Aerco KC Series User Manual Download

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REVISED JULY 8, 2011

GF-111LN

OMM-0029_0B

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

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

Summary of Contents for KC Series

Page 1: ...w NOx Gas Fired Water Heater USER MANUAL Applicable to Serial Numbers G 11 0694 and Above KC Series Low NOx Gas Fired 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 ...

Page 2: ...he 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 con...

Page 3: ... Configuration Menu 3 5 3 7 Tuning Menu 3 7 3 8 Start Sequence 3 8 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 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 ...

Page 4: ...surement 6 16 6 17 6 18 Section 7 TROUBLESHOOTING 7 1 Para Subject Page 7 1 Introduction 7 1 Para Subject Page Section 8 RS232 COMMUNICATION 8 1 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 APPENDICES App Subject Page A Water Heater Menu Item Descriptions A 1 B Startup Status an...

Page 5: ...IMPORTANT Read the following restrictions prior to installing the water heater 1 The water heater can only be used for applications where the chlorine concentra tions 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...

Page 6: ...gency 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 system operating parameters If there is an emergency turn off the electrical power supply to the AERCO heater and close the manual gas valve loca...

Page 7: ...mply 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 ...

Page 8: ...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 h...

Page 9: ...refully 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 The freight carrier should be notified immediately if any damage is detected The following standard accessories are included with each...

Page 10: ... 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 require ments must be given All piping must include ample provision for expansion Figure 2 2 Lifting Lug Location 3 2 3 2 WATER INLET AND OUTLET PIPING Th...

Page 11: ...ose Bib cannot be omitted 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 VALVE INSTALLATION An ASME rated Pressure Temperature Relief Va...

Page 12: ...d drain hose into the condensate cup Allow 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 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...

Page 13: ...ld 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...

Page 14: ...EMENTS 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 th...

Page 15: ...pplied signals must be floating unground ed 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 si...

Page 16: ...ving 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...

Page 17: ...refrigerants Whenever the environment contains these types of chemicals combustion air MUST be supplied from a clean area outdoors for the protection and longevity of the equipment and warranty validation The more common methods of combustion air supply are outlined in the following paragraphs For combustion air supply from ducting consult the AERCO GF 1050 Gas Fired Venting and Combustion Air Gui...

Page 18: ...r 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 6 MINIMUM 6x3 REDUCER COLD AIR DAMPER FOR KC1000 LOW NOX Figure 2 12 Sealed Combustion Air Connection ...

Page 19: ...RNING 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 ...

Page 20: ...eater Control Panel 5 READY Indicator Lights when all Pre Purge conditions have been satisified 6 ON OFF Switch Enables and disables heater operation 7 LOW WATER LEVEL TEST RESET Switches 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 Pr...

Page 21: ...on in 5 increments from 0 to 100 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 unauthoriz...

Page 22: ...riptions 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 Read Only it can be viewed at any ti...

Page 23: ... 59 pm Date 01 01 00 12 31 99 Unit of Temp Fahrenheit Celsius Fahrenheit Comm Address 0 127 0 Baud Rate 2400 4800 9600 19 2K 9600 Software Ver 0 00 Ver 9 99 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 m...

Page 24: ...oint Constant Setpoint Remote Signal If Mode Remote Setpoint 4 20 mA 1 5V 0 20 mA 0 5V PWM Input BMS Network 4 20 mA 1 5V Bldg Ref Temp If Mode Outdoor Reset 40 F 230 F 70 F Reset Ratio If Mode Outdoor Reset 0 1 9 9 1 2 Outdoor Sensor Enabled or Disabled Disabled System Start Tmp If Outdoor Sensor Enabled 30 F 100 F 60 F Setpt Lo Limit 40 F Setpt Hi Limit 60 F Setpt Hi Limit Setpt Lo Limit 200 F 1...

Page 25: ...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 3 7 TUNING MENU The Tuning Menu items in Table 3 5 are Factory set for each individual unit Do not change these menu entries unless specifically requested to do so by factory trained personnel Table 3 5 Tuning Menu Available Choices or Limits Menu Item Display Minimum Max...

Page 26: ...ropriate fault messages will be displayed throughout the start sequence if the required conditions are not observed 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 Safety Shut Off Valve 3 With all required safety switches closed a purge cycle will be initiated and the followi...

Page 27: ...me will be displayed in place of the flame strength 8 With the unit firing properly it will be controlled by the temperature controller cir cuitry The VALVE POSITION will be continuously displayed on the front panel bargraph 9 STEPPER MOTOR DETAIL A DIAL DETAIL A BLOWER BURNER 25 Figure 3 6 Air Fuel Valve In Ignition Position 10 Once the demand for hot water has been satisfied the Control Box will...

Page 28: ...nd Energy Input of a Unit Running on Natural Gas Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 0 0 0 10 0 0 13 Stop Level 50 000 5 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 ...

Page 29: ... 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 equi...

Page 30: ...ustion calibrated from the factory Recalibration as part of a start up 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 mini...

Page 31: ... 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 intake air temperature in Table 1 Also ensure that the carbon mo...

Page 32: ...nd 2 8 3 21 Change the valve position to 100 and allow the combustion analyzer to settle 22 If the optional Cold Air Damper P N 99026 is installed compare the measured oxygen level with the levels in Table 3 If the Cold Air Damper is not installed compare the oxygen levels with the readings in Table 3A Table 3 Combustion Oxygen Levels for a 100 Valve Position With Cold Air Damper Inlet Air Temp Ox...

Page 33: ...ll natural gas combustion calibration procedures are completed 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 to the other using the regulator spring change procedure in Appendix I Since the required gas supply pressures for propane differ from those req...

Page 34: ...n analyzer probe into the stack NOTE Always approach a valve position percentage from the same direction i e 100 to 30 30 to 20 etc Whenever going to an increased valve position from below i e 20 to 30 first go above and then back down to the desired valve position This is necessary due to hysteresis in the air fuel stepper motor Hysteresis causes the air fuel valve to stop in a slightly different...

Page 35: ...100 ppm 30 ppm 100 F 10 100 ppm N A NOx readings corrected to 3 oxygen NOTE At a 100 valve position the KC1000 will not operate reliably at inlet air temperatures below 55 F if the Cold Air Damper P N 99026 is not installed See paragraphs 2 8 2 and 2 8 3 21 Change the valve position to 100 and allow the combustion analyzer to settle If the optional Cold Air Damper P N 99026 is installed compare th...

Page 36: ...ompleted 4 5 UNIT REASSEMBLY Once combustion calibration is set properly the unit can be re assembled for permanent operation 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...

Page 37: ... OUTLET TEMPER ATURE display should read no more than 2 to 3 degrees above the unit s setpoint 4 If the outlet temperature is stabilized proceed to the Maximum Load Adjustment procedure in paragraph 4 6 3 If the unit is not stabilized proceed to step 5 5 Press the MENU key and select the Tuning Menu 6 Press the or arrow key until Min Load Adj is displayed 7 Press the CHANGE key The display will be...

Page 38: ...ture Limit switches that turn off the unit when the outlet water temperature becomes too hot The lower over temperature limit switch is adjustable and should be adjusted 20 F to 40 F above the operating header temperature The upper over temperature limit switch is a manual reset device and is not adjustable It will shut the unit off if the water temperature reaches 240 F DO NOT attempt to adjust i...

Page 39: ...LT 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 5 1 3 Open the gas supply to the unit and depress the CLEAR button to clear any fault mes sages 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 pres...

Page 40: ...l 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 5 5 WATER TEMPERATURE FAULT TEST 1 In the normal operating mode allow the...

Page 41: ...IN terminals remove one side of the jumper If the interlock is connected to a proving switch of an external device discon nect 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 recon nected depress the CLEAR button The unit should start 5 7 FLAME FAULT TEST 1 Place the ON...

Page 42: ...TRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TESTING PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 154 155 AIR FUEL VALVE BLOWER PROOF SWITCH TO FRAME HARNESS Figure 5 5 Blower Proof Switch Location and Wiring 5 9 SSOV PROOF OF CLOSURE SWITCH 1 Set the unit s ON OFF switch to the OFF position Place the unit in manual mo...

Page 43: ...ay PRG SWITCH OPEN DURING PURGE 5 Replace the wire on the purge switch and depress the CLEAR button The unit should restart VALVE COVER Figure 5 7 Air Fuel Valve Cover Location 5 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 5 7 by rotating t...

Page 44: ...ON SWITCH 169 170 172 171 STEPPER MOTOR DIAL BLOWER BURNER Figure 5 8 Air Fuel Valve Purge and Ignition Switch Locations 5 12 SAFETY PRESSURE RELIEF VALVE TEST Test the Safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI ...

Page 45: ...e ignitor extension Remove the silicone ignitor plug from the burner shell by simultaneously twisting and pulling downward 4 Insert the ignitor removal 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...

Page 46: ... 6 11 Low Water Cutoff Probe 69126 Inspect Inspect Replace Every 24 Mos 20 mins Recommended only when unit will be run in an extreme condensing mode for prolonged periods of time In areas where water quality is poor or not qualified inspection and cleaning may be required to assure trouble free operation Hard water deposits must be removed to prevent corrosion and leaking Checking at more frequent...

Page 47: ...ion instructions 6 5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed Certain code requirements such as ASME CSD 1 require that these tests be performed on a scheduled basis Test schedules must conform to local jurisdictions The results of the tests should be recorded and preserved as directed ...

Page 48: ...lding the BTU transmitter pump to the impeller housing Remove and set the pump aside See Fig 6 3 NOTE It is not necessary to disconnect the electrical wires to the pump Figure 6 3 BTU Transmitter Pump Disassembly 9 Using a 5 8 and 9 16 wrench loosen the 4 compression fittings holding the lower tubing assembly in place See Fig 6 4 COMPRESSION FITTINGS LOWER TUBING ASSEMBLY Figure 6 4 Compression Fi...

Page 49: ...TE The cold water mixing orifice P N GP 122401 is slightly larger than the hot water mixing orifice P N GP 122760 Each orifice must be correctly installed for proper temperature control HYDRAULIC ZERO CONTROL ORIFICE TUBING ASSEMBLY COLD WATER MIXING ORIFICE HOT WATER MIXING ORIFICE HYDRAULIC ZERO NEEDLE VALVE LOWER TUBING ASSEMBLY Figure 6 5 BTU Transmitter Disassembly COMPRESSION FITTINGS IMPELL...

Page 50: ...ing securing it to the hot water tube See Fig 6 7 15 Loosen the 90o compression fitting at the top of the shell holding the hot water tube See Fig 6 8 Slide the hot water tube down slightly but do not remove it from the unit Remove the 90o fitting 16 Inspect all fittings and tubing for blockage due to scale or debris Clean or replace as necessary 17 Inspect the mixing orifice for blockage or degra...

Page 51: ...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 124749 Lower Burner Gasket 124834 Upper Bu...

Page 52: ...s inlet pipe flange at the air fuel valve see Fig 6 11 Figure 6 10 Grounding Terminal Location 9 Loosen the hose clamp at the air fuel valve outlet and slide the clamp back towards the burner see Fig 6 11 10 Using a 1 2 socket wrench remove six 5 16 18 hex nuts supporting the burner see Fig 6 11 Figure 6 11 Burner Disassembly Diagram 11 Lower the burner while sliding the air hose off the air fuel ...

Page 53: ...Disconnect wires 24 and 17 from the blower proof switch See Fig 6 13 TO FRAME HARNESS BLOWER PROOF SWITCH AIR FUEL VALVE Figure 6 13 Blower Proof Switch Wire Location older style switch shown at left newer style at right 15 Loosen the hose clamp on the air fuel valve inlet and slide the clamp back towards the blower See Fig 6 14 To Frame Harness ...

Page 54: ...ferential pressure regulator See Fig 6 15 18 Remove the air fuel valve taking care not to damage the flexible tubing on the throat of the air fuel valve Figure 6 15 Feedback Tube and Air Fuel Valve to Differential Regulator Bolts 19 Remove the flue venting from the exhaust manifold 20 Removing the exhaust manifold insulation will prevent it from being damaged and will make it easier to handle the ...

Page 55: ...t adhesive is recommended 26 Replace the gasket between the manifold and tubesheet P N GP 18900 Do not use any gasket adhesive this gasket has an adhesive backing 27 Beginning with the manifold reinstall all the components in the reverse order that they were removed Replace the o ring seals removed with the air fuel valve AERCO recommends that NEW o ring seals be used when reassembling 6 8 1 PROPA...

Page 56: ... the unit without venting the shell A vacuum in the unit may displace the liner causing serious damage not covered by warranty 4 Remove the wing nut from the top center of the shell cap and remove the cap 5 Remove the nuts and cap screws from the upper head Remove the upper head and upper head liner See Fig 6 18 Remove scale from all shell penetration points and sensors 6 Inspect and if necessary ...

Page 57: ...ons and our website www aerco com for additional information or call technical service at 800 526 0288 NOTICE Mix the HydroSkrub with an equal volume of water to obtain a 50 concentration 11 5 gallons of each 23 gallons total NOTICE If the isolation valves are located more than one foot from the supply and return ports of the exchanger add in the piping volume from the exchanger to the valves CAUT...

Page 58: ...lug in the pump and periodically check for leaks Maintain liquid level in the bucket as a lowering volume indicates an open drain or system Operating level should be 1 3 of the receiving bucket the remaining space is for foaming and expansion 8 Check circuit again The HydroSkrub solution should flow from the circulation bucket through the pump and the equipment and back to the top of the bucket 9 ...

Page 59: ...ion on the calcium carbonate Foaming and bubbling indicates the solution is still active Little or no reaction indicates that the solution is expended This test should be performed near the end of the circulating time If the solution has been expended more HydroSkrub will be required to complete the job If the solution is still active at the end of the time all the scale has been dissolved pH Tren...

Page 60: ...ear the top of the heat exchanger Unscrew the brass coupling in which the probe is installed and remove the probe coupling assembly from the recess Take care to not damage the wire connected to the probe See Figure 6 20 for a picture of the probe installed and uninstalled shown with brass coupling attached and wire hardware removed 3 Inspect the metal end of the probe for scale and or corrosion 4 ...

Page 61: ...perature displayed on the top line The temperature value is displayed on the bottom line This is a measurement of the water temperature at the BTU transmitter sensor 9 Adjust the needle valve until the FFW Temp is 18 to 24 F below the outlet temperature and stable i e if the outlet temperature is 135 F then the FFW Temp should read between 117 to 111 F Now complete the Temperature Control Calibrat...

Page 62: ...liable way to determine if there is acceptable flame strength Only by using a Digital Multimeter sensitive enough to measure current in microamps µA can the flame strength be properly measured The meter must at least be capable of measuring between 0 1 µA and 10 0 µA of DC current with a minimum measurement resolution of 0 1 µA Typically the operating range of the flame strength will be between 3 ...

Page 63: ...are clean and free of dust dirt or debris If they are not take them out clean them and reinstall Cleaning removes impedance from the current circuit and thus should increase the flame current If a low reading is still observed replace the flame sensing rod A new flame sensing rod should now produce the correct measurement However if an acceptable measurement is still not observed the problem may l...

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Page 65: ...ermits service personnel to view menu items and data logs which can be useful in isolating faults Refer to Section 8 of this manual for detailed RS232 communication set up and procedures When a fault occurs in the KC1000 Water Heater 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 fo...

Page 66: ...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 s...

Page 67: ...er 4 Defective Ignition Stepper IGST Board 5 Defective SSOV 6 Defective Differential Pressure Regulator 7 Carbon or other debris on Burner 8 Staged ignition ball valve closed 1 Remove and inspect the flame detector for signs of wear Replace if necessary 2 Close the internal gas valve in the boiler Install and arc a spark ignitor outside the unit 3 If there is no spark check for 120VAC at the prima...

Page 68: ...or debris Clean and reinstall 5 Remove blockage from condensate drain HEAT DEMAND FAILURE 1 The Heat Demand Relays on the Ignition Stepper IGST board failed to activate when commanded 2 Relay is activated when not in Demand 1 Press CLEAR button and restart the unit If the fault persists replace IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Defective exhaust sensor 2 Ca...

Page 69: ...the BTU transmitter per Maintenance Section 2 Test the temperature switch to insure it trips at its actual water temperature setting 3 Using the resistance charts in 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 swit...

Page 70: ...position 2 Defective ignition switch 3 Defective Power Supply Board or fuse 4 Defective 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 Fue...

Page 71: ... 3 Defective water level probe 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 MODBUS COMM FAULT 1 Water Heater not seeing information from modbus network 1 Check network co...

Page 72: ...1 and verify it is blinking ON OFF every second If not replace IGST Board REMOTE SETPT SIGNAL FAULT 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 Check I O Box to ensure signal is ...

Page 73: ... 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 STEPPER MOTOR FAILURE 1 Air Fuel Valve out of calibration 2 Air Fuel Valve unplugged 3 Loose wiring connection ...

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Page 75: ...r case letters and press Enter Welcome to Aerco will appear in the laptop or dumb terminal display with a listing of the following available entry choices M Display next 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 password 159 must be entered to change options in the Setup Configurati...

Page 76: ...tc and press Enter 8 4 2 Operation Time Log The Operation Time Log consists of a string of ASCII records stored in non volatile memory 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...

Page 77: ... 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 8 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 OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPE...

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Page 79: ...erating Flame Strength Displays flame strength from 0 to 100 Run Cycles Displays the total number of run cycles from 0 to 999 999 Run Hours Displays total run time of unit in hours from 0 to 9 999 999 Fault Log Displays information on the last 20 faults 0 19 SETUP MENU Password Allows password to be entered Once the valid password 159 is entered options in the Setup Configuration and Tuning Menus ...

Page 80: ...able setpoint Setpoint Lo Limit to 240 F Default is 200 F Temp Hi Limit This is the maximum allowable outlet temperature 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 Max Valve Position Sets the maximum allowable valve position for the unit 40 to 100 Default is 100 Pump De...

Page 81: ...ition 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 Deadband Low Deadband High and Deadband Low settings create an Outlet Temperature Zone In which no Valve Position corrections will be attempted The Deadband ZONE is defined as operating with an Outlet Temperature between Active ...

Page 82: ... the time that this action advances the output Min Load Adj Setting is adjustable from 50 F to 50 F Default is zero It adjusts the output by adding an offset to the breakpoint chart at minimum flow This is used to fine tune Feed Forward FFWD output at low flow levels Max Load Adj Setting is adjustable from 50 F to 50 F Default is zero It adjusts the output by changing the scaling of the breakpoint...

Page 83: ...econds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during the purge cycle during startup The duration of the purge cycle counts up in seconds STANDBY Displayed when ON OFF switch...

Page 84: ...activate when commanded HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switch is closed HIGH GAS PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is open IGN BOARD COMM FAULT A communication fault has occurred be...

Page 85: ...RING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during purge SSOV FAULT DURING IGN The SSOV s...

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Page 87: ...APPENDIX C Temperature Sensor Resistance Chart Balco ...

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Page 89: ...e 1 0 MBTU Fuel Type Natural Gas Heater Mode Constant Setpoint Remote Signal If Heater Mode Remote Setpoint 4 20 mA 1 5V Outdoor Sensor Disabled Setpt Lo Limit 60 F Setpt Hi Limit 195 F Temp Hi Limit 195 F Max Valve Position 100 Aux Start On Dly 0 sec Failsafe Mode Shutdown mA Output Off Lo Fire Timer 2 sec Setpt Limiting Disabled Setpt Limit Band 5 F Network Timeout 30 seconds HI DB Setpt En 30 D...

Page 90: ...n Min Load Adj 0 F Max Load Adj 0 F FFWD Temp N A Outlet Feedback On Feedback Gain 0 05 Breakpoint At 100 77 F Breakpoint At 90 81 F Breakpoint At 80 85 F Breakpoint At 70 91 F Breakpoint At 60 95 F Breakpoint At 50 102 F Breakpoint At 40 110 F Breakpoint At 30 112 F Breakpoint At 20 114 F Breakpoint At 10 130 F Breakpoint At 0 135 F Reset Defaults No ...

Page 91: ...APPENDIX E E 1 ...

Page 92: ...NLET 29 3 8 c g INLET ADAPTER COMB AIR INTAKE AERCO NORTHVALE NEW JERSEY 07647 MODEL KC1000 GAS FIRED 22 1 4 57 47 119 4 22 56 FLOOR FLANGE 2 DRAIN VALVE RELIEF VALVE AND FLEX CONNECTOR ARE INCLUDED SEPARATELY IN SHIPMENT B 2 1 95 DIMENSIONAL DRAWING AC SERVICE C0NN 3 4 CONDUIT 120VAC SINGLE PHASE 20 AMP W GRD 35 89 TYP 4 PLCS c g 78 1 2 199 4 13 9 16 34 4 3 4 NPT GAS VENT CONN FOR IRI GAS TRAIN O...

Page 93: ... BY SIZE SCALE APPD CHKD B WATER OUTLET WATER INLET 29 3 8 c g INLET ADAPTER COMB AIR INTAKE AERCO NORTHVALE NEW JERSEY 07647 KCGWW DP GAS FIRED POTABLE WATER HTR 22 1 4 57 47 119 4 22 56 FLOOR FLANGE 2 DRAIN VALVE RELIEF VALVE ARE INCLUDED SEPARATELY IN SHIPMENT A 100206 DIMENSIONAL DRAWING AC SERVICE C0NN 3 4 CONDUIT 120VAC SINGLE PHASE 20 AMP W GRD 35 89 TYP 4 PLCS c g 78 1 2 199 4 13 9 16 34 4...

Page 94: ...ASE GASKET GP 123077 GP 18532 GP 18556 11 12 13 2 1 1 DESCRIPTION PART NO ITEM QTY GASKETS 39 GP 122569 1 IGNITION CABLE ASSEMBLY GAS TRAIN WIRING HARNESS 1 161450 42 39 40 161560 1 INPUT OUTPUT I O BOX ASSEMBLY CONDENSATE CUP ASSEMBLY GP 123337 9 1 VENT MOUNTING FLANGE GP 122849 10 2 23 GP 123050 1 EXTERNAL GAS SHUT OFF VALVE NOT SHOWN IN THE DRAWING TEMPERATURE SWITCH THERMOWELL 123711 50 2 50 S...

Page 95: ...3 4 27 28 49 43 SEE DETAIL A EXPLODED DETAIL A 13 12 11 42 9 5 8 SEE DRAWING PL B 134 52 AERCO LOW NOX KC1000 WATER HEATER CZ DWN BY APPD SCALE 022505 DATE SH 2 OF 2 PL A 144 DATE I INTERNATIONAL INC NORTHVALE NJ 07647 PARTS LIST FOR AVAILABLE PARTS 53 54 57 57 55 56 ...

Page 96: ... 3 8 OD TUBE STR COMP FTG 1 4 NPT x 3 8 OD TUBE 45 COMP FTG HOT WATER MIXING ORIFICE ASS Y COLD WATER MIXING ORIFICE ASS Y BTU TRANSMITTER SENSOR ORIFICE DISC ORIFICE RETAINING CLIP TUBING ASS Y HYDRAULIC ZERO NEEDLE VALVE 122075 GP 122677 1 GP 122613 1 GM 122687 GM 122761 GP 122506 GM 122400 11 9 8 10 12 14 13 1 1 1 1 1 4 1 123449 GP 122552 GM 161212 SEE TABLE 1 16 15 17 18 1 1 1 1 ITEM DESCRIPTI...

Page 97: ... E 7 J DWN BY APPD SCALE PL A 134 CZ 041304 DATE DATE D AERCO INTERNATIONAL INC NORTHVALE NJ 07647 SH 2 OF 2 COMPLETE ASS Y GM 20872 BTU TRANSMITTER ASSEMBLY KC1000 WATER HEATER 17 14 15 1 5 9 8 4 5 11 10 4 13 12 ...

Page 98: ...RCO 3 4 NORMALLY OPEN VENT VALVE P N GP 122774 LOW GAS PRESSURE SWITCH P N GP 122403 SSOV ACTUATOR W P O C SWITCH P N 64047 SSOV ACTUATOR W O P O C SWITCH P N 69038 VENT TO ATMOSPHERE PER ANSI Z223 1 NFPA54 HEATER BOUNDARY TOP VIEW 1 1 2 IRI SSOV P N 124137 1 1 4 NPT GAS REGULATOR P N 124802 TO AIR FUEL VALVE ASS Y HIGH GAS PRESSURE SWITCH PN GP 122412 ...

Page 99: ...1 2 TO 1 4 NPT 5 1 124933 UNION 1 4 NPT 6 1 124934 1 4 X 1 8 REDUCING COUPLING 7 2 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 8 1 124932 REDUCING COUPLING 1 2 TO 1 4 NPT 9 1 124910 NIPPLE 1 4 NPT CS 9 LG 10 1 92076 1 4 NPT BALL VALVE 11 1 124939 1 4 NPT ORIFICE PIPE NIPPLE 12 1 124979 1 8 C S STREET ELBOW 13 2 124891 FEMALE FAST ON CONNECTOR 14 1 12607 2 CLOSE NIPPLE 1 4 NPT SCH 40 C S LOW NOx STAGED IG...

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Page 101: ...ABOVE THE FLOOR 3 ALL ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT 4 THIS IS A TYPICAL INSTALLATION DRAWING LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED 5 HOSE CONNECTION AT HEATER OUTLET IS FOR INITIAL HEATER CALIBRATION DURING START UP 6 LOCATE WATER INLET AND OUTLET FITTINGS i e UNIONS ELBOWS ETC A MINIMUM OF 6 FROM WATER HEATER FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF HEATER PANELS WHE...

Page 102: ...AND OTHER 3 ALL ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A HEIGHT 18 ABOVE THE FLOOR CONNECTIONS TO THE HEATER SEE DIMENSIONAL DRAWING NOTES 7 HEATERS SHOULD BE PIPED REVERSE RETURN AS SHOWN OR BALANCING DEVICES ON THE OUTLETS OF THE HEATERS SHOULD BE EMPLOYED CHECK VALVE LEGEND STOP VALVE DRAIN VALVE UNION THERMOMETER T 7 7 W C PROPANE GAS AT MAXIMUM BT...

Page 103: ...EATER SEE DIMENSIONAL DRAWING NOTES CHECK VALVE LEGEND STOP VALVE DRAIN VALVE UNION 7 PUMP SHOULD BE CAPABLE OF HEATER S RATED FLOW AT DESIGN TEMPERATURE RISE 8 MOUNT TEMPERATURE SWITCH 1 3 UP FROM THE BOTTOM OF THE TANK SWITCH WILL TURN PUMP ON AND OFF GAS FIRED WATER HEATER KC1000 1 MIL BTU LOW NOx STRATIFIED STORAGE TANK INSTALLATION NORTHVALE NJ 07647 INTERNATIONAL INC APPD DWN BY SCALE DATE D...

Page 104: ...ER DRAIN VALVE STOP VALVE T UNION LEGEND 9 HEATERS SHOULD BE PIPED REVERSE RETURN AS SHOWN OR BALANCING DEVICES ON THE HEATERS SHOULD BE EMPLOYED GAS FIRED WATER HEATER KC1000 1 MIL BTU LOW NOx MULT UNIT STRAT TANK INSTALLATION NORTHVALE NJ 07647 INTERNATIONAL INC APPD DWN BY SCALE DATE DATE JK NTS 113006 AERCO SD A 708 D REV TAP FOR SEE NOTE 7 HOSE CONNECTION W H E N E M P L O Y E D NOTE 11 NOTE ...

Page 105: ...7 PUMP SHOULD BE CAPABLE OF HEATER S RATED FLOW AT DESIGN TEMPERATURE RISE FOR TWO TEMPERATURE ZONE INSTL RELIEF VALVE THERMOMETER T C O L D W A T E R S U P P L Y 1 2 0 F H O T W A T E R O U T 1 4 0 F 1 2 0 F R E C I R C TEMPERING VALVE 1 4 0 F R E C I R C BALANCING VALVE APPD CHKD DWN BY SIZE SCALE DATE REV NORTHVALE NJ 07647 INTERNATIONAL INC AERCO 8 MOUNT TEMPERATURE SWITCH 1 3 UP FROM THE BOTT...

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Page 107: ...MP 183 183 184 182 191 141 184 194 193 137 155 136 154 135 192 138 182 140 190 195 172 171 170 169 168 167 166 165 164 163 162 161 149 148 147 146 145 141 149 148 146 145 147 181 136 137 209 208 WATER HEATERS ONLY 6 PIN CONNECTOR SHEET 1 OF 2 321 TO CONTROL BOX 320 321 322 TO BURNER GND AS FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE...

Page 108: ... B RS 485 IN A 1 2 4 3 7 8 6 5 9 10 12 11 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 12 11 10 9 13 14 15 231 234 232 233 238 236 235 237 239 INPUT OUTPUT BOX KC 1000 LS2 1 LS1 LS4 LS3 J3 J2 J1 SHEET 2 OF 2 AS FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX 015 XXX 005 FRACTIONS 1 32 ANGLES 1 PERPENDICULARITY PARALLELISM FLATNESS 003 TOTAL DIAME...

Page 109: ... BOARD P N 124363 PMC BOARD P N 124364 IGNITION STEPPER BOARD P N 124361 V F D DISPLAY MODULE P N 124527 DISPLAY BOARD P N 124365 FISH PAPER INSULATOR P N 124960 FRONT FACE PLATE KC1000 P N 124949 HORIZONTAL OVERLAY KC1000 P N 124717 ENCLOSURE P N 124951 KC1000 CONTROL PANEL EXPLODED VIEW ...

Page 110: ... CONNECTOR 19 PIN INTERLOCK HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN SENSOR HARNESS CONNECTOR 7 PIN TO INPUT OUTPUT I O BOX KC1000 CONTROL PANEL REAR VIEW ...

Page 111: ...sary to convert the unit from Natural Gas to Propane operation Proceed as follows 1 Shut down the unit and close the external gas supply valve 2 Remove the sheet metal covers and locate the differential regulator on the left side of the unit 3 Refer to Figure 1 and remove the cap on the differential regulator 4 Using a flat blade screwdriver remove the adjustment screw by turning it counter clockw...

Page 112: ......

Page 113: ...thout Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Over Temperature Switch GP 122822 Table J 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Ignitor 124570 Flame Detector 124837 Combustion Chamber liner 124839 Exhaust Manifold Combustion Chamber gasket GP 122537 Manifold Tubesheet gasket GP 18900 Burner gasket GP 18899 Burner release gasket GP 12255...

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Page 115: ...100 4 70 5 40 C MORE CONTROL PANEL 2 YEARS FROM SHIPMENT AERCO labeled control panels are conditionally warranted against failure for 2 two years from shipment OTHER COMPONENTS 18 MONTHS FROM SHIPMENT All other components with the exception of the igniter and flame detector are conditionally guaranteed against any failure for 18 months from shipment AERCO shall accept no responsibility if such ite...

Page 116: ...ation adjustment and or repairs to the item The use of replacement parts not manufactured or sold by AERCO will void any warranty express or limited In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item In addition the returned item must include a Returned Goods Authorization RGA label attached to the shipping carton which identifies...

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