energy Management
System or other suitable device.
2.6.8 EXHAUST SWITCH IN
These terminals permit an external exhaust
switch to be connected to the exhaust manifold
of the heater. The exhaust sensor should be a
normally open type switch (such as AERCO P/N
123463) that closes (trips) at 500
o
F.
2.6.9 INTERLOCKS
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers or
other accessories. These interlocks are called
the Remote Interlock and Delayed Interlock
(Figure 2.11). The wiring terminals for these
interlocks are located inside the I/O Box on the
left side of the unit. The I/O Box cover contains a
wiring diagram which shows the terminal strip
2-7
INSTALLATION
mA OUT
RS-485
COMM.
+
-
+
-
ANALOG IN
SENSOR COMMON
OUTDOOR SENSOR IN
REMOTE INTL'K IN
B.M.S. (PWM) IN
SHIELD
+
-
+
-
AUX SENSOR IN
NOT USED
EXHAUST SWITCH IN
DELAYED INTL
'K IN
FAULT RELAY
120
VAC, 5A, RES
AUX RELAY
120 VAC, 5A, RES
G
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
NOT USED
NOT USED
NC
COM
NO
NC
COM
NO
NOT USED
locations for these interlocks (REMOTE INTL’K
IN and DELAYED INTL’K IN). Both interlocks,
described below, are factory wired in the closed
position.
NOTE:
Both the Delayed Interlock and Remote Interlock
must be in the closed position for the unit to fire.
2.6.9.1 REMOTE INTERLOCK IN
The remote interlock circuit is provided to
remotely start (enable) and stop (disable) the
unit if desired. The circuit is labeled REMOTE
INTL’K IN and is located inside the I/O Box on
the left side of the unit. The circuit is 24 VAC
and comes factory pre-wired closed (jumped).
2.6.9.2 DELAYED INTERLOCK
The delayed interlock is typically used in
conjunction with the auxiliary relay described in
paragraph 2.6.11. This interlock circuit is located
in the purge 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 unit’s auxiliary relay. The
delayed interlock must be closed for the heater
to fire. If the delayed interlock is connected to a
proving device that requires time to close
(make), a time delay (Aux Start On Dly) that
holds the start sequence of the unit long enough
for a proving switch to make (close) can be
programmed.
Should the proving switch not prove within the
programmed time frame, the unit will shut down.
The Aux Start On Dly can be programmed from
0 to 120 seconds. This option is locate in the
Configuration Menu (Section 3).
2.6.10 FAULT RELAY
The fault relay is a single pole double throw
(SPDT) relay having a normally open and
normally closed set of relay contacts that are
rated for 5 amps at 120 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.
2.6.11 AUXILIARY RELAY CONTACTS
Each unit is equipped with a single pole double
throw (SPDT) relay that is energized when there
is a demand for heat and de-energized after the
demand for heat is satisfied. The relay is
provided for the control of auxiliary equipment,
such as pumps and louvers, or can be used as a
unit status indictor (firing or not firing). Its
contacts are rated for 120 VAC @ 5 amps.
Refer to Figure 2.11 to locate the AUX RELAY
terminals for wiring connections.
2-8
Figure 2.11 I/O Box Wiring
INSTALLATION
2.7 FLUE GAS VENT INSTALLATION
AERCO Gas Fired Venting and Combustion Air
Guide, GF-1050, must be consulted before any
flue or combustion air venting is designed or
installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used
for safety and UL certification. Because the unit
is capable of discharging low temperature
exhaust gases, the flue must be pitched back
towards the unit a minimum of 1/4" per foot to
avoid any condensate pooling and to allow for
proper drainage.
While there is a positive flue pressure during
operation, the combined pressure drop of vent
and combustion air systems must not exceed
140 equivalent feet of 0.81” W.C. Fittings as
well as pipe lengths must be calculated as part
of the equivalent length. For a natural draft
installation the draft must not exceed - 0.25”
W.C. These factors must be planned into the
vent installation. If the maximum allowable
equivalent lengths of piping are exceeded, the
unit will not operate properly or reliably.
For Massachusetts 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:
The more common methods of combustion air
supply are outlined in the following paragraphs.
For combustion air supply from ducting, consult
the AERCO GF-1050, Gas Fired Venting and
Combustion Air Guide.
2.8.1 COMBUSTION AIR FROM OUTSIDE
THE BUILDING
Air supplied from outside the building must be
provided through two permanent openings. For
each unit these two openings must have a free
area of not less than one square inch for each
4000 BTUs input of the equipment or 250
square inches of free area. The free area must
take into account restrictions such as louvers
and bird screens. For Canada installations, refer
to the requirements specified in CSA B149.1-10,
8.4.1 and 8.4.3.
2.8.2 COMBUSTION AIR FROM INSIDE
THE BUILDING
When combustion air is provided from within the
building, it must be supplied through two
permanent openings in an interior wall. Each
opening must have a free area of not less than
one square inch per 1000 BTUH of total input or
1000 square inches of free area. The free area
must take into account any restrictions, such as
louvers.
Selkirk Corporation
Heatfab Division
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
2.8 COMBUSTION AIR
The AERCO Gas-Fired Heater Venting and
Combustion Air Guide, GF-1050 MUST be
consulted before any flue or inlet air venting is
designed or installed. Air supply is a direct
requirement of ANSI 223.1, NFPA-54, CSA
B149.1 and local codes. These codes should be
consulted before a permanent design is
determined.
The combustion air must be free of chlorine,
halogenated hydrocarbons or other chemicals
that can become hazardous when used in gasfired equipment. Common sources of these
compounds are swimming pools, degreasing
compounds, plastic processing, and refrigerants.
Whenever the environment contains these types
of chemicals, combustion air MUST be supplied
from a clean area outdoors for the protection
and longevity of the equipment and warranty
validation.
NOTE
KC1000 units equipped with Low NOx
Burners require an optional Cold Air
Damper for operation with Direct
Vent/Sealed Combustion. The Cold Air
Damper is also required when the unit is
installed in an area where the combustion
air supply temperature can drop below
55°F. Refer to the following paragraph
(2.8.3) and GF-1050 for installation details
2.8.3 SEALED COMBUSTION
The KC Heater is UL approved for 100% sealed
combustion application when installed properly.
When a sealed combustion air application is
installed, the sealed combustion air piping must
be deducted from the maximum allowable
discharge piping amounts. Each unit must have
a minimum 6" diameter connection made to the
special Inlet Air Adapter # GP-18917 available
from AERCO. This adapter bolts directly on to
the air inlet of the unit’s blower. See installation
instructions with adapter. All inlet air ducts must
be sealed air tight.
2-9
INSTALLATION
6" MINIMUM
6x3 REDUCER
COLD AIR DAMPER
(FOR KC1000 LOW NOX)
In addition, Cold Air Damper # 99026 must be
installed. It should be located along the inlet duct
run as close as possible to the KC1000 (See
Figure 2.12). The Cold Air Damper must be
placed on individual sections (one Damper per
unit), not in a manifold section. The adjustment
screw on the Damper should be moved to the
center of the slot position and tightened 1/2 turn
past “finger-tight”. DO NOT over-tighten.
See AERCO Venting Guide GF-1050 for further
details.
Figure 2.12
Sealed Combustion Air Connection
2-10
CONTROL PANEL OPERATING PROCEDURES
3
1
2
7
4
6
10
8
9
5
11
12
SECTION 3 - CONTROL PANEL OPERATING PROCEDURES
3.1. INTRODUCTION
The information in this Section provides a guide
to the operation of the KC1000 Water Heater
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
HEATER. 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 controls, indicators and displays
necessary to operate, adjust and troubleshoot
the KC1000 Water Heater. 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
FUNCTION
follows:
COMM
Lights when RS-232 communication is occurring
keypad
from an Energy Management System
DEMAND
Lights when there is a demand for heat
Menu Selection
in degrees Fahrenheit or degrees Celsius.
connected to the water heater Control Panel.
5
READY Indicator
Lights when all Pre-Purge conditions have been satisified.
6
ON/OFF Switch
Enables and disables heater operation.
Pressing CLEAR resets the display.
condition occurs. An alarm message will appear in the VFD.
alarms
the Control Panel Menus:
The Menu categories wrap around in the order shown.
category.
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
MANUAL
REMOTE
2 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines, each
3
OUTLET
TEMPERATURE
Display
4 RS-232 Port Port permits a Laptop Computer or External Modem to be
7
LOW WATER LEVEL
TEST/RESET Switches
Lights when the unit is being controlled using the front panel
Lights when the unit is being controlled by an external signal
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
Startup Messages
Alarm Messages
Operating Status Messages
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
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.
8 FAULT Indicator Red FAULT LED indicator lights when a heater alarm
9 CLEAR Key Turns off the FAULT indicator and clears the 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
10 MENU Keypad Consists of 6 keys which provide the following functions for
MENU
BACK
Steps through the main menu categories shown in Figure 3-2.
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
3-2
CONTROL PANEL OPERATING PROCEDURES
FUNCTION
pressing the ▲ arrow key will increment the selected setting.
setting.
flashing will increment or decrement the displayed setting.
display will stop flashing.
Bargraph
Air/Fuel Valve Position in 5% increments from 0 to 100%
Table 3-1. Operating Controls, Indicators and Displays - Continued
ITEM
NO.
CONTROL, INDICATOR
OR DISPLAY
10
(Cont.)
▲ (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,
▼ (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
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
Saves the modified menu information in memory. The
CHANGE
ENTER
11 AUTO/MAN Switch This switch toggles the water heater 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.
12
VALVE POSITION
20-segment red LED bargraph continuously shows the
3.3. CONTROL PANEL MENUS
The Control Panel incorporates an extensive
menu structure to permit the operator to set up
and configure the unit. The menu structure
consists of the four major menu categories
shown in Figure 3-2. Each of these menus
contains options to permit operating parameters
to be viewed or changed. The menus are
password-protected 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. Continue pressing the MENU key until the
desired menu is displayed.
3-3
CONTROL PANEL OPERATING PROCEDURES
OPERATION
SETUP
CONFIGURATION
TUNING
PASSWORD
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.
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 will time out after 1 hour. Therefore,
the password must be re-entered 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.
Figure 3-2. Menu Structure
3-4
CONTROL PANEL OPERATING PROCEDURES
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Status Message
Active Setpoint
40°F
240°F
Aux Temp
30°F
245°F
Outdoor Temp*
-70°F
130°F
Valve Position In
0%
Max Valve
Position
Flame Strength
0%
100%
Run Cycles
0
999,999
Run Hours
0
999,999
Fault Log 0 19
0
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
Celsius
Fahrenheit
Comm Address
0
127
0
Baud Rate
2400
9600
Software
Ver 0.00
Ver 9.99
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
Table 3-3. Setup Menu
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
4800
9600
19.2K
may or may not be displayed, depending on the
current operating mode setting.
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.
3-5
CONTROL PANEL OPERATING PROCEDURES
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Table 3-4. Configuration Menu
Internal Setpt Lo Temp Limit Hi Temp Limit 130°F
Unit Type
Unit Size
Fuel Type Natural Gas, Propane Natural Gas
Water Heater Mode
Remote Signal
(If Mode = Remote
Setpoint)
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)
Setpt Lo Limit 40°F Setpt Hi Limit 60°F
Setpt Hi Limit Setpt Lo Limit 200°F 195°F
Temp Hi Limit 40°F 200°F 195°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
KC Boiler, KC Boiler LN,
BMK Boiler, BMK Boiler LN,
BMK Boiler Dual, KC Water
Heater, KC Water Heater LN,
Water Heater 2010
0.5 MBTU, 1.0 MBTU
1.5 MBTU, 2.0 MBTU
3.0 MBTU, 3.5 MBTU
4.0 MBTU, 5.0 MBTU
6.0 MBTU
Constant Setpoint,
Remote Setpoint,
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input (BMS)
Network
40°F 230°F 70°F
0.1 9.9 1.2
30°F 100°F 60°F
KC Water
Heater LN
1.0 MBTU
Constant
Setpoint
4 – 20 mA,
1-5V
3-6
*Analog Output
(See CAUTION at
end of Table 3-4 )
Off, Setpoint, Outlet Temp,
Valve Position 4-20 mA,
Valve Position 0-10V
*Valve
Position
0-10V
Table 3-4. Configuration Menu - Continued
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Available Choices or Limits
Menu Item Display
Minimum
Maximum
Default
Min Load Adj
-50°F
50°F
0°F
Max Load Adj
-50°F
50°F
0°F
FFWD Temp
30°F
245°F
Outlet Feedback
On
Off
On
Reset Defaults?
Yes
Are You Sure?
No
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
*CAUTION:
DO NOT CHANGE the Analog Output Menu Item from its Default setting
(Valve Position 0-10V).
CONTROL PANEL OPERATING PROCEDURES
3.7. TUNING MENU
The Tuning Menu items in Table 3-5 are Factory
set for each individual unit.
Table 3-5. Tuning Menu
Do not change these menu entries unless
specifically requested to do so by factory trained
personnel.
No
3-7
CONTROL PANEL OPERATING PROCEDURES
STEPPER
MOTOR
DETAIL "A"
DIAL
(DETAIL “A”)
100
BLOWER
BURNER
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 (hot water), 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 the 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%).
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).
Figure 3-3.
Figure 3-4.
Air/Fuel Valve In Purge Position
4. The blower proof switch (Figure 3-5) closes;
the display shows Purging and indicates the
elapsed time of the purge cycle in seconds.
3-8
Safety Shut-Off Valve
CONTROL PANEL OPERATING PROCEDURES
154
155
AIR/FUEL VALVE
BLOWER PROOF
SWITCH
TO FRAME
HARNESS
STEPPER
MOTOR
DETAIL "A"
DIAL
(DETAIL “A”)
BLOWER
BURNER
2
5
9.
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 pro-
vides ignition spark.
(c) The gas Safety Shut Off Valve (SSOV)
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.
Figure 3-6.
Air/Fuel Valve In Ignition Position
10. Once the demand for hot water 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.
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 water heater is
not linearly related to the fire rate percentage
(Air/Fuel Valve position). Refer to Table 3-6 for
the relationship between the energy input and
Air/Fuel Valve position (% open) 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
Air/Fuel Valve
Position
(% Open)
0 0 0
10 0 0
13
(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
INITIAL START-UP
4.1 INITIAL START- UP REQUIREMENTS
The initial start-up of the KC-1000 Low NOx
Water Heater is comprised of the following
steps:
• Installation completed 100%
• Combustion calibration
• Proper setting of controls and limits
• Temperature calibration
• Safety device testing (see Section 5)
Installation procedures should be completed
100% before performing initial start-up. Also, the
initial start-up must be complete prior to putting
the unit into service. Starting a unit without the
proper piping, venting, or electrical systems can
be dangerous and void the product’s warranty.
These start-up instructions should be precisely
followed in order for the unit to operate safely, at
a high thermal efficiency, and with low flue gas
emissions.
Initial unit start-up must be performed ONLY by
AERCO factory trained start-up and service
personnel. After following the steps in this
section, it will be necessary to perform the safety
device test procedures in Section 5 to complete
the initial unit start-up.
An AERCO Gas Fired Startup Sheet included
with each KC-1000 must be completed for each
unit for warranty validation and a copy must be
returned promptly to AERCO at:
AERCO International, Inc.
159 Paris Ave.
Northvale, NJ 07647
WARNING!
DO NOT ATTEMPT TO FIRE THE UNIT
WITHOUT FULL WATER LEVEL. 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 start the
unit.
4.2 TOOLS AND INSTRUMENTATION
FOR COMBUSTION CALIBRATION
To properly perform combustion calibration on a
KC Heater equipped with a low NOx burner, 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 a
low NOx unit:
1. Digital Combustion Analyzer - Oxygen
accuracy to ± 0.4%; Carbon Monoxide and
NOx resolution to 1 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. Small and large flat blade screwdrivers.
5. 7/16" open end wrench and small adjustable
wrenches.
6. Tube of silicone adhesive
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
SSOV
1/8" NPT PLUG
(INSTALL
MANOMETER
HERE)
3/8" - 1/2"
HOLE FOR
COMBUSTION
ANALYZER
PROBE
EXHAUST
MANIFOLD
12" - 18"
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 covers
vent connections must be loosened and
moved to uncover the hole (see Figure 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
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. If desired, the
unit can be easily switched from one fuel type to
the other using the regulator spring change
procedure in Appendix I.
For propane units, disregard paragraph 4.3 and
proceed to paragraph 4.4.
4.3 NATURAL GAS COMBUSTION
CALIBRATION
The KC-1000 is shipped combustion calibrated
from the factory. Recalibration as part of a startup is necessary due to differences in 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
combustion will be kept to a minimum.
1. Open the supply and return valves to the
unit and ensure that the system pumps are
running.
2. Open the gas supply valve(s) to the unit.
3. If a lockup style regulator is installed as a
gas supply regulator, adjust the gas supply
until a reading of 12” W.C. static pressure 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 position in % open. Also,
the MANUAL LED will light.
NOTE:
For a review of the 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 position to 25% using the
▲ arrow key. This will put the unit into the
starting sequence.
4-2
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