Instruction
No.
GF-109LN
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
KC Series
Gas Fired
Low NOx
Boiler System
Natural Gas and Propane Fired,
Condensing and Forced Draft Hot Water Boiler
970,000 BTU/HR Input (Natural Gas)
1,000,000 BTU/HR Input (Propane)
Applicable to Serial Numbers G-03-807 and above
Patent No. 4,852,524
REVISED JANUARY, 2009
Telephone Support
Direct to AERCO Technical Support
(8am to 5 pm EST, Monday - Friday):
1-800-526-0288
The information contained in this
operation and maintenance manual
is subject to change without notice
from AERCO International, Inc.
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco.com
© AERCO International, Inc., 2009
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.
CONTENTS
GF-109LN - AERCO KC1000 GAS FIRED LOW NOx BOILER
Operating & Maintenance Instructions
FOREWORD
A
SECTION 1 – SAFETY PRECAUTIONS
Para.
1.1
1.2
Subject
Warnings & Cautions
Emergency Shutdown
Page
1-1
1-2
1-1
Para.
1.3
Subject
Prolonged Shutdown
SECTION 2 – INSTALLATION PROCEDURES
Para.
2.1
2.2
2.3
2.4
2.5
2.6
Subject
Receiving the Unit
Unpacking
Installation
Gas Supply Piping
Electrical Supply
Mode of Operation and Field
Control Wiring
Page
2-1
2-1
2-2
2-4
2-6
2-6
Para.
2.7
2.8
2.9
2.10
Page
1-2
2-1
Subject
I/O Box Connections
Auxiliary Relay Contacts
Flue Gas Vent Installation
Combustion Air
Page
2-8
2-10
2-10
2-10
SECTION 3 – CONTROL PANEL OPERATING PROCEDURES
3-1
Para.
3.1
3.2
3.3
3.4
3.5
Subject
Introduction
Control Panel Description
Control Panel Menus
Operating Menu
Setup Menu
Page
3-1
3-1
3-3
3-4
3-4
Para.
3.6
3.7
3.8
3.9
Subject
Configuration Menu
Tuning Menu
Start Sequence
Start/Stop Levels
SECTION 4 – INITIAL START-UP
Para.
4.1
4.2
4.3
Subject
Initial Startup Requirements
Tools and Instrumentation for
Combustion Calibration
Natural Gas Combustion
Calibration
4-1
Page
4-1
4-1
Para.
4.4
4.5
4.6
4-2
Subject
Propane Combustion Calibration
Unit Reassembly
Over-Temperature Limit Switch
Adjustments
Section 5 – MODE OF OPERATION
Para.
5.1
5.2
5.3
5.4
5.5
Subject
Introduction
Indoor/Outdoor Reset Mode
Constant Setpoint Mode
Remote Setpoint Modes
Direct Drive Modes
Page
3-5
3-7
3-7
3-9
Page
5-1
5-1
5-2
5-2
5-3
Page
4-5
4-7
4-8
5-1
Para.
5.6
5.7
Subject
Boiler Management System
(BMS)
Combination Control System
(CCS)
Page
5-4
5-5
i
CONTENTS
SECTION 6 – SAFETY DEVICE TESTING PROCEDURES
Para.
6.1
6.2
6.3
6.4
6.5
6.6
6.7
Subject
Testing of Safety Devices
Low Gas Pressure Fault Test
High Gas Pressure Fault Test
Low Water Level Fault Test
Water Temperature Fault Test
Interlock Fault Tests
Flame Fault Test
Page
6-1
6-1
6-1
6-2
6-2
6-3
6-3
Para.
6.8
6.9
6.10
6.11
6.12
6-1
Subject
Air Flow Fault Test
SSOV Proof of Closure Switch
Purge Switch Open During
Purge
Ignition Switch Open During
Ignition
Safety Pressure Relief Valve
Test
SECTION 7 – MAINTENANCE
Para.
7.1
7.2
7.3
7.4
7.5
Subject
Maintenance Schedule
Spark Igniter
Flame Detector
Combustion Calibration
Safety Device Testing
Page
7-1
7-1
7-2
7-2
7-2
Para.
7.5
7.6
7.7
7.8
6-6
Subject
Safety Device Testing
Manifold and Exhaust Tubes
Heat Exchanger Water Side
Inspection
Condensate Drain Assembly
Page
7-2
7-2
7-4
7-5
8-1
Subject
Page
8-1
Para.
Subject
Boiler Menu Item Descriptions
Startup, Status and Fault
Messages
Temperature Sensor Resistance
Chart
Indoor/Outdoor Reset Ratio
Charts
Page
A-1
B-1
App
E
F
G
H
I
J
Introduction
6-5
7-1
SECTION 8 – TROUBLESHOOTING
Para.
8.1
Page
6-4
6-4
6-5
Subject
Page
APPENDICES
App
A
B
C
D
WARRANTIES
ii
C-1
D-1
Subject
Boiler Default Settings
Dimensional and Part Drawings
Piping Drawings
Wiring Schematics
KC1000 Control Panel Views
KC1000 Low NOx Dual-Fuel
Switch-Over Instructions
Page
E-1
F-1
G-1
H-1
I-1
J-1
W-1
FOREWORD
Foreword
This system can be operated using natural gas or propane fuel. A simple spring change in the
differential regulator and combustion calibration is all that is needed to switch fuels.
The AERCO KC Low NOx Boiler is a true industry advance that meets the needs of today's
energy and environmental concerns. Designed for application in any closed loop hydronic
system, the load tracking capability relates energy input directly to fluctuating system loads
through a 11:1 modulating turndown ratio. The boiler’s condensing capability offers extremely
high efficiencies and makes the KC Boiler ideally suited for modern low temperature, as well as,
conventional heating systems.
When installed and operated on natural gas in accordance with this Instruction Manual, the KC
Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
• Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117,
Rule117.465.
In addition, when operated using propane fuel, the KC Boiler is certified by AERCO to provide
NOx emissions of less than 30 ppm at full rated input.
The KC Boiler can be used singular or in modular arrangements for inherent standby with
minimum space requirements. Venting capabilities offer maximum flexibility and allow
installation without normal restrictions. The advanced electronics of each KC Boiler control
system offer selectable modes of operation and interface capabilities.
After prolonged shutdown, it is recommended that the startup procedures in Section 4 and the
safety device test procedures in Section 6 of this manual be performed, to verify system
operating parameters. If there is an emergency, turn off the electrical power supply to the KC
Boiler or close the manual gas valve located before the unit. The installer is to identify the
emergency shut-off device. FOR SERVICE OR PARTS, contact your local sales representative
or AERCO INTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________
A
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. NFPA54) for gas-fired boilers and ANSI/NFPASB for
LP gas-fired boilers. Where applicable, the
equipment shall be installed in accordance with
the current Installation Code for Gas Burning
Appliances and Equipment, CGA B149, and
applicable Provincial regulations for the class;
which should be carefully followed in all cases.
Authorities having jurisdiction should be
consulted before installations are made.
IMPORTANT
This Instruction Manual is an integral
part of the product and must be
maintained in legible condition. It must
be given to the user by the installer
and kept in a safe place for future
reference.
WARNINGS!
MUST BE OBSERVED TO PREVENT
SERIOUS INJURY.
WARNING!
BEFORE
ATTEMPTING
TO
PERFORM ANY MAINTENANCE ON
THE UNIT, SHUT OFF ALL GAS AND
ELECTRICAL INPUTS TO THE UNIT.
WARNING!
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
DO NOT USE MATCHES, CANDLES,
FLAMES, OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS
LEAKS.
WARNING!
FLUIDS UNDER PRESSURE MAY
CAUSE INJURY TO PERSONNEL
OR DAMAGE TO EQUIPMENT
WHEN RELEASED. BE SURE TO
SHUT OFF ALL INCOMING AND
OUTGOING
WATER
SHUTOFF
VALVES. CAREFULLY DECREASE
ALL TRAPPED PRESSURES TO
ZERO
BEFORE
PERFORMING
MAINTENANCE.
WARNING!
ELECTRICAL VOLTAGES OF 120
VAC
ARE
USED
IN
THIS
EQUIPMENT. THEREFORE THE
COVER ON THE UNIT’S POWER
BOX (LOCATED ON THE FRONT
RIGHT SIDE OF THE UNIT UNDER
THE HOOD AND SHEET METAL
SIDE PANEL) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING
MAINTENANCE AND SERVICING.
CAUTIONS!
Must be observed to prevent
equipment damage or loss of
operating effectiveness.
CAUTION!
Many soaps used for gas pipe leak
testing are corrosive to metals. The
piping must be rinsed thoroughly with
clean water after leak checks have
been completed.
CAUTION!
DO NOT use this boiler if any part has
been under water. Call a qualified
service technician to inspect and
replace any part that has been under
water.
1-1
SAFETY PRECAUTIONS
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to
shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
IMPORTANT
The Installer must identify and indicate
the location of the emergency shutdown
manual gas valve to operating personnel.
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended
that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of
this manual be performed, to verify all systemoperating parameters. If there is an emergency,
turn off the electrical power supply to the
AERCO boiler and close the manual gas valve
located upstream the unit. The installer must
identify the emergency shut-off device.
Figure 1-1
Manual Gas Shutoff Valve
1-2
INSTALLATION
SECTION 2 - INSTALLATION PROCEDURES
2.1. RECEIVING THE UNIT
Each KC1000 Boiler is shipped as a single
crated unit. The crated shipping weight of the
unit is approximately 1500 pounds, and must be
moved with the proper rigging equipment for
safety and to avoid damages. The unit should be
completely inspected for shipping damage and
completeness at the time of receipt from the
carrier and before the bill of lading is signed.
Each unit has Tip-N-Tell indicator on the outside
of the crate that indicates if the unit has been
turned on its side. If the Tip-N-Tell indicator is
tripped, do not sign for the shipment. Request a
freight claim and inspection by a claims adjuster
before proceeding or refuse delivery of the
equipment.
2.2. UNPACKING
Carefully unpack the unit. Take care not to
damage the unit jacket when cutting away
packaging materials. An inspection of the unit
should be made to determine if damage during
shipment occurred that was not indicated by the
Tip-N-Tell. The freight carrier should be notified
immediately if any damage is detected. The
following accessories come standard with each
unit and are packed separately within the unit’s
packing container
•
•
•
•
•
•
•
•
•
•
•
•
•
Spare Spark Ignitor
Spare Flame Detector
Manual 1-1/4" Gas Shutoff Valve
Drain Valve Assembly
ASME Pressure Relief Valve
Differential Regulator Spring:
P/N 122548 (Propane) or
P/N 124803 (Natural Gas)
Ignitor Removal Tool (One per Site)
Regulator Adjustment Tool (One per
site)
Temperature/Pressure Gauge and
Fittings
2 Lifting Lugs
Stainless Steel Condensate Cup
Shell Cap
Wing Nut for Shell Cap
Optional accessories are also separately packed
within the unit’s packing container. Standard and
optional accessories shipped with the unit
should be identified and put in a safe place until
installation or use.
Figure 2.1. Boiler Clearances
2-1
2.3 INSTALLATION
The unit must be installed with the prescribed
clearances for service as shown in Figure 2.1.
The minimum clearance dimensions, required by
AERCO, are listed below. Local building codes
may require additional clearance and take
precedence
Minimum clearances required:
Sides
24"
Front
18"
Rear
18"
Top
18"
All gas piping, water piping, and electrical
conduit or cable must be arranged so that they
do not interfere with the removal of any cover, or
inhibit service or maintenance of the unit.
Figure 2.2
Lifting Lug Location
WARNING!
KEEP UNIT AREA CLEAR AND FREE
FROM COMBUSTIBLE MATERIALS AND
FLAMMABLE VAPORS AND LIQUIDS.
2.3.1. SETTING THE UNIT
Remove the unit from the wooden skid and
place in position using a block and tackle or
hoist attached to the lifting lugs, (see Fig. 2.2).
USE ONLY THE LIFTING LUGS TO MOVE
THE UNIT.
The KC-1000 is U/L approved for installation on
combustible flooring. A 4 to 6 inch high housekeeping concrete pad is recommended and
allows for sufficient drainage of the condensate.
It is suggested that units be secured using the
holes provided in the frame base. Piping must
not be used to secure the unit in place. See
drawing AP-A-816 in Appendix F for the base
frame dimensions.
In multiple unit installations, it is important to
plan the position of each unit. Sufficient space
for piping connections and future maintenance
requirements must be given. All piping must
include ample provision for expansion.
If installing a Combination Control (CCP)
system, it is important to identify and place the
Combination Mode units in the proper physical
location.
2-2
2.3.2 SUPPLY AND RETURN PIPING
The locations of the 4" flanged system supply,
and return piping connections, to the unit are
shown in figure 2.3. The return connection is
located on the left side near the base of the
unit’s shell. The supply connection is located on
the left side near the top of the unit’s shell.
Whether installing single or multiple units, install
the piping and accessories as shown in the
appropriate piping diagram located in Appendix
G. For applications other than standard space
heating, consult the AERCO Boiler Application
Guide, GF-1070, or AERCO for the appropriate
piping schematics.
The minimum flow rate through the unit is 25
GPM and the maximum flow rate is 150 GPM.
Each unit is fitted with 4" flanges for high flow
application and the system velocity at the unit
return should not exceed 5 feet per second.
Each unit must have individual valves on the
supply, and return, for maintenance. In multiple
unit installations, the flow through each unit must
be balanced.
Every boiler plant must have a source of makeup water to it. As with any closed loop hydronic
system, air elimination and expansion equipment must be provided as part of the overall
installation. All piping MUST include ample
provision for expansion.
INSTALLATION
2.3.4 TEMPERATURE/PRESSURE
INDICATOR
The unit is supplied with one of two styles of
Temperature/Pressure Indicators that must be
installed in the tapping on the supply flange of
the unit (see Figs. 2.5a and 2.5b). A suitable
pipe compound should be used sparingly to the
threaded connection.
Figure 2.3
Supply and Return Location
2.3.3 PRESSURE RELIEF AND DRAIN
VALVE INSTALLATION
An ASME rated Relief Valve is supplied with
each unit. The supplied pressure relief valve
setpoint will be 30, 50, 75, 100, or 150 psig as
ordered from the factory. Install the pressure
relief valve in the tapping provided opposite the
system supply connection, (see figure 2.4). The
pressure relief valve should be piped in the
vertical position using the fittings supplied. A
suitable pipe compound should be used on the
threaded connections, and excess should be
wiped off to avoid getting any into the valve
body. The discharge from the relief valve should
be piped to within 12 inches of the floor to
prevent injury in the event of a discharge.
The relief piping must be full size without
reduction. No valves, restrictions, or other
blockages should be allowed in the discharge
line. In multiple unit installations the relief valve
discharge lines must not be manifolded,
(connected), together. Each must be individually
run to a suitable discharge location. The drain
valve provided should be installed on the right
hand side of the unit towards the bottom of the
shell. The valve should be pointed in the down
position, (see Fig. 2.4).
Figure 2.4
Relief and Drain Valve Location
Figure 2.5a
Pressure /Temperature Gauge Installation
2-3
Figure 2.5b
Pressure/Temperature Gauge Installation
Figure 2.6
Condensate Drain System Location
2.3.5 CONDENSATE PIPING
2.4. GAS SUPPLY PIPING
The KC Boiler is designed to condense. Therefore, the installation site must include suitable
provisions for condensate drainage or collection.
A stainless steel condensate cup is separately
packed within the unit’s shipping container. To
install the condensate cup, pro-ceed as follows:
The AERCO Gas Fired Equipment Gas Components and Supply Design Guide (GF-1030) must
be consulted before any gas piping is designed
or started.
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).
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.
2-4
WARNING!
DO NOT USE MATCHES, CANDLES,
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS LEAKS.
CAUTION!
Soaps used for gas pipe leak testing can be
corrosive to metals. Piping must be rinsed
thoroughly with clean water after leak
checks have been completed.
NOTE:
All gas piping must be arranged so that it
does not interfere with removal of any
cover, inhibit service or maintenance, or
prevent access between the unit and walls,
or another unit.
INSTALLATION
The location of the 1-1/4" inlet gas connection is
on the right side of the unit as shown in Figure
2.7.
All pipe should be de-burred and internally
cleared of any scale or iron chips before
installation. No flexible connectors or nonapproved gas fittings should be installed. Piping
should be supported from floor or walls only and
must not be secured to the unit.
A suitable piping compound, approved for use
with gas, should be used sparingly. Any excess
must be wiped off to prevent clogging of
components.
To avoid damage to the unit, when pressure
testing gas piping, isolate the unit from the
supply gas piping. At no time should there be
more than 14” W.C. the unit. Bubble test all
external piping thoroughly for leaks using a soap
and water solution or suitable equivalent. The
gas piping must meet all applicable codes.
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
2.4.2 MANUAL GAS SHUTOFF VALVE
A 1-1/4” manual gas shut-off valve is furnished
with each unit. The valve should be positioned
as shown in Figure 2.7. The manual gas shut-of
valve must be installed upstream of the supply
regulator in a readily accessible location.
2.4.3 IRI GAS TRAIN KIT
The IRI gas train is an optional gas train
required in some areas by code or for insurance
purposes. The IRI gas train is factory pre-piped
and wired. (See Appendix F, Drawing No. SD-A660).
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. 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.
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, Single Phase, 60 Hz, 20 Amps from a
dedicated electrical circuit. No other devices
should be on the same electrical circuit as the
KC1000 unit. A means for disconnecting AC
power from the unit (such as a service switch)
must be installed near the unit for normal operation and maintenance. All electrical connections
should be made in accordance with the National
Electrical Code and/or with any applicable local
codes.
The AC power wiring diagram is shown in Figure
2.9.
POWER BOX
Figure 2.9
AC Power Wiring Diagram
FRAME
2.6 MODE OF OPERATION and FIELD
CONTROL WIRING
SSOV
ACTUATOR
BLOWER
Figure 2.8
AC Power Box Location
2-6
The KC Boiler is available in several different
modes of operation. While each unit is factory
configured and wired for the mode specified on
the equipment order, some field wiring may be
required to complete the installation. This wiring
is typically routed to the Input/Output (I/O) Box
located on the left side of the unit beneath the
removable side panel (see Fig. 2.10). Field
wiring for each particular mode of operation is
described in the following paragraphs. For
additional information concerning modes of
operations, refer to Section 5.
INSTALLATION
2.6.1 CONSTANT SETPOINT MODE
The Constant Setpoint Mode is used when it is
desired to have a fixed setpoint that does not
deviate.
No wiring connections other than
electrical supply connections are required for
this mode. However, if desired, fault monitoring
or enable/disable interlock wiring can be utilized
(see paragraphs 2.7.9 and 2.7.10).
2.6.2 INDOOR/OUTDOOR RESET MODE
This mode of operation increases supply water
temperature as outdoor temperatures decrease.
An outside air temperature sensor (AERCO PN
122790) is required. The sensor MUST BE
wired to the I/O Box wiring terminals (see Fig.
2.11). For more information concerning the
outside air sensor installation, refer to paragraph
2.7.1. For programming and setup instructions
concerning the indoor/outdoor-reset mode of
operation, refer to Section 5, paragraph 5.1.
Figure 2.10
Input/Output (I/O) Box Location
OUTDOOR SENSOR IN
SENSOR COMMON
AUX SENSOR IN
REMOTE INTL'K IN
EXHAUST SWITCH IN
DELAYED INTL'K IN
NOT USED
NOT USED
NC
COM
NO
+
ANALOG IN +
B.M.S. (PWM) IN -
NC
COM
NO
RS-485
COMM.
NOT USED
AUX RELAY
120 VAC, 5A, RES
NOT USED
SHIELD
mA OUT
FAULT RELAY
120 VAC, 5A, RES
+
+
G
-
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
Figure 2.11
I/O Box Terminal Strip
2-7
2.6.3
BOILER MANAGEMENT SYSTEM
(BMS) MODE
NOTE
information on wiring the 4 to 20 mA / 1to 5VDC
or the 0 to 20 mA / 0 to 5 VDC, see paragraph
2.7.3.
2.6.5 COMBINATION MODE
BMS Model 168 can utilize either pulse
width modulation (PWM) or RS485
Modbus signaling to the Boiler. BMS II
Model 5R5-384 can utilize only RS485
signaling to the Boiler.
When using an AERCO Boiler Management
System (BMS), the field wiring is connected
between the BMS Panel and each Boiler’s I/O
Box terminal strip (Figure 2-11). Twisted
shielded pair wire from 18 to 22 AWG must be
utilized for the connections. The BMS Mode can
utilize either pulse width modulation (PWM)
signaling, or RS485 Modbus signaling. For PWM
signaling, connections are made from the
AERCO Boiler Management System to the
B.M.S. (PWM) IN terminals on the I/O Box
terminal strip. For RS485 Modbus signaling,
connections are made from the BMS to the
RS485 COMM terminals on the I/O Box terminal
strip. Polarity must be maintained and the shield
must be connected only at the AERCO BMS.
The boiler end of the shield must be left floating.
For additional instructions, refer to Chapter 5,
paragraph 5.6 in this manual. Also, refer to GF108M (BMS Model 168) and GF-124 (BMS II
Model 5R5-184), BMS -Operations Guides.
2.6.4 REMOTE SETPOINT and DIRECT
DRIVE MODES
The KC1000 Boiler can accept several types of
signal formats from an Energy Management
System or other source to control either the
setpoint (Remote Setpoint Mode) or firing rate
(Direct Drive Mode) of the Boiler. These formats
are:
NOTE
Only BMS Model 168 can be utilized for
the Combination Mode, not the BMS II
(Model 5R5-384).
With a Combination Mode unit, field wiring is
between the unit’s I/O Box, the CCP
(Combination Control Panel), and the BMS
Model 168 (Boiler Management System). The
wiring must be done using a shielded twisted
pair of 22 AWG wire. Polarity must be
maintained between the unit, the CCP, and the
BMS.
For further instructions and wiring
diagrams, refer to the GF-108 Boiler
Management System Operations Guide and the
CCP-1 data sheet.
2.7 I/O BOX CONNECTIONS
The types of input and output/signals and
devices to be connected to the I/O Box terminals
shown in Figure 2.11 are described in the
following paragraphs.
CAUTION!
DO NOT make any connections to the I/O
Box terminals labeled “NOT USED”.
Attempting to do so may cause equipment
damage.
2.7.1 OUTDOOR SENSOR IN
Network – (RS485 Modbus. See para. 2.7.7)
An outdoor air temperature sensor (AERCO Part
No. 122790) will be required mainly for the
Indoor/Outdoor Reset mode of operation. It can
also be used with another mode if it is desired to
use the outdoor sensor enable/disable feature.
This feature allows the boiler to be enabled or
disabled based on the outdoor air temperature.
The factory default for the outdoor sensor is
DISABLED. To enable the sensor and or choose
an enable/disable outdoor temperature, see the
Configuration menu in Section 3 and Appendix
A.
While it is possible to control one or more boilers
using one of the above modes of operation, it
may not be the method best suited for the
application. Prior to selecting one of the above
modes of operation, it is recommended that you
consult with your local AERCO representative or
the factory for the mode of operation that will
work best with your application. For more
The outdoor sensor may be wired up to 200 feet
from the boiler and is connected to the
OUTDOOR SENSOR IN and SENSOR
COMMON terminals in the I/O box (see Figs.
2.10 and 2.11). Wire the sensor using a twisted
shielded pair cable of 18-22 AWG wire. There is
no polarity when terminating the wires. The
4 to 20 mA/1 to 5 Vdc
0 to 20 mA/0 to 5 Vdc
PWM – (Pulse Width Modulated signal.
paragraph 2.7.4)
2-8
See
INSTALLATION
shield is to be connected only to the terminals
labeled SHEILD in the I/O Box. The sensor end
of the shield must be left free and ungrounded.
When mounting the sensor, it must be located
on the North side of the building where an
average outside air temperature is expected.
The sensor must be shielded form direct sunlight
as well as impingement by the elements. If a
shield is used, it must allow for free air
circulation.
2.7.2 AUX SENSOR IN
The AUX SENSOR IN terminals can 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 provided in Appendix C.
2.7.4
B.M.S. (PWM) IN
NOTE
Only BMS Model 168 can utilize Pulse
Width Modulation (PWM), not the BMS II
(Model 5R5-384).
These terminals are used to connect the
AERCO Boiler Management System (BMS)
Model 168 to the unit. The BMS Model 168
utilizes a 12 millisecond, ON/OFF duty cycle.
This duty cycle is Pulse Width Modulated (PWM)
to control firing rate. A 0% firing rate = a 5% ON
pulse and a 100% firing rate = a 95% ON pulse.
2.7.5 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.
2.7.3 ANALOG IN
2.7.6 mA OUT
The ANALOG IN + and – terminals are used
when an external signal is used to drive the
firing rate (Direct Drive Mode) or change the
setpoint (Remote Setpoint Mode) of the Boiler.
Either a 4 to 20 mA / 1 to 5 VDC or a 0 to 20
mA / 0 to 5 VDC signal may be used to vary the
setpoint or firing rate. The factory default setting
is 4 to 20 mA / 1 to 5 VDC, however this may be
changed to 0 to 20 mA / 0 to 5 VDC using the
Configuration Menu described in Section 3. If
voltage rather than current is selected as the
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.
These terminals provide a 4 to 20 mA output
that can be used to monitor setpoint (40°F to
220°F), outlet temperature (30°F to 245°F), or
fire rate (0% to 100%). This function is enabled
in the Configuration Menu (Section 3, Table 3.4).
All of the supplied signals must be floating
(ungrounded) signals. Connections between the
source and the Boiler’s I/O Box must be made
using twisted shielded pair of 18 –22 AWG wire
such as Belden 9841(see Fig. 211). Polarity
must be maintained and the shield must be
connected only at the source end and must be
left floating (not connected) at the Boiler’s I/O
Box.
Whether using voltage or current for the drive
signal, they are linearly mapped to a 40°F to
240°F setpoint or a 0% to 100% firing rate. No
scaling for these signals is provided.
2.7.7 RS-485 COMM
These terminals are used for RS-485 MODBUS
serial communication between the unit and an
external “Master”, such as a Boiler Management
System or other suitable device.
2.7.8 EXHAUST SWITCH IN
These terminals permit an external exhaust
switch to be connected to the exhaust manifold
of the boiler. The exhaust sensor should be a
normally open type switch (such as AERCO Part
No. 123463) that closes (trips) at 500oF.
2.7.9 INTERLOCKS
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers.
These interlocks are called the Remote Interlock
and Delayed Interlock (Fig. 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 locations for these interlocks which are labeled REMOTE INTL’K IN and
DELAYED INTL’K IN. Both interlocks, described
in the following paragraphs, are factory wired in
the closed position.
2-9
NOTE:
Both the Delayed Interlock and Remote
Interlock must be in the closed position to
allow the unit to fire.
2.7.9.1 REMOTE INTERLOCK IN
The remote interlock circuit (REMOTE INTL’K
IN) is provided to remotely start (enable) and
stop (disable) the Boiler if desired. The circuit is
24 VAC and comes factory pre-wired closed
(jumpered).
2.7.9.2 DELAYED INTERLOCK IN
The delayed interlock circuit (DELAYED INTL’K
IN) is typically used in conjunction with the
auxiliary relay described in paragraph 2.8. 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
boiler’s auxiliary relay. The delayed interlock
must be closed for the boiler to fire. If the
delayed interlock is connected to a proving
device that requires time to close (make), a time
delay (Aux Start On Dly) that holds the start
sequence of the boiler long enough for for a
proving switch to make can be programmed.
Should the proving switch not prove within the
programmed time frame, the boiler will shut
down. The Aux Start On Dly can be
programmed from 0 to 120 seconds. This option
is locate in the Configuration Menu (Section 3).
2.7.10 FAULT RELAY
The fault relay is a single pole double throw
(SPDT) relay having a normally open and
normally close set of relay contacts that are
rated for 5 amps at 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.
2.8 AUXILIARY RELAY CONTACTS
Each KC Boiler is equipped with a single pole
double throw (SPDT) relay that is energized
when there is a demand for heat and deenergized after the 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 Boiler 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.
2-10
2.9 FLUE GAS VENT INSTALLATION
The AERCO Venting and Combustion Air Guide,
GF-1050, must be consulted before any flue or
inlet air venting is designed or installed.
Suitable, U/L approved, positive pressure,
water-tight vent materials as specified in
AERCO’s GF-1050, must be used for safety and
UL certification. Because the unit is capable of
discharging low temperature exhaust gases, the
flue must be pitched back to the unit a minimum
of 1/4" per foot to avoid any condensate pooling
and to allow for proper drainage.
While 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.
2.10 COMBUSTION AIR
The AERCO Venting and Combustion Air Guide,
GF-1050, MUST be consulted before any flue or
combustion supply air venting is designed or
started. Combustion air supply is a direct
requirement of ANSI 223.1, NFPA-54, and local
codes. These codes should be consulted before
a permanent design is determined.
The combustion air must be free of chlorine,
halogenated hydrocarbons, or other chemicals
that can become hazardous when used in gasfired equipment. Common sources of these
compounds are swimming pools, degreasing
compounds, plastic processing and refrigerants.
Whenever the environment contains these types
of chemicals, combustion air must be supplied
from a clean area outdoors for the protection
and longevity of the equipment.
The more common methods of supplying
combustion air are outlined below. For more
information on combustion air, consult the
AERCO GF-1050, Venting and Combustion Air
Guide.
2.10.1 COMBUSTION AIR FROM
OUTSIDE THE BUILDING
Air supplied from outside the building must be
provided through two permanent openings. For
each unit these two openings must have a free
area of not less than one square inch for each
4000 BTUs input of the equipment or 250
INSTALLATION
square inches of free area. The free area must
take into account restrictions such as louvers
and bird screens.
2.10.2 COMBUSTION AIR FROM INSIDE
THE BUILDING
When combustion air is provided from within the
building, it must be supplied through two
permanent openings in an interior wall. Each
opening must have a free area of not less than
one square inch per 1000 BTUH of total input or
1000 square inches of free area. The free area
must take into account any restrictions such as
louvers.
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 (2.10.3)
and GF-1050 for installation details.
Figure 2.12
Sealed Combustion Air Connection
2.10.3 SEALED COMBUSTION
The KC Boiler is UL approved for 100% sealed
combustion application when installed properly.
When a sealed combustion air application is
installed, the sealed combustion air piping must
be deducted from the maximum allowable
discharge piping amounts. Each unit must have
a minimum 6" diameter connection made to the
special Inlet Air Adapter # GP-18917 available
from AERCO. This adapter bolts directly on to
the air inlet of the unit’s blower. See installation
instructions with adapter. All inlet air ducts must
be sealed air tight.
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.
2-11
CONTROL PANEL OPERATING PROCEDURES
SECTION 3 - CONTROL PANEL OPERATING PROCEDURES
3.1. INTRODUCTION
The information in this Section provides a guide
to the operation of the KC1000 Boiler using the
Control Panel mounted on the front of the unit.
It is imperative that the initial startup of this unit
be performed by factory trained personnel.
Operation prior to initial startup by factory
trained personnel will void the equipment
warranty. In addition, the following WARNINGS
and CAUTIONS must be observed at all times.
CAUTION:
All initial installation procedures must be
satisfied before attempting to start the unit.
WARNING:
THE ELECTRICAL VOLTAGES IN THIS
SYSTEM INCLUDE 120 AND 24 VOLTS
AC. IT MUST NOT BE SERVICED OR
ACCESSED BY OTHER THAN FACTORY
CERTIFIED SERVICE TECHNICIANS.
WARNING:
DO NOT ATTEMPT TO DRY FIRE THE
BOILER. STARTING THE UNIT WITHOUT
A FULL WATER LEVEL CAN SERIOUSLY
DAMAGE THE UNIT AND MAY RESULT IN
PERSONNEL INJURY OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID
ANY WARRANTY.
3.2. CONTROL PANEL DESCRIPTION
The KC1000 Control Panel shown in Figure 3-1
contains all of the controls, indicators and
displays necessary to operate, adjust and
troubleshoot the KC1000 Boiler. These operating controls, indicators and displays are
listed and described in Table 3-1. Additional
information on these items are provided in the
individual operating procedures provided in this
Section.
Figure 3-1. Control Panel Front View
3-1
CONTROL PANEL OPERATING PROCEDURES
Table 3-1. Operating Controls, Indicators and Displays
ITEM
NO.
1
CONTROL, INDICATOR
OR DISPLAY
LED Status Indicators
COMM
MANUAL
REMOTE
2
DEMAND
VFD Display
3
OUTLET
TEMPERATURE
Display
4
RS-232 Port
5
6
7
READY Indicator
ON/OFF Switch
8
FAULT Indicator
9
CLEAR Key
10
MENU Keypad
LOW WATER LEVEL
TEST/RESET Switches
MENU
BACK
3-2
FUNCTION
Four Status LEDs indicate the current operating status as
follows:
Lights when RS-232 communication is occurring
Lights when the unit is being controlled using the front panel
keypad.
Lights when the unit is being controlled by an external signal
from an Energy Management System
Lights when there is a demand for heat.
Vacuum Fluorescent Display (VFD) consists of 2 lines, each
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
Startup Messages
Alarm Messages
Operating Status Messages
Menu Selection
3–Digit, 7–Segment LED display continuously displays the
outlet water temperature. The °F or °C LED next to the
display lights to indicate whether the displayed temperature is
in degrees Fahrenheit or degrees Celsius.
Port permits a Laptop Computer or External Modem to be
connected to the boiler Control Panel.
Lights when all Pre-Purge conditions have been satisified.
Enables and disables boiler operation.
Allow the operator to test the operation of the water level
monitor.
Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing CLEAR resets the display.
Red FAULT LED indicator lights when a boiler alarm
condition occurs. An alarm message will appear in the VFD.
Turns off the FAULT indicator and clears trhe alarm message
if the alarm is no longer valid. Lockout type alarms will be
latched and cannot be cleared by simply pressing this key.
Troubleshooting may be required to clear these types of
alarms
Consists of 6 keys which provide the following functions for
the Control Panel Menus:
Steps through the main menu categories shown in Figure 3-2.
The Menu categories wrap around in the order shown.
Allows you to go back to the previous menu level without
changing any information. Continuously pressing this key will
bring you back to the default status display in the VFD. Also,
this key allows you to go back to the top of a main menu
category.
CONTROL PANEL OPERATING PROCEDURES
Table 3-1. Operating Controls, Indicators and Displays - Continued
ITEM
NO.
10
(Cont.)
CONTROL, INDICATOR
OR DISPLAY
▲ (Up) Arrow
▼ (Down) Arrow
When in one of the main menu categories (Figure 3-2),
pressing this key will select the displayed menu category. If
the CHANGE key was pressed and the menu item is flashing,
pressing the ▼ (Down) arrow key will increment the selected
setting.
CHANGE
Permits a setting to be changed (edited). When the
CHANGE key is pressed, the displayed menu item will begin
to flash. Pressing the ▲ or ▼ arrow key when the item is
flashing will increment or decrement the displayed setting.
Saves the modified menu information in memory. The
display will stop flashing.
This switch toggles the boiler between the Automatic and
Manual modes of operation. When in the Manual (MAN)
mode, the front panel controls are enabled and the MANUAL
status LED lights.
ENTER
11
FUNCTION
When in one of the main menu categories (Figure 3-2),
pressing this key will select the displayed menu category. If
the CHANGE key was pressed and the menu item is flashing,
pressing the ▲ arrow key will increment the selected setting.
AUTO/MAN Switch
When in the Automatic (AUTO) mode, the MANUAL status
LED will be off and the front panel controls disabled.
12
FIRE RATE Bargraph
20 segment red LED bargraph continuously shows the Fire
Rate in 5% increments from 0 to 100%
3.3. CONTROL PANEL MENUS
3.3.1. Menu Processing Procedure
The Control Panel incorporates an extensive
menu structure which permits the operator to set
up, and configure the unit. The menu structure
consists of four major menu categories as
shown in Figure 3-2. Each of the menus shown,
contain options which permit operating
parameters to be viewed or changed. The
menus are protected by a password to prevent
unauthorized use.
Accessing each menu and option is accomplished using the Menu Keys shown in Figure 31. Therefore, it is imperative that you be
thoroughly familiar with the following basic steps
before attempting to perform specific menu
procedures.
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.
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
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
OPERATION
PASSWORD
SETUP
CONFIGURATION
TUNING
Figure 3-2. Menu Structure
3-4
The Setup Menu (Table 3-3) permits the
operator to set the unit password which is
required to change any of the menu options. To
prevent unauthorized use, a previously entered
password entry will time-out after 1 hour.
Therefore, the password must be reentered
when required.
In addition to permitting
password entries, the Setup Menu is also used
to enter date and time, language to be used for
display messages, units of temperature
measurements and entries required for external
communication and control of the unit via the
RS-232 port. A view-only software version
display is also provided to indicate the current
Control Box software version.
CONTROL PANEL OPERATING PROCEDURES
NOTE
The Outdoor Temp display item shown with an asterisk in Table 32 will not be displayed unless the Outdoor Sensor function has
been enabled in the Configuration Menu (Table 3-4).
Table 3-2. Operating Menu
Menu Item Display
Status Message
Active Setpoint
Aux Temp
Outdoor Temp*
Fire Rate In
Flame Strength
Run Cycles
Run Hours
Fault Log
Available Choices or Limits
Minimum
Maximum
40°F
30°F
-70°F
0%
0%
0
0
0
240°F
245°F
130°F
Max Fire Rate
100%
999,999
999,999
9
Default
0
Table 3-3. Setup Menu
Menu Item Display
Passsword
Language
Time
Date
Unit of Temp
Comm Address
Baud Rate
Software
Available Choices or Limits
Minimum
Maximum
0
9999
English
12:00 am
11:59 pm
01/01/00
12/31/99
Fahrenheit
Celsius
0
127
2400
4800
9600
19.2K
Ver 0.00
Default
0
English
Fahrenheit
0
9600
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
mode. The remaining options in this menu
require the valid password to be entered, prior to
changing existing entries. This menu contains a
number of other configuration settings which
may or may not be displayed, depending on the
current operating mode setting.
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
Table 3-4. Configuration Menu
Menu Item Display
Internal Setpt
Unit Type
Unit Size
Boiler Mode
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
Bldg Ref Temp
(If Boiler Mode =
Outdoor Reset)
Reset Ratio
(If Boiler Mode =
Outdoor Reset)
Outdoor Sensor
System Start Tmp
(If Outdoor Sensor =
Enabled)
Setpt Lo Limit
Setpt Hi Limit
Temp Hi Limit
Max Fire Rate
Pump Delay Timer
Aux Start On Dly
Failsafe Mode
mA Output
Lo Fire Timer
Setpt Limiting
Setpt Limit Band
3-6
Available Choices or Limits
Minimum
Maximum
Lo Temp Limit
Hi Temp Limit
Boiler
Water Heater
0.5 MBTU
1.0 MBTU
1.5 MBTU
2.0 MBTU
2.5 MBTU
3.0 MBTU
Constant Setpoint
Remote Setpoint
Direct Drive
Combination
Outdoor Reset
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input (BMS)
Network
40°F
240°F
0.1
9.9
Default
130°F
Boiler
1.0 MBTU
Constant
Setpoint
4 – 20 mA,
1-5V
70°F
1.2
Enabled or Disabled
30°F
100°F
Disabled
60°F
40°F
Setpt Hi Limit
Setpt Lo Limit
240°F
40°F
240°F
40%
100%
0 min
30 min
0 sec
120 sec
Shutdown or Constant Setpt
Setpoint, Outlet Temp,
Fire Rate Out, Off
2 sec
120 sec
Enabled or Disabled
0°F
10°F
60°F
200°F
215°F
100%
0 min
0 sec
Shutdown
Off
2 sec
Disabled
5°F
CONTROL PANEL OPERATING PROCEDURES
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 FactoryTrained personnel.
Table 3-5. Tuning Menu
Menu Item Display
Prop Band
Integral Gain
Derivative Time
Reset Defaults?
Available Choices or Limits
Minimum
Maximum
1°F
120°F
0.00
2.00
0.0 min
2.0 min
Yes
No
Are You Sure?
Default
70°F
1.00
0.0 min
No
3.8. START SEQUENCE
When the Control Box ON/OFF switch is set to
the ON position, it checks all pre-purge safety
switches to ensure they are closed. These
switches include:
• Safety Shut-Off Valve Proof of Closure
(POC) switch
• Low Water Level switch
• High Water Temperature switch
• High Gas Pressure switch
• Low Gas Pressure switch
If all of the above switches are closed, the
READY light above the ON/OFF switch will light
and the unit will be in the Standby mode.
When there is a demand for heat, the following
events will occur:
NOTE:
If any of the Pre-Purge safety device switches
are open, the appropriate fault message will be
displayed. Also, the appropriate fault messages
will be displayed throughout the start sequence,
if the required conditions are not observed.
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 following
events will occur:
3-7
CONTROL PANEL OPERATING PROCEDURES
(a) Blower relay energizes and turns on
blower.
(b) Air/Fuel Valve rotates to the full-open
purge position and closes purge position
switch. The dial on the Air/Fuel Valve
(Figure 3-4) will read 100 to indicate that
the valve is full-open (100%).
(c) The FIRE RATE bargraph will show
100%.
DIAL
(DETAIL “A”)
STEPPER
MOTOR
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:
100
DETAIL "A"
Figure 3-4.
(a) The Air/Fuel Valve rotates to the low-fire
ignition position and closes the ignition
switch. The dial on the Air/Fuel Valve
(Figure 3-6) will read between 25 and 35
to indicate that the valve is in the lowfire position.
(b) The igniter relay is activated and
provides ignition spark.
(c) The gas Safety Shut Off Valve (SSOV)
is energized (opened) allowing gas to
flow into the Air/Fuel Valve.
Air/Fuel Valve In Purge Position
4. Next, the blower proof switch (Figure 3-5)
closes and the display will show Purging and
indicate the elapsed time of the purge cycle
in seconds. The normal (default) time for the
purge cycle is 7 seconds.
3-8
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.
CONTROL PANEL OPERATING PROCEDURES
BURNER
BLOWER
8. With the unit firing properly, it will be
controlled by the temperature controller
circuitry. The FIRE RATE will be continuously displayed on the front panel bargraph.
9. Once the demand for heat has been
satisfied, the Control Box will turn off the gas
valve. The blower relay will be deactivated
and the Air/Fuel Valve will be closed.
Standby will be displayed.
3.9. START/STOP LEVELS
The start and stop levels are the fire rate
percentages that start and stop the unit, based
on load. These levels are Factory preset as
follows:
•
•
Start Level:
Stop Level:
20%
16%
Normally, these settings should not require
adjustment.
Figure 3-6.
Air/Fuel Valve In Ignition Position
3-9
INITIAL START-UP
SECTION 4 - INITIAL START- UP
4.1 INITIAL START- UP REQUIREMENTS
The initial start-up of the KC-1000 Low NOx
Boiler is comprised of the following steps:
•
•
•
•
•
Installation completed 100%
Combustion calibration
Proper setting of controls and limits
Mode of operation settings (see Section 5)
Safety device testing (see Section 6)
Installation procedures should be completed
100% before performing initial start-up. 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 mode
of operation settings in Section 5, and the safety
device test procedures in Section 6 to complete
the initial unit start-up.
An AERCO Gas Fired Startup Sheet included
with each KC-1000 must be completed for each
unit for warranty validation and a copy must be
returned promptly to AERCO at:
AERCO International, Inc.
159 Paris Ave.
Northvale, NJ 07647
WARNING!
DO NOT ATTEMPT TO FIRE THE UNIT
WITHOUT FULL WATER LEVEL. 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 Boiler 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. AERCO differential gas pressure regulator
adjustment tool P/N GM-122643 (one
supplied per installation site)
5. Small and large flat blade screwdrivers.
6. 7/16" open end wrench and small adjustable
wrenches.
7. 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
INITIAL START-UP
4.2.4 INSTALLING THE DIFFERENTIAL
REGULATOR ADJUSTMENT TOOL
1. First, remove the cap from the differential
pressure regulator (see Figure 4.3).
2. Place the gasket from the regulator cap onto
the regulator adjustment tool.
3. Prior to Installing the tools on the regulator,
pull up the tool's screwdriver blade. Then,
thread the tool into the regulator.
4. Engage the tool’s screwdriver blade into the
regulator’s adjustment screw slot.
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 4.3
Differential Regulator Adjustment Tool
Installation
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 natural gas to
propane (or vice versa) using the regulator
spring change procedure in Appendix J.
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.
Figure 4.2
Analyzer Probe Hole Location
4-2
The following combustion calibration procedure
closely follows the factory procedure. By
following this procedure, readjustment of
combustion will be kept to a minimum.
INITIAL START-UP
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
Fire Rate message will be displayed with the
present rate in %. Also, the MANUAL LED
will light.
NOTE:
For a review of the control panel operating
procedures, refer to Section 3.
6. Adjust the rate to 0% by pressing the ▼
arrow key.
7. Set the ON/OFF switch to the ON position.
8. Change the firing rate to 25% using the ▲
arrow key. This will put the unit into the
starting sequence.
NOTE:
10. Once 8.8” W.C. or 9.2” W.C. is set at the
100% level change the firing rate to 30%.
Insert the combustion analyzer probe into
the stack.
NOTE:
Always approach a firing rate percentage from
the same direction, (i.e., 100% to 30%, 30% to
20%, etc.). Whenever going to an increased
firing rate from below (i.e., 20% to 30%), first go
above and then back down to the desired firing
rate. This is necessary due to hysteresis in the
air/fuel stepper motor. Hysteresis causes the
air/fuel valve to stop in a slightly different position
if the firing rate percentage is approached from
below or above. This results in a difference in
oxygen readings for the same firing rate
percentage causing unnecessary recalibration.
11. Allow enough time for the combustion
analyzer to settle. Compare the measured
oxygen level to the oxygen range for intake
air temperature in Table 1 (page 4-5). Also,
ensure that the carbon monoxide (CO) and
nitrogen oxide (NOx) readings do not
exceed the values shown.
12. If the measured oxygen level, CO and NOx
emissions are within the ranges shown in
Table 1, no adjustment is necessary.
Proceed to step 17.
13. If the measured oxygen level is below the
range in Table 1, rotate the differential
regulator adjustment tool counterclockwise
1/4 to 1/2 revolution to decrease gas flow.
On initial start-up, or return to service from a
fault condition, the unit will remain at a 29% firing
rate for two-minutes, although the control signal
may indicate a greater input.
14. Wait for the combustion analyzer to settle,
then compare the new oxygen reading to
Table 1. Repeat adjustment until oxygen is
within the specified range.
9. Following the warm-up period, increase the
firing rate in 20% increments while
monitoring the gas pressure after every
increase. If gas pressure dips below 8.8”
W.C. for FM gas trains and 9.2” for IRI gas
trains at any input firing rate percentage,
stop and raise the pressure. Once 100% is
reached, adjust the gas pressure for 8.8”
W.C. (FM) or 9.2” W.C. (IRI).
15. If the measured oxygen level is above the
oxygen range in Table 1, rotate the
differential
regulator
adjustment
tool
clockwise 1/4 to 1/2 revolution to increase
gas flow.
16. Wait for the analyzer reading to settle, then
compare the new reading to Table 1. Repeat
adjustment until oxygen is within the
specified range.
NOTE:
If 8.8” W.C. for FM gas trains or 9.2” W.C. for IRI
gas trains cannot be obtained at the 100% firing
rate, it will be necessary to stop calibration and
contact the local AERCO representative in your
area. Running the unit on insufficient gas
pressure will void the warranty
NOTE:
Adjust only the differential regulator at 30%
control signal; do not adjust the air shutter.
17. Once the oxygen level is within the specified
range at 30%, change the firing rate to 16%.
4-3
INITIAL START-UP
18. Oxygen levels at the 16% firing rate should
be as shown in Table 2 (page 4-5). Also,
ensure that the CO and NOx readings do not
exceed the values shown. No adjustment
should be necessary. Contact the Factory if
the oxygen, CO or NOx levels are not within
the specified ranges.
NOTE:
At a 100% firing rate, 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 2.10.2 and 2.10.3.
19. Change the firing rate to 100% and allow the
combustion analyzer to settle. 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.
20. If the measured oxygen reading is below the
oxygen range in Table 3 (or 3A), loosen the
two bolts that secure the inlet air shutter to
the unit using a 7/16” wrench (see Figure
4.4). Open the shutter 1/4” to 1/2” to
increase the oxygen level, then tighten the
nuts.
BLOWER
INLET
SCREEN
SHUTTER
SHUTTER
LOCKING NUTS
BLOWER
OUTLET
Figure 4.4
Air Shutter Locking Nut Location
21. Wait for the analyzer to settle then compare
the new oxygen reading to Table 3 (or 3A).
Repeat the inlet air shutter adjustment until
the oxygen is within the specified range.
Also, ensure that the CO and NOx
emissions do not exceed the values shown.
Firmly tighten the inlet air shutter locking
nuts when finished.
4-4
REMINDER:
At 30% firing rate, adjust only the differential
pressure regulator. At 100% firing rate, adjust
only the inlet air shutter.
22. If the measured oxygen reading is above the
oxygen range in Table 3, loosen the two
7/16" locking nuts securing the inlet air
shutter. Close the air shutter 1/4” to 1/2” to
decrease the oxygen level and tighten the
two nuts.
23. Allow the analyzer to settle then compare the
new oxygen reading to Table 3 (or 3A).
24. Repeat the adjustment until the oxygen is
within the specified range. Also, ensure that
the CO and NOx readings do not exceed the
values shown. Firmly tighten the inlet air
shutter locking nuts when finished.
NOTE:
Adjust the inlet air shutter only at 100% firing
rate. Do Not adjust the differential pressure
regulator.
25. Change the firing rate to 30%. Allow time for
the combustion analyzer to settle. Check the
measured oxygen level, CO and NOx
emissions to ensure that they are still within
the ranges shown in Table 1.
26. Continue these procedures until all oxygen
levels are within the ranges specified in
Tables 1, 2 and 3 (or 3A) on page 4-5.
27. Record all readings on the AERCO start-up
sheet provided with each unit. Proceed to
paragraph 4.5 when all natural gas
combustion calibration procedures are
completed.
INITIAL START-UP
Table 1
Combustion Oxygen Levels for a 30%
Firing Rate
Inlet Air
Temp
-25°F
-10°F
0°F
10°F
25°F
40°F
55°F
70°F
85°F
100°F
Oxygen
(±0.2%)
7.8%
7.5%
7.4%
7.2%
6.9%
6.5%
6.4%
6.2%
5.9%
5.7%
Carbon
Monoxide
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
*NOx
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
N/A
* NOx readings corrected to 3% oxygen.
Table 2
Combustion Oxygen Levels for a 16%
Firing Rate
Inlet Air
Temp
-25°F
-10°F
0°F
10°F
25°F
40°F
55°F
70°F
85°F
100°F
Oxygen
(±0.2%)
<10%
<10%
<10%
<10%
<10%
<10%
<10%
<10%
<10%
<10%
Carbon
Monoxide
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
*NOx
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
N/A
* NOx readings corrected to 3% oxygen.
Table 3
Combustion Oxygen Levels for a 100%
Firing Rate With Cold Air Damper
Inlet Air
Temp
-25°F
-10°F
0°F
10°F
25°F
40°F
55°F
70°F
85°F
100°F
Oxygen
(±0.2%)
6.7
6.5
6.4
6.3
6.2
6.1
5.9
5.8
5.6
4.7
Carbon
Monoxide
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
<100 ppm
*NOx
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
<30 ppm
N/A
Table 3A
Combustion Oxygen Levels for a 100%
Firing Rate Without Cold Air Damper
Inlet Air
Temp
55°F
70°F
85°F
100°F
Oxygen
(±0.2%)
7.5%
6.5%
5.5%
4.5%
Carbon
Monoxide
<100 ppm
<100 ppm
<100 ppm
<100 ppm
*NOx
<30 ppm
<30 ppm
<30 ppm
N/A
* NOx readings corrected to 3% oxygen.
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 natural gas to
propane (or vice versa) using the regulator
spring change procedure in Appendix J.
Since the required gas supply pressures for
propane differ from those required for natural
gas, the Propane Combustion Calibration
procedures are repeated in their entirety in
paragraph 4.4. It should be noted that the
Combustion Calibration data in Tables 1, 2, 3
(and 3A) apply to both natural gas and propane
units.
4.4 PROPANE 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.
Prior to starting these procedures, ensure that
the KC1000 has been set up as specified in
paragraphs 4.2 through 4.2.4.
The following combustion calibration procedure
closely follows the factory procedure. By
following this procedure, readjustment of
combustion will be kept to a minimum.
* NOx readings corrected to 3% oxygen.
4-5
INITIAL START-UP
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 11” 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
Fire Rate message will be displayed with the
present rate in %. Also, the MANUAL LED
will light.
NOTE:
For a review of the control panel operating
procedures, refer to Section 3.
6. Adjust the rate to 0% by pressing the ▼
arrow key.
7. Set the ON/OFF switch to the ON position.
8. Change the firing rate to 25% using the ▲
arrow key. This will put the unit into the
starting sequence.
NOTE:
On initial start-up, or return to service from a
fault condition, the unit will remain at a 29% firing
rate for two-minutes, although the control signal
may indicate a greater input.
9. Following the warm-up period, increase the
firing rate in 20% increments while
monitoring the gas pressure after every
increase. If gas pressure dips below 7.7”
W.C. for FM gas trains and 8.1” for IRI gas
trains at any input firing rate percentage,
stop and raise the pressure. Once 100% is
reached, adjust the gas pressure for 7.7”
(FM) W.C. or 8.1” W.C. (IRI).
NOTE:
If 7.7” W.C. for FM gas trains or 8.1” W.C. for IRI
gas trains cannot be obtained at the 100% firing
rate, it will be necessary to stop calibration and
contact the local AERCO representative in your
area. Running the unit on insufficient gas
pressure will void the warranty
4-6
10. Once 7.7” W.C. or 8.1” W.C. is set at the
100% level change the firing rate to 30%.
Insert the combustion analyzer probe into
the stack.
NOTE:
Always approach a firing rate percentage from
the same direction, (i.e., 100% to 30%, 30% to
20%, etc.). Whenever going to an increased
firing rate from below (i.e., 20% to 30%), first go
above and then back down to the desired firing
rate. This is necessary due to hysteresis in the
air/fuel stepper motor. Hysteresis causes the
air/fuel valve to stop in a slightly different position
if the firing rate percentage is approached from
below or above. This results in a difference in
oxygen readings for the same firing rate
percentage causing unnecessary recalibration.
11. Allow enough time for the combustion
analyzer to settle. Compare the measured
oxygen level to the oxygen range for intake
air temperature in Table 1. Also, ensure that
the carbon monoxide (CO) and nitrogen
oxide (NOx) readings do not exceed the
values shown.
12. If the measured oxygen level, CO and NOx
emissions are within the ranges shown in
Table 1, no adjustment is necessary.
Proceed to step 17.
13. If the measured oxygen level is below the
range in Table 1, rotate the differential
regulator adjustment tool counterclockwise
1/4 to 1/2 revolution to decrease gas flow.
14. Wait for the combustion analyzer to settle,
then compare the new oxygen reading to
Table 1. Repeat adjustment until oxygen is
within the specified range.
15. If the measured oxygen level is above the
oxygen range in Table 1, rotate the
differential
regulator
adjustment
tool
clockwise 1/4 to 1/2 revolution to increase
gas flow.
16. Wait for the analyzer reading to settle, then
compare the new reading to Table 1. Repeat
adjustment until oxygen is within the
specified range.
NOTE:
Adjust only the differential regulator at 30%
control signal; do not adjust the air shutter.
INITIAL START-UP
the CO and NOx readings do not exceed the
values shown. Firmly tighten the inlet air
shutter locking nuts when finished.
17. Once the oxygen level is within the specified
range at 30%, change the firing rate to 16%.
18. Oxygen levels at the 16% firing rate should
be as shown in Table 2. Also, ensure that
the CO and NOx readings do not exceed the
values shown. No adjustment should be
necessary. Contact the Factory if the
oxygen, CO or NOx levels are not within the
specified ranges.
NOTE:
At a 100% firing rate, 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 2.10.2 and 2.10.3.
19. Change the firing rate to 100% and allow the
combustion analyzer to settle. 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.
NOTE:
Adjust the inlet air shutter only at 100% firing
rate. Do Not adjust the differential pressure
regulator.
25. Change the firing rate to 30%. Allow time for
the combustion analyzer to settle. Check the
measured oxygen level, CO and NOx
emissions to ensure that they are still within
the ranges shown in Table 1.
26. Continue these procedures until all oxygen
levels are within the ranges specified in
Tables 1, 2 and 3.
27. Record all readings on the AERCO start-up
sheet provided with each unit. Proceed to
paragraph 4.5 when all propane combustion
calibration procedures are completed.
4.5 UNIT REASSEMBLY
20. If the measured oxygen reading is below the
oxygen range in Table 3 (or 3A) , loosen the
two bolts that secure the inlet air shutter to
the unit using a 7/16” wrench (see Figure
4.4). Open the shutter 1/4” to 1/2” to
increase the oxygen level, then tighten the
nuts.
Once combustion calibration is set properly, the
unit can be re-assembled for permanent
operation.
21. Wait for the analyzer to settle then compare
the new oxygen reading to Table 3 (or 3A).
Repeat the inlet air shutter adjustment until
the oxygen is within the specified range.
Also, ensure that the CO and NOx
emissions do not exceed the values shown.
Firmly tighten the inlet air shutter locking
nuts when finished.
2. Shut off the gas supply to the unit.
REMINDER:
At 30% firing rate, adjust only the differential
pressure regulator. At 100% firing rate, adjust
only the inlet air shutter.
22. If the measured oxygen reading is above the
oxygen range in Table 3, loosen the two
7/16" locking nuts securing the inlet air
shutter. Close the air shutter 1/4” to 1/2” to
decrease the oxygen level and tighten the
two nuts.
23. Allow the analyzer to settle then compare the
new oxygen reading to Table 3 (or 3A).
24. Repeat the adjustment until the oxygen is
within the specified range. Also, ensure that
1. Set the ON/OFF switch to the OFF position.
Disconnect the AC power supply from the
unit.
3. Remove the regulator adjustment tool by
first pulling up the screwdriver blade to
disengage it from the regulator adjusting
screw, and then turning the tool out of the
top of the regulator.
4.
Apply a drop of silicone adhesive to the
regulator adjusting screw to lock its setting.
5. Remove the gasket from the tool and place it
back onto the regulator cap.
6. Reinstall the cap and gasket back on the
regulator. Tighten the cap using a
screwdriver or wrench.
7. Remove all of the manometers and barbed
fittings and reinstall the pipe plugs using a
suitable thread compound.
8. Remove the combustion analyzer probe
from the vent hole. Seal the probe hole and
replace the vent connection cover.
9. Replace the unit’s panels and hood.
4-7
INITIAL START-UP
4.6 OVER TEMPERATURE LIMIT
SWITCH ADJUSTMENTS
There are two Over-Temperature Limit switches
that turn off the unit when the outlet water
temperature becomes too hot. The lower overtemperature limit switch is adjustable and should
be adjusted 20° 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 its setpoint.
To adjust the lower over temperature switch limit
switch:
1. Remove the wing nut from the top center of
the shell cap. Lift the cap off the shell.
2. The two over-temperature limit switches are
located at the top of the shell (see Fig. 4.6).
Do not adjust the upper switch it has been
factory preset. Adjust the lower switch
between 20° to 40°F higher than the
maximum header temperature the unit may
see.
3. Replace the shell cap and wing nut.
Figure 4.6
Over Temperature Limit Switch Location
4-8
MODE OF OPERATION
SECTION 5 - MODE OF OPERATION
5.1 INTRODUCTION
The following paragraphs provide detailed
descriptions of the six different modes of
operation for the KC1000 Boiler. Each unit is
shipped from the factory tested and configured
for the ordered mode of operation. All
temperature related parameters are at factory
defaults and work well in most applications.
However, it may be necessary to change certain
parameters to customize the unit to the system.
A complete listing and descriptions of the
temperature related parameters are included in
Appendix A. Factory defaults are listed in Appendix E. After reading this section, parameters can
be customized to suit the needs of the specific
application.
5.2 INDOOR/OUTDOOR RESET MODE
This mode of operation is based on outside air
temperatures. As the outside air temperature
decreases, the supply header temperature will
increase and vice versa. For this mode, it is
necessary to install an outside air sensor as well
as select a building reference temperature and a
reset ratio.
5.2.1 RESET RATIO
Reset ratio is an adjustable number from 0.1 to
9.9. Once it is adjusted, the supply header
temperature will increase by that number for
each degree that the outside air temperature
decreases. For instance, if a reset ratio of 1.6 is
used, for each degree that outside air
temperature decreases the supply header
temperature will increase by 1.6 degrees.
5.2.2. BUILDING REFERENCE
TEMPERATURE
This is a temperature from 40°F to 240°F. Once
selected, it is the temperature that the system
references to begin increasing its temperature.
For instance, if a reset ratio of 1.6 is used and
we select a building reference temperature of
70°F, then at an outside temperature of 69°F,
the supply header temperature will increase by
1.6° to 71.6°F.
5.2.3 OUTDOOR AIR TEMPERATURE
SENSOR INSTALLATION
The outdoor air temperature sensor must be
mounted on the North side of the building in an
area where the average outside air temperature
is expected. The sensor must be shielded from
the sun's direct rays, as well as from direct
impingement by the elements. If a cover or
shield is used, it must allow free air circulation.
The sensor may be mounted up to 200 feet from
the unit. Sensor connections are made inside
the Input/Output (I/O) Box on the left side of the
KC1000 Boiler. Connections are made at the
terminals labeled OUTDOOR SENSOR IN and
SENSOR COMMON inside the I/O Box using
shielded 18 to 22 AWG wire. A wiring diagram is
provided on the cover of the I/O Box. Refer to
Section 2, paragraph 2.6.2 for additional wiring
information.
5.2.4 INDOOR/OUTDOOR STARTUP
1. Refer to the indoor/outdoor reset ratio charts
in Appendix D.
2. Choose the chart corresponding to the
desired building reference temperature.
3. Go down the left column of the chart to the
coldest design outdoor air temperature
expected in your area.
NOTE:
A design engineer typically provides design
outdoor air temperature and supply header
temperature data
4. Once the design outdoor air temperature is
chosen, go across the chart to the desired
supply header temperature for the design
temperature chosen in step 3.
5. Next, go up that column to the Reset Ratio
row to find the corresponding reset ratio.
6. Access the Configuration Menu and scroll
through it until the display shows Bldg Ref
Temp (Building Reference Temperature).
7. Press the CHANGE key. The display will
begin to flash.
8. Use the ▲ and ▼ arrow keys to select the
desired building reference temperature.
9. Press ENTER to save any changes.
10. Next, scroll through the Configuration Menu
until the display shows Reset Ratio.
5-1
MODE OF OPERATION
11. Press the CHANGE key.
begin to flash.
The display will
12. Use the ▲ and ▼ arrow keys to select the
reset ratio determined in step 5.
13. Press ENTER to save the change.
Refer to paragraph 3.3 for detailed instructions
on menu changing.
5.3 CONSTANT SETPOINT MODE
The Constant Setpoint mode is used when a
fixed header temperature is desired. Common
uses of this mode of operation include water
source heat pump loops, and indirect heat
exchangers for potable hot water systems or
processes.
There are no external sensors necessary to
operate in this mode. While it is necessary to set
the desired setpoint temperature, it is not
necessary to change any other temperaturerelated functions. The unit is factory preset with
settings that work well in most applications.
Prior to changing any temperature-related
parameters, other than the setpoint, it is
suggested that an AERCO representative be
contacted. For a complete listing of factory
defaults and descriptions of temperature related
functions, see Appendices A and E.
5.3.1 SETTING THE SETPOINT
The setpoint temperature of the unit is adjustable
from 40°F to 240°F. To set the unit for operation
in the Constant Setpoint Mode, the following
menu settings must be made in the
Configuration Menu:
MENU OPTION
Boiler Mode
Internal Setpt
SETTING
Constant Setpoint
Select desired setpoint
using ▲ and ▼ arrow
keys (40°F to 240°F)
Refer to paragraph 3.3 for detailed instructions
on changing menu options.
5-2
5.4 REMOTE SETPOINT MODES
The unit’s setpoint can be remotely controlled by
an Energy Management System (EMS) or
Building Automation System (BAS). The Remote
Setpoint can be driven by a current or voltage
signal within the following ranges:
4-20 mA/1-5 Vdc
0-20 mA/0-5 Vdc
The factory default setting for the Remote
Setpoint mode is 4 - 20 mA/1 - 5 Vdc. With this
setting, a 4 to 20 mA/1 to 5 Vdc signal, sent by
an EMS or BAS, is used to change the unit's
setpoint. The 4 mA/1V signal is equal to a 40°F
setpoint while a 20 mA /5V signal is equal to a
240°F setpoint. When a 0 to 20 mA/0 to 5 Vdc
signal is used, 0 mA is equal to a 40°F setpoint.
In addition to the current and voltage signals
described above, the Remote Setpoint mode can
also driven by a RS485 Modbus Network signal
from an EMS or BAS.
The Remote Setpoint modes of operation can be
used to drive single as well as multiple units.
NOTE:
If a voltage, rather than current signal is used to
control the remote setpoint, a DIP switch
adjustment must be made on the PMC Board in
the Control Box. Contact your local AERCO
representative for details.
In order to enable the Remote Setpoint Mode,
the following menu setting must be made in the
Configuration Menu:
MENU OPTION
SETTING
Boiler Mode
Remote Setpoint
Remote Signal
4-20mA/1-5V,
0-20mA/0-5V, or
Network
Refer to paragraph 3.3 for detailed instructions
on changing menu options.
MODE OF OPERATION
If the Network setting is selected for RS485
Modbus operation, a valid Comm Address must
be entered in the Setup Menu. Refer to Modbus
Communication Manual GF-114 for additional
information.
While it is possible to change the settings of
temperature related functions, the unit is factory
preset with settings that work well in most
applications. It is suggested that an AERCO
representative be contacted, prior to changing
any temperature related function settings. For
descriptions of temperature-related functions
and their factory defaults, refer to Appendices A
and E.
5.4.1 REMOTE SETPOINT FIELD WIRING
The only wiring connections necessary for the
Remote Setpoint mode are connection of the
remote signal leads from the source to the unit’s
I/O Box. The I/O Box is located on the front
panel of the Benchmark Boiler. For either a 420mA/0-5V or a 0-20mA/0-5V setting, the
connections are made at the ANALOG IN
terminals in the I/O Box. For a Network setting,
the connections are made at the RS-485 COMM
terminals in the I/O Box. The signal must be
floating, (ungrounded) at the I/O Box and the
wire used must be a two wire shielded pair from
18 to 22 AWG. Polarity must be observed. The
source end of the shield must be connected at
the source. When driving multiple units, each
unit’s wiring must conform to the above.
5.4.2 REMOTE SETPOINT STARTUP
Since this mode of operation is factory preset
and the setpoint is being externally controlled, no
startup instructions are necessary. In this mode,
the REMOTE LED will light when the external
signal is present.
To operate the unit in the Manual mode, press
the AUTO/MAN switch. The REMOTE LED will
go off and the MANUAL LED will light.
To change back to the Remote Setpoint mode,
simply press the AUTO/MAN switch.
The
REMOTE LED will again light and the MANUAL
LED will go off.
5.5 DIRECT DRIVE MODES
The unit’s fire rate can be changed by a remote
signal which is typically sent from an Energy
Management System (EMS) or from a Building
Automation System (BAS). The Direct Drive
mode can be driven by a current or voltage
signal within the following ranges:
4-20 mA/1-5 Vdc
0-20 mA/0-5 Vdc
The factory default setting for the Direct Drive
mode is 4-20 mA/1-5 Vdc. With this setting, a 4
to 20 mA signal, sent by an EMS or BAS is used
to change the unit’s fire rate from 0% to 100%. A
4 mA/1V signal is equal to a 0% fire rate, while a
20 mA /5V signal is equal to a 100% fire rate.
When a 0-20 mA/0-5 Vdc signal is used, zero is
equal to a 0% fire rate.
In addition to the current and voltage signals
described above, the Direct Drive mode can also
driven by a RS485 Modbus Network signal from
an EMS or BAS.
When in a Direct Drive mode, the unit is a slave
to the EMS or BAS and does not have a role in
temperature control. Direct Drive can be used to
drive single, or multiple units.
NOTE:
If a voltage, rather than current signal is used to
control the fire rate, a DIP switch adjustment
must be made on the PMC Board in the Control
Box. Contact your local AERCO representative
for details.
To enable the Direct Drive Mode, the following
menu setting must be made in the Configuration
Menu:
MENU OPTION
SETTING
Boiler Mode
Direct Drive
Remote Signal
4-20mA/1-5V,
0-20mA/0-5V, or
Network
Refer to paragraph 3.3 for instructions on
changing menu options.
5-3
MODE OF OPERATION
If the Network setting is selected for RS485
Modbus operation, a valid Comm Address must
be entered in the Setup Menu. Refer to Modbus
Communication Manual GF-114 for additional
information.
5.5.1 DIRECT DRIVE FIELD WIRING
The only wiring connections necessary for Direct
Drive mode are connection of the remote signal
leads from the source to the unit’s I/O Box. For
either a 4-20mA/0-5V or a 0-20mA/0-5V setting,
the connections are made at the ANALOG IN
terminals in the I/O Box. For a Network setting,
the connections are made at the RS-485 COMM
terminals in the I/O Box. The signal must be
floating, (ungrounded) at the I/O Box and the
wire used must be a two wire shielded pair from
18 to 22 AWG. Polarity must be observed. The
source end of the shield must be connected at
the source. When driving multiple units, each
unit’s wiring must conform to the above.
5.5.2 DIRECT DRIVE STARTUP
Since this mode of operation is factory preset
and the fire rate is being externally controlled, no
startup instructions are necessary. In this mode,
the REMOTE LED will light when the signal is
present.
To operate the unit in manual mode, press the
AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light.
To change back to the Direct Drive mode, simply
press the AUTO/MAN switch. The REMOTE
LED will again light and the MANUAL LED will
go off.
5.6 BOILER MANAGEMENT SYSTEM
(BMS) MODE
NOTE
BMS Model 168 can utilize either pulse
width modulation (PWM) or RS485
Modbus signaling to the Boiler. BMS II
Model 5R5-384 can utilize only RS485
signaling to the Boiler.
The BMS mode of operation is used in
conjunction with an AERCO Boiler Management
System. The BMS mode is used when it is
desired to operate multiple units in the most
efficient manner possible. The BMS can control
up to 40 boilers; 8 via pulse width modulation
(PWM) and up to 32 via Modbus (RS485)
network communication. For BMS programming
5-4
and operation, see GF-108M (BMS Model 168)
and GF-124 (BMS II Model 5R5-384), BMS
Operations Guides. For operation via an RS485
Modbus
network,
refer
to
Modbus
Communication Manual GF-114.
To enable the BMS Mode, the following menu
settings must be made in the Configuration
Menu:
MENU OPTION
SETTING
Boiler Mode
Direct Drive
Remote Signal
BMS (PWM Input)
or
Network (RS485)
Refer to paragraph 3.3 for instructions on
changing menu options.
5.6.1 BMS EXTERNAL FIELD WIRING
Wiring connections for BMS control using PWM
signaling are made between connector JP2 on
the BMS panel (boilers 1 through 8), and the
B.M.S. (PWM) IN terminals in the I/O Box on the
front of the Benchmark Boilers. Refer to the
wiring diagram provided on the cover of the I/O
Box.
Wiring connections for RS485 Modbus control
are made between connector JP11 on the BMS
(boilers 9 through 40) and the RS485 COMM
terminals in the I/O Box on the front of the unit.
Wire the units using shielded twisted pair wire
between 18 and 22 AWG. Observe the proper
polarity for the B.M.S. (PWM) IN and/or RS485
COMM wiring connections. Shields should be
terminated only at the BMS and the boiler end
must be left floating. Each unit’s wiring must
conform to the above.
5.6.2 BMS SETUP AND STARTUP
This mode of operation is factory preset and the
AERCO BMS controls the firing rate. There are
no setup instructions for each individual unit.
To operate the unit in manual mode, press the
AUTO/MAN switch. The REMOTE LED will go
off and the MANUAL LED will light
To change back to the BMS mode, simply press
the AUTO/MAN switch. The REMOTE LED will
again light and the MANUAL LED will go off.
MODE OF OPERATION
5.7 COMBINATION CONTROL SYSTEM
(CCS)
NOTE
Only BMS Model 168 can be utilized for
the Combination Mode, not the BMS II
(Model 5R5-384).
A Combination Control System (CCS) is one that
uses multiple boilers to cover both space-heating
and domestic hot water needs. An AERCO
Boiler Management System (BMS) Model 168
and a Combination Control Panel (CCP) are
necessary to configure this system. Typically, an
adequate number of boilers are installed to cover
the space-heating load on the design day,
however one or more units are used for the
domestic hot water load.
The theory behind this type of system is that the
maximum space-heating load and the maximum
domestic hot water load do not occur simultaneously. Therefore, boilers used for the domestic
hot water are capable of switching between
constant setpoint and BMS modes of operation.
These boilers are the combination units and are
referred to as the combo boilers. The combo
boilers heat water to a constant setpoint
temperature. That water is then circulated
through a heat exchanger in a domestic hot
water storage tank.
When the space-heating load is such that all the
space-heating boilers are at 100% firing rate, the
BMS will then ask the Combination Control
Panel for the domestic boilers to become spaceheating boilers. Provided the domestic hot water
load is satisfied, the combo (hot water) boilers
will then become space-heating boilers. If the
domestic hot water load is not satisfied, the
combo boiler(s) remain on the domestic hot
water load. If the combo boilers switch over to
space heating, but there is a call for domestic
hot water, the CCP switches the combo units
back to the domestic load.
When the combo units are satisfying the
domestic load they are in constant setpoint
mode of operation. When the combo units switch
over to space heating, their mode of operation
changes to the BMS mode. For more information
concerning the operation of the Combination
Control Panel see the AERCO CCP-1 literature.
5.7.1 COMBINATION CONTROL SYSTEM
FIELD WIRING
Wiring for this system is between the BMS
Model 168 panel, the CCP and the B.M.S.
(PWM) IN terminals in the I/O Box. Wire the
units using a shielded twisted pair of 18 to 22
AWG wire. When wiring multiple units, each
unit’s wiring must conform to the above. For a
complete CCP system-wiring diagram see the
AERCO CCP-1 literature.
5.7.2 COMBINATION CONTROL SYSTEM
SETUP AND STARTUP
Setup for the Combination Mode requires entries
to be made in the Configuration Menu for boiler
mode, remote signal type and setpoint. The
setpoint is adjustable from 40°F to 240°F.
Enter the following settings in the Configuration
Menu:
MENU OPTION
SETTING
Boiler Mode
Combination
Remote Signal
BMS (PWM Input)
Internal Setpt
40°F to 240°F
Refer to paragraph 3.3 for instructions on
changing menu options.
While it is possible to change other temperaturerelated functions for combination mode, these
functions are preset to their factory default
values. These default settings work well in most
applications. It is suggested that AERCO be
contacted prior to changing settings other than
the unit’s setpoint. For a complete listing of
temperature related function defaults, see
Appendix E.
To set the unit to the manual mode, press the
AUTO/MAN switch. The MANUAL LED will light.
To set the unit back to the auto mode, press the
AUTO/MAN switch. The MANUAL LED will go
off and the REMOTE LED will light.
When the boiler is switched to BMS mode, the
AERCO BMS controls the firing rate. There are
no setup requirements to the boiler(s) in this
mode.
5-5
SAFETY DEVICE TESTING
SECTION 6-SAFETY DEVICE TESTING PROCEDURES
6.1 TESTING OF SAFETY DEVICES
Periodic testing of all controls and safety devices
is required to insure that they are operating as
designed. Precautions must be taken while tests
are being performed to protect against bodily
injury and property damage.
6. Open the gas supply to the unit and press
the CLEAR button on the Control Box.
7. The unit should restart.
Systematic and thorough testing of the operating
and safety controls should be performed on a
scheduled basis, or whenever a control
component has been serviced or replaced. All
testing must conform to local jurisdictions or
codes such as ASME CSD-1.
NOTE:
MANUAL and AUTO modes are required to
perform the following tests. For a complete
explanation of these modes, see Section 3.
NOTE:
It will be necessary to remove the sheet
metal covers and cap from the unit to
perform the following tests.
WARNING!
ELECTRICAL VOLTAGES USED 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.
6.2 LOW GAS PRESSURE FAULT TEST
1. Shut off the gas supply to the unit.
2. Install a 0-16” W.C. manometer in the gas
pipe assembly below the low gas pressure
switch. (See Fig. 6.1)
3. Open the gas supply to the unit and depress
the CLEAR button to clear any displayed
fault messages..
4. Place the unit in Manual Mode and fire the
unit at a firing rate between 25% and 30%.
5. Slowly close the manual gas supply valve
while monitoring the gas pressure. The unit
should fault and shutdown on LOW GAS
PRESSURE when the manometer indicates
approximately 6.5” W.C.
Figure 6.1
1/8” Pipe Plug Position for Manometer
Installation
NOTE:
After faulting the unit, the fault message will
be displayed and the fault indicator light will
flash until the CLEAR button is pressed.
6.3 HIGH GAS PRESSURE TEST
1. Start the unit in manual mode and fire
between 25% and 30%.
2. Remove either wire # 150 or wire #151 from
the high gas pressure switch. See Fig. 6.2.
3. The unit should shut down on a HIGH GAS
PRESSURE FAULT.
4. Reconnect the wire previously removed from
the high gas pressure switch and depress
the CLEAR button.
5. The unit should restart.
6-1
SAFETY DEVICE TESTING
low water cutoff. Press the CLEAR button to
reset the FAULT LED and clear the error
message.
11. Set the ON/OFF switch to the ON position.
The unit is now ready for operation.
6.5 WATER TEMPERATURE FAULT
TEST
1. In the normal operating mode, allow the unit
to stabilize at its setpoint.
2. Lower the adjustable temperature limit
switch setting to match the outlet water
temperature. (See Fig. 6.3).
Figure 6.2
High Gas Pressure Switch
6.4
LOW WATER LEVEL FAULT TEST
1. Set the ON/OFF switch in the OFF position.
2. Close shut-off valves in the supply and
return piping to the unit.
3. Open the drain valve on the unit.
4. Allow air flow into the unit by either opening
the relief valve or by removing the 1/4” plug
in the top of the unit.
5. The LOW WATER LEVEL message will be
displayed and the FAULT LED will flash after
the water level has gone below the level of
the probe.
6. Set the ON/OFF switch to ON. The READY
light should remain off and the unit should
not start. If the unit does start, shut the unit
off immediately and refer fault to qualified
service personnel.
7. Close the drain and pressure relief valve or
reinstall the plug in the top of the unit if
removed.
8. Open the water shut-off valve in the return
piping to the unit to fill the shell.
9. Open the water shut-off valve in the supply
piping to the unit.
10. After the shell is full, press the LOW
WATER LEVEL RESET button to reset the
6-2
Figure 6.3
Temperature Limit Switch Setting
3. Once the switch setting is approximately at
the actual water temperature, the unit should
shutdown. The red FAULT LED should be
flashing and the message HIGH WATER
TEMP SWITCH OPEN should be displayed.
The unit should not start.
4. Reset the temperature limit switch setting to
its prior setting.
5. The unit should start once the adjustable
temperature limit switch setting is above the
actual outlet water temperature.
SAFETY DEVICE TESTING
6.6 INTERLOCK TESTS
The unit is equipped with two interlock circuits
called the Remote Interlock and the Delayed
Interlock. Terminal connections for these circuits
are located in the I/O Box and are labeled
REMOTE INTL’K IN and DELAYED INTL’K IN.
These circuits can shut down the unit in the
event that an interlock is opened. These
interlocks are shipped from the factory jumped
(closed). However, each of these interlocks may
be utilized in the field as a remote stop and start,
an emergency cut-off, or to prove that a device
such as a pump gas booster, or louver is
operational.
6.7 FLAME FAULT TEST
6.6.1 REMOTE INTERLOCK
5. The unit should shut down after reaching the
Ignition cycle and display FLAME LOSS
DURING IGN.
1. Remove the cover from the I/O Box and
locate the REMOTE INTL’K IN terminals.
2. Start the unit in manual mode and fire at
25% to 30% firing rate.
3. If there is a jumper across the REMOTE
INTL’K IN terminals, remove one side of the
jumper. If the interlock is being controlled by
an external device, either open the interlock
via the external device or disconnect one of
the wires leading to the external device.
4. The unit should shut down and display
INTERLOCK OPEN.
5. Once the interlock connection is reconnected, the INTERLOCK OPEN message
should automatically clear and the unit
should resume running.
1. Place the ON/OFF switch in the OFF
position.
2. Place the unit in the Manual Mode and set
the firing rate between 25% and 30%.
3. Close the manual leak detection valve
located between the safety shut-off valve
and the differential regulator (see Fig. 6.4).
4. Start the unit.
6. Open the valve previously closed in step 3
and depress the CLEAR button.
7. Restart the unit and allow it to prove flame.
8. Once flame is proven, close the manual leak
detection valve located between the safety
shut-off valve and the differential regulator.
9. The unit should shut down and display
FLAME LOSS DURING RUN.
10. Open the valve previously closed in step 8
and depress the CLEAR button. The unit
should restart and fire.
6.6.2 DELAYED INTERLOCK
1. Remove the cover from the I/O Box and
locate the DELAYED INTL’K IN terminals.
2. Start the unit in manual mode and fire at a
25% to 30% firing rate.
3. If there is a jumper across the DELAYED
INTL’K IN terminals, remove one side of the
jumper. If the interlock is connected to a
proving switch of an external device, disconnect one of the wires leading to the
proving switch.
4. The unit should shut down and display
DELAYED INTERLOCK OPEN. The FAULT
LED should be flashing.
5. Once the interlock connection is reconnected, depress the CLEAR button. The unit
should start.
Figure 6.4
Manual Leak Detection Valve
6-3
SAFETY DEVICE TESTING
6.8 AIR FLOW FAULT TEST
1. Start the unit in manual mode and set the
fire rate between 25% and 30%.
2. Once the unit has proved flame, remove
either wire #154 or #155 from the blower
proof switch (see Fig. 6.5) located on the
air/fuel valve.
3. The unit should shut down and display
AIRFLOW FAULT DURING RUN.
4. Replace the wire previously removed from
the blower-proof switch and depress the
CLEAR button. The unit should restart.
WARNING!
ELECTRICAL VOLTAGES USED 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.
6.9 SSOV PROOF OF CLOSURE
SWITCH
1. Set the unit’s ON/OFF switch to the OFF
position. Place the unit in manual mode and
set the fire rate between 25% and 30%.
2. Remove the Safety Shut-Off Valve (SSOV)
cover to access the terminal connections.
See Fig. 6.6. For units with IRI gas trains,
access the terminals of the downstream
SSOV (see drawing SD-A-660 in Appendix
F.
3. Remove either wire #149 or #148 from the
SSOV.
4. The unit should fault and display SSOV
SWITCH OPEN.
5. Replace the wire previously removed and
depress the CLEAR button.
6. Start the unit.
7. Remove the wire again when the unit
reaches the purge cycle.
8. The unit should shut down and display
SSOV FAULT DURING PURGE.
9. Replace the wire on the SSOV and depress
the CLEAR button. The unit should restart.
Figure 6.5
Blower Proof Switch Location and Wiring
Figure 6.6
SSOV Actuator Cover Screw Location
6-4
SAFETY DEVICE TESTING
6.10 PURGE SWITCH OPEN DURING
PURGE
6.11 IGNITION SWITCH OPEN DURING
IGNITION
1. Set the unit’s ON/OFF switch to the OFF
position. Place the unit in manual mode and
set the fire rate between 25% and 30%
1. Set the unit’s ON/OFF switch to the OFF
position. Place the unit in manual mode and
set the fire rate between 25% and 30%.
2. Remove the air/fuel valve cover by rotating
the cover counterclockwise to unlock it and
then pulling it towards you. See Fig. 6.7.
2. Remove the air/fuel valve cover (Fig. 6.7) by
rotating the cover counterclockwise to
unlock it then pulling it towards you.
3. Remove one of the two wires from the purge
switch (Fig. 6.8) and start the unit.
3. Remove one of the two wires from the
ignition switch (Fig. 6.8) and start the unit.
4. The unit should begin to start, then shut
down and display PRG SWITCH OPEN
DURING PURGE.
4. The unit should begin to start then shut
down and display IGN SWITCH OPEN
DURING IGNITION.
5. Replace the wire on the purge switch and
depress the CLEAR button. The unit should
restart.
5. Replace the wire on the ignition switch and
depress the CLEAR button. The unit should
restart.
Figure 6.7
Air/Fuel Valve Cover Location
Figure 6.8
Air/Fuel Valve Purge and Ignition Switch
Locations
6-5
SAFETY DEVICE TESTING
6.12 SAFETY PRESSURE RELIEF VALVE
TEST
Test the unit’s Safety Pressure Relief Valve in
accordance with ASME Boiler and Pressure
Vessel Code, Section VI.
6-6
MAINTENANCE
SECTION 7 - MAINTENANCE
7.1 MAINTENANCE SCHEDULE
The unit requires regular routine maintenance to
keep up efficiency and reliability. For best
operation and life of the unit, the routine
maintenance procedures listed in Table 1 should
be performed within the specified time periods.
Table 1 Maintenance Schedule
Para
7.2
7.3
7.4
7.5
7.6
Item
Spark
Igniter
Flame
Detector
Combustion
Cal.
Testing of
Safety
Devices
*Manifold
& Tubes
6
Mos.
Inspect
12
Mos.
Replace
Inspect
Replace
Check
Check
24
Mos.
Test
20
mins.
Inspect
& clean
if
needed
Inspect
7.7
Water Side
Inspection
7.8 Condensate
Drain
Inspect
& clean
Labor
Time
20
mins.
20
mins.
1 hr.
4 hrs.
2 hr.
30
mins.
* Recommended only when unit will be run in an
extreme condensing mode for prolonged periods
of time.
2. To access the spark igniter, remove the
unit’s left side paneland left rear cover.
3. Disconnect the igniter cable from the igniter
contact.
4. Using a 15/16” open-end wrench, remove
the igniter from the burner shell.
5. Inspect the igniter for erosion or carbon
build-up. If there is substantial erosion of the
spark gap or ground electrode, the igniter
should be replaced. If carbon build-up is
present, clean the igniter using fine emery
cloth. Repeated carbon build-up on the
igniter is an indication that a check of the
combustion settings is required. See Section
4 for Combustion Calibration procedures.
6. Prior to reinstalling the igniter, a conductive
anti-seize compound must be applied to the
igniter threads.
7. Reinstall the igniter in the burner shell. Do
Not over-tighten. A slight snugging up is
sufficient.
8. Reconnect the igniter cable.
9. Replace the left side panel and left rear
cover on the unit.
WARNING!
TO AVOID PERSONAL INJURY, BEFORE
SERVICING:
(A) DISCONNECT AC POWER FROM THE
UNIT.
(B) SHUT OFF THE GAS SUPPLY TO THE
UNIT.
(C) ALLOW THE UNIT TO COOL TO A SAFE
TEMPERATURE.
7.2 SPARK IGNITER
The spark igniter assembly is located in the body
of the burner (Figure 7.1). The igniter may be
HOT. Care should be exercised. It is easier to
remove the igniter from the unit after the unit has
cooled to room temperature.
To inspect or replace the Igniter :
1. Set the ON/OFF switch on the control panel
to the OFF position and disconnect AC
power from the unit.
Figure 7.1
Spark Igniter and Flame Detector Location
7-1
MAINTENANCE
7.3 FLAME DETECTOR
The flame detector assembly is located in the
body of the burner (Figure 7.1). The flame
detector may be HOT. Allow the unit to cool
sufficiently before removing the flame detector.
To inspect or replace the flame detector:
The following replacement parts will be required
for reassembly after inspection:
GP-122537
GP-18900
Combustion Chamber
Gasket
Manifold to Tubesheet
Gasket
Burner Head/Plate Gasket
Burner Plate/Shell Gasket
Combustion Chamber Liner
1. Set the ON/OFF switch on the control panel
to the OFF position and disconnect AC
power from the unit.
124749
124834
*124839
2. To access the flame detector, remove the
unit’s left side panel and left rear cover.
*Not necessary to change but should be on hand
in case damage occurs during the inspection.
3.
Disconnect the flame detector wire lead.
4. Using a 15/16” open-end wrench, loosen
and remove the flame detector from the
burner shell.
5. Inspect the detector thoroughly. If eroded,
the detector should be replaced. Otherwise,
clean the detector with a fine emery cloth.
6. Reinstall the flame detector in the burner
shell. Do Not over-tighten. A slight snugging
up is sufficient.
7. Reconnect the flame detector wire lead.
8. Replace the left side panel and left rear
cover on the unit.
7.4 COMBUSTION CALIBRATION
Combustion settings must be checked at the
intervals shown in Table 1 as part of the scheduled maintenance requirements. Refer to the
combustion calibration instructions in Section 4..
7.5 SAFETY DEVICE TESTING
To remove the manifold for inspection:
1. Remove the sheet metal covers from the
unit.
2. Disconnect the plastic tubing from the
condensate cup to drain and remove the
rear covers.
3. Remove the condensate cup from under the
unit Disconnect AC power and turn off the
gas supply to the unit.
4. and disconnect the condensate drain tubing
from the exhaust manifold.
5. Remove the flame detector and ignition
cable wires from the flame detector and
igniter contactor. Remove the igniter and
flame detector per paragraphs 7.2, and 7.3.
6. Remove the grounding terminal from the
burner by loosening the upper screw and
sliding the connector from the grounding rod.
(See Fig. 7.2)
Systematic and thorough testing of the operating
and safety devices should be performed to
ensure that they are operating properly. 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 in a log book. See Section 6
- Safety Device Testing Procedures.
7.6 MANIFOLD AND EXHAUST TUBES
The presence of even trace amounts of
chlorides and/or sulfur, in the combustion air and
fuel sources, can lead to the formation of
deposits on the inside of the exchanger tubes,
exhaust manifold, and/or the condensate cup.
The degree of deposition is influenced by the
extent of the condensing operation and the
chloride and sulfur levels that vary significantly
from application to application.
7-2
Figure 7.2
Grounding Terminal Location
MAINTENANCE
7. Loosen the 1/4” NPT union on the low NOx
staged ignition assembly (Figure 7.3).
8. Disconnect the staged ignition assembly 1/8”
elbow from the 3” long NPT nipple at the
bottom of the burner shell.
Figure 7.4
Exhaust Sensor Connector Location
16. Disconnect the air/fuel valve 12-pin connector from the KC wiring harness.
17. Disconnect wires #24 and #17 from the
blower proof switch (Figure 7.5).
Figure 7.3
Burner Disassembly Diagram
9. Remove the 3” long NPT nipple and 1/4”
O.D. tube (Figure 7.3) from the burner shell.
10. Using a 7/16” socket or open end wrench,
remove the four 1/4-20 nuts on the gas inlet
pipe flange at the burner.
11. Using two 9/16” wrenches, remove the two
3/8-16 hex nuts and bolts on the gas inlet
pipe flange at the air/fuel valve (Figure 7.3).
Remove the gas inlet pipe.
12. Loosen the hose clamp on the air/fuel valve
outlet (Figure 7.3).
13. Using a 1/2” socket wrench, remove the six
5/16-18 hex nuts supporting the burner
(Figure 7.3).
Figure 7.5
Blower Proof Switch Wire Locations
18. Loosen the hose clamp on the air/fuel valve
inlet and slide the clamp back towards the
blower (Figure 7.6).
14. Lower the burner while sliding the air hose
off the air/fuel valve. Remove the burner
through the rear of the unit. Due to space
limitations, it will be necessary to separate
the burner head and shell during the removal
process.
15. Disconnect the exhaust temperature sensor
by unscrewing it from the exhaust manifold
(Figure 7.4).
Figure 7.6
Air/Fuel Valve Inlet Hose Clamp
7-3
MAINTENANCE
19. Using an 11/16” wrench, loosen the
compression fittings on the feedback tube
between the air/fuel valve and the differential
pressure regulator. Remove the feedback
tube (Figure 7.7).
NOTE:
The combustion chamber liner should be
installed prior to reinstalling the exhaust
manifold
20. Using two 9/16” wrenches, remove the two
3/8-16 hex nuts and bolts securing the
air/fuel valve to the differential pressure
regulator (Figure 7.7).
21. Remove the air/fuel valve, taking care not to
damage the flange “O”- ring.
AIR/FUEL
VALVE
COMPRESSION
FITTINGS
Figure 7.8
Manifold Nut and Bolt Locations
3/8 - 16
HEX NUT/BOLT
DIFFERENTIAL PRESS.
REGULATOR
Figure 7.7
Feedback Tube and Air/Fuel Valve to
Differential Regulator Bolts
22. Remove the flue venting from the exhaust
manifold.
23. To prevent damage and simplify handling of
the exhaust manifold, it will be necessary to
remove the exhaust manifold insulation.
Using a 7/16” wrench or socket, remove the
3 bolts and fender washers securing the
insulation to the exhaust manifold (Figure
7.8).
24. Loosen the three 1-1/16” nuts that hold the
manifold. Remove the two side nuts. DO
NOT REMOVE THE FRONT NUT (Figure
7.8).
25. Carefully pull the manifold down and back,
removing it through the back of the unit.
26. Inspect the manifold and exhaust tubes for
debris. Clean out any debris as necessary.
27. Inspect the combustion chamber and liner.
Replace the liner if any signs of cracking or
warping are observed.
7-4
28. Replace the gasket between the manifold
and the combustion chamber (Part Number
GP-122537). The use of Permatex or a
similar gasket adhesive is recommended.
Replace the gasket between the manifold
and tubesheet (Part No. GP-18900). Do not
use any gasket adhesive; this gasket has an
adhesive backing.
29. Beginning with the manifold, reinstall all the
components in the reverse order that they
were removed.
7.7 HEAT EXCHANGER WATER SIDE
INSPECTION
Per CSD-1, the water side of the heat exchanger
requires an inspection. To inspect the heat
exchanger, proceed as follows:
1. Shut off AC power to the unit.
2. Close the supply and return valves to the
unit (Figure 7.9).
3. Open the drain valve and allow the unit to
fully drain. The 1/4 inch plug in the top of
the shell may be removed to aid in drainage
or the relief valve may be opened (Figure
7.9).
MAINTENANCE
1/4" PLUG
RELIEF VALVE
REDUCING
BUSHING
HOT WATER
SUPPLY (OUTLET)
HOT WATER
RETURN (INLET)
REDUCING
BUSHING
DRAIN VALVE
Figure 7.9
Heat Exchanger Supply and Return
Locations
4. Remove the 2 ½ inch plug located in the
shell at the rear of the unit (Figure 7.10).
5. Remove the relief valve, drain valve (Figure
7.9) and any reducing bushings.
6. Perform the inspection. Reassemble the unit
once the inspection is completed.
7. Open the supply and return valves and
reconnect AC power to the unit.
Figure 7.10
Heat Exchanger 2 ½ Inch Inspection Plug
Location
7.8 Condensate Drain Assembly
KC Boilers contain a condensate drain cup
(Figure 2.6) which should be inspected and
cleaned annually to ensure proper operation.
To inspect and clean the assembly, proceed as
follows:
1. Remove the left side panel and left rear
cover to provide access to the condensate
drain components (see Figure 2.6).
2. Disconnect the plastic tubing from the
condensate cup drain tube to the drain.
3. Remove the condensate cup from the unit.
Thoroughly clean the cup and inspect the
cup drain tube for blockage.
4. After the above items have been cleaned
and inspected, reassemble the drain
components by reversing the previous steps.
7-5
TROUBLESHOOTING
Chapter 8- TROUBLESHOOTING GUIDE
8.1 INTRODUCTION
This troubleshooting guide is intended to aid
service/maintenance personnel in isolating the
cause of a fault in a KC1000 Boiler. The troubleshooting procedures contained herein are
presented in tabular form on the following pages.
These tables are comprised of three columns
labeled: Fault Indication, Probable Cause and
Corrective Action. The numbered items in the
Probable Cause and Corrective Action columns
correspond to each other. For example,
Probable Cause No. 1 corresponds to Corrective
Action No. 1, etc.
When a fault occurs in the KC1000 Boiler,
proceed as follows to isolate and correct the
fault:
1. Observe the fault messages displayed in the
Control Box display.
2. Refer to the Fault Indication column in the
following troubleshooting tables and locate
the Fault that best describes the existing
conditions.
3. Proceed to the Probable Cause column and
start with the first item (1) listed for the Fault
Indication.
4. Perform the checks and procedures listed in
the Corrective Action column for the first
Probable Cause candidate.
5. Continue checking each additional Probable
Cause for the existing fault until the fault is
corrected.
6. If the fault cannot be corrected using the
information provided in the Troubleshooting
Tables, please contact your local AERCO
Representative.
8-1
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING
FAULT INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
AIRFLOW FAULT
DURING IGNITION
1. Blower stopped running due to thermal
or current overload
2. Blocked Blower inlet or inlet ductwork
1. Check combustion blower for signs of excessive heat or high
current drain that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.
3. Remove the airflow switch and inspect for signs of blockage,
clean or replace as necessary.
4. Measure the airflow switch for continuity with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the switch.
1. Start the unit. If the blower does not run check the blower solid
state relay for input and output voltage. If the relay is okay, check
the blower.
2. Start the unit. If the blower runs, check the airflow switch for
continuity. Replace the switch if there is no continuity.
3. Remove the air flow switch and inspect for signs of blockage,
clean or replace as necessary.
4. Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.
5. Measure for 24 VAC during start sequence from each side of the
switch to ground. If 24VAC is not present refer to qualified
service personnel.
1. Check combustion blower for signs of excessive heat or high
current draw that may trip thermal or current overload devices.
2. Inspect the inlet to the combustion blower including any ductwork
leading up to the combustion blower for signs of blockage.
3. Remove the airflow switch and inspect for signs of blockage,
clean or replace as necessary.
4. Measure the airflow switch for continuity with the combustion
blower running. If there is an erratic resistance reading or the
resistance reading is greater than zero ohms, replace the switch.
5. Run unit to full fire. If the unit rumbles or runs rough, perform
combustion calibration.
3. Blocked airflow switch
4. Defective airflow switch
AIRFLOW FAULT
DURING PURGE
1. Blower not running or running too slow
2. Defective Air Flow Switch
3. Blocked Air flow Switch
4. Blocked Blower inlet or inlet ductwork.
5. No voltage to switch from control box.
AIRFLOW FAULT
DURING RUN
1. Blower stopped running due to thermal
or current overload
2. Blocked Blower inlet or inlet ductwork
3. Blocked airflow switch
4. Defective airflow switch
5. Combustion oscillations
8-2
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
DELAYED
INTERLOCK OPEN
DIRECT DRIVE
SIGNAL FAULT
FLAME LOSS
DURING IGN
PROBABLE CAUSES
1. Delayed Interlock Jumper not
installed or removed.
2. Device proving switch hooked to
interlocks is not closed
1. Direct drive signal is not present:
Not yet installed.
Wrong polarity.
Signal defective at source.
Broken or loose wiring.
2. Signal is not isolated (floating).
3. Control Box signal type selection
switches not set for correct signal
type (voltage or current).
1. Burner Ground Screw not installed
or loose.
2. Worn flame detector
3. No spark from Spark Plug
4. Defective Ignition Transformer
5. Defective Ignition/Stepper (IGST)
Board
6. Defective SSOV
7. Defective Differential Pressure
Regulator.
8. Carbon or other debris on Burner.
8-3
CORRECTIVE ACTION
1. Check for a jumper properly installed across the delayed
interlock terminals in the I/O box.
2. If there are 2 external wires on these terminals, check to see if
an end switch for a device (i.e. a pump, louver, etc.) is tied to
these interlocks. Ensure that the device and its end switch are
functional. (jumper may be temporarily installed to test interlock
1. Check I/O Box to ensure signal is hooked up.
Hook up if not installed.
If installed, check polarity.
Measure signal level.
Check continuity of wiring between source and boiler.
2. Check signal at source to ensure it is isolated.
3. Check DIP switch on PMC board to ensure it is set correctly for
the type of signal being sent. Check control signal type set in
Configuration Menu.
1. Inspect and install/retighten Burner Ground Screw.
2. Remove and inspect the flame detector for signs of wear.
Replace if necessary.
3. Close the internal gas valve in the boiler. Install and arc a spark
ignitor outside the unit.
4. If there is no spark, check for 120VAC at the primary side to the
ignition transformer during the ignition cycle.
5. If 120VAC is not present, the IGST Board in the Control Box
may be defective. Refer fault to qualified service personnel.
6. While externally arcing the spark ignitor, observe the
open/close indicator in the Safety Shut-Off Valve to ensure it is
opening. If the valve does not open, check for 120VAC at the
valves input terminals. If 120VAC is not present, the IGST
board in the Control Box may be defective. Refer fault to
qualified service personnel.
7. Check gas pressure using gauge or manometer into and out of
the Air/Fuel Valve to ensure gas is getting to burner.
8. Remove burner and inspect for any carbon or debris. Clean and
reinstall
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
FLAME LOSS
DURING RUN
PROBABLE CAUSES
1. Worn Flame Detector or cracked
ceramic.
1. Remove and inspect the Flame Detector for signs of wear or
cracked ceramic. Replace if necessary.
2. Defective Differential Regulator.
2. Check gas pressure readings using a gauge or manometer into
and out of the Air/Fuel Valve to ensure that the gas pressure
into and out of the valve is correct.
3. Check combustion calibration. Adjust as necessary.
4. Remove the burner and inspect for any carbon or debris. Clean
and reinstall.
5. Remove blockage in condensate drain.
1. Press CLEAR button and restart the unit. If the fault persists,
replace Ignition/Stepper (IGST) Board.
3. Poor combustion calibration.
4. Debris on burner.
HEAT DEMAND
FAILURE
HIGH EXHAUST
TEMPERATURE
HIGH GAS
PRESSURE
5. Blocked condensate drain.
1. The Heat Demand Relays on the
Ignition/Stepper board failed to
activate when commanded
2. Relay is activated when not in
Demand
1. Defective exhaust sensor.
2. Carboned heat exchanger due to
incorrect combustion calibration
1. Incorrect supply gas pressure.
2. Defective Supply Regulator or
Wrong Style Regulator
3. Defective High Gas Pressure Switch
8-4
CORRECTIVE ACTION
2. Defective relay. Replace IGST Board.
1. Measure the actual exhaust temperature and continuity of the
o
exhaust sensor. If the exhaust temperature is less than 475 F
and the exhaust sensor shows continuity replace the sensor.
o
2. If exhaust temperature is greater than 500 F, check
combustion calibration. Calibrate or repair as necessary.
1. If using a non-lock up style regulator for the gas supply,
measure static gas pressure downstream, it should be 14”WC
or less. Adjust as necessary.
2. If gas supply pressure cannot be lowered, a lock-up style
regulator may be required or the supply regulator may be
defective.
3. Remove the leads from the high gas pressure switch. Measure
continuity across the common and normally closed terminals
with the unit not firing. Replace the switch if it does not show
continuity.
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
HIGH WATER TEMP
SWITCH OPEN
PROBABLE CAUSES
1. Faulty Water temperature switch.
2. Incorrect PID settings.
3. Faulty shell temperature sensor.
4. Unit in Manual mode
5. Unit setpoint is greater than Over
Temperature Switch setpoint.
6. Boiler Management System PID or
other settings not correctly setup.
7. No interlock to boiler or BMS to
disable boiler(s) in event that system
pumps have failed.
8. System flow rate changes are
occurring faster than boilers can
respond.
HIGH WATER
TEMPERATURE
IGN BOARD
COMM FAULT
8-5
1. See HIGH WATER TEMPERATURE
SWITCH OPEN.
2. Temp HI Limit setting is too low.
1. Communication fault has occurred
between the PMC board and
Ignition/Stepper (IGST) board
CORRECTIVE ACTION
1. Test the temperature switch to insure it trips at its actual water
temperature setting.
2. Check PID settings against Menu Default settings in the
Appendix. If the settings have been changed, record the current
readings then reset them to the default values.
3. Using the resistance charts in the Appendix C, Measure the
resistance of Shell sensor and BTU sensor at a known water
temperature.
4. If unit is in Manual Mode switch to Auto Mode.
5. Check setpoint of unit and setpoint of Temperature Switch;
Ensure that the temperature switch is set higher than the unit’s
setpoint.
6. Check the BMS for changes to PID default values, correct as
necessary.
7. If system pump is controlled by Energy Management System
other than BMS or pumps are individually controlled by boiler,
check to see if there are flow switches interlocked to the BMS or
boiler.
8. If the system is a variable flow system, monitor system flow
changes to ensure that the rate of flow change is not faster than
what the boilers can respond to.
1. See HIGH WATER TEMPERATURE SWITCH OPEN.
2. Check Temp HI Limit setting.
1. Press CLEAR button and restart unit. If fault persists, contact
qualified Service Personnel.
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
IGN SWTCH CLOSED
DURING PURGE
PROBABLE CAUSES
1. Air/Fuel Valve not rotating
2. Defective or shorted switch
3. Switch wired incorrectly
4. Defective Power Supply Board or
fuse
5. Defective IGST Board
IGN SWTCH OPEN
DURING IGNITION
1. Air/Fuel Valve not rotating to ignition
position.
2. Defective ignition switch
3. Defective Power Supply Board or
fuse
4. Defective IGST Board
INTERLOCK
OPEN
1. Interlock jumper not installed or
removed
2. Energy Management System does
not have boiler enabled.
3. Device proving switch hooked to
interlocks is not closed.
8-6
CORRECTIVE ACTION
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position. If the valve does not rotate at all or does not
rotate fully open, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air-Fuel Valve or
the Control Box. Refer to qualified service personnel
2. . If the Air/Fuel Valve does rotate to purge, check the ignition
switch for continuity between the N.O. and COM terminals. If the
switch shows continuity when not in contact with the cam replace
the switch.
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals). If the switch is wired
correctly, replace the switch
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to the
ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve or
the Control Box. Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
ignition position switch for continuity between the N.O. and COM
terminals when in contact with the cam.
3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. Check for a jumper properly installed across the interlock
terminals in the I/O box
2. If there are two external wires on these terminals check any
Energy Management system to see if they have the units
disabled (a jumper may be temporarily installed to see if the
interlock circuit is functioning).
3. Check that proving switch for any device hooked to the interlock
circuit is closing and that the device is operational.
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
LINE VOLTAGE
OUT OF PHASE
LOW GAS
PRESSURE
PROBABLE CAUSES
1. Line and Neutral switched in AC
Power Box.
2. Incorrect power supply transformer
wiring.
1. Incorrect supply gas pressure.
2. Defective or incorrectly sized Gas
Supply Regulator.
3. Defective Low Pressure Gas Switch
LOW WATER
LEVEL
1. Insufficient water level in system
2. Defective water level circuitry.
3. Defective water level probe.
MODBUS COMM
FAULT
PRG SWTCH CLOSED
DURING IGNITION
1. Boiler not seeing information from
Modbus network
1. A/F Valve rotated open to purge and
did not rotate to ignition position
2. Defective or shorted switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or
fuse
8-7
CORRECTIVE ACTION
1. Check hot and neutral in AC Power Box to ensure they are not
reversed
2. Check transformer wiring, in AC Power Box, against the power
box transformer wiring diagram to ensure it is wired correctly
1. Measure gas pressure upstream of the supply gas regulator with
the unit firing ensure it is 14” WC or greater.
2. Measure gas pressure downstream of the supply regulator with
unit firing and adjust the gas supply regulator to increase the
outlet gas pressure; if outlet gas pressure cannot be increased,
check the sizing of the Supply regulator.
3. Measure gas pressure at the low gas pressure switch, if it is
greater than 5” WC, measure continuity across the switch and
replace if necessary.
1. Check system for sufficient water level.
2. Test water level circuitry using the Control Box front panel LOW
WATER TEST and RESET buttons. Replace water level
circuitry if it does not respond.
3. Check continuity of probe end to the shell, change probe if there
is no continuity.
1. Check network connections. If fault persists, contact qualified
Service Personnel.
1. Start the unit. The Air/Fuel Valve should rotate to the purge
(open) position, then back to ignition position (towards closed)
during the ignition cycle. If the valve does not rotate back to the
ignition position, check the Air/Fuel Valve calibration. If
calibration is okay, the problem may be in the Air/Fuel Valve or
the Control Box. Refer fault to qualified service personnel.
2. If the Air/Fuel Valve does rotate to the ignition position, check the
purge switch for continuity between the N.O. and COM terminals.
If the switch shows continuity when not in contact with the cam,
check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
3. If the switch is wired correctly, replace the switch.
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
PROBABLE CAUSES
continued
5. Defective IGST Board
PRG SWTCH OPEN
DURING PURGE
1. Defective purge switch.
2. No voltage present at switch.
3. Switch wired incorrectly.
4. Defective Power Supply Board or
fuse
5. Defective IGST Board
OUTDOOR TEMP
SENSOR FAULT
REMOTE SETPT
SIGNAL FAULT
RESIDUAL
FLAME
1. Loose or broken wiring.
2. Defective Sensor.
3. Incorrect Sensor.
1. Remote setpoint signal not present:
Not yet installed.
Wrong polarity.
Signal defective at source.
Broken or loose wiring.
2. Signal is not isolated (floating) if 4 to
20 mA.
3. Control Box signal type selection
switches not set for correct signal
type (voltage or current).
1. SSOV not fully closed.
CORRECTIVE ACTION
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. If the air-fuel valve does rotate, check the purge switch for
continuity when closing. Replace switch if continuity does not
exist.
2. Measure for 24 VAC from each side of the switch to ground. If
24VAC is not present, refer fault to qualified service personnel.
3. Check to ensure that the switch is wired correctly (correct wire
numbers on the normally open terminals).
4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
1. Inspect Outdoor Temperature sensor for loose or broken wiring.
2. Check resistance of sensor to determine if it is within
specification.
3. Ensure that the correct sensor is installed.
1. Check I/O Box to ensure signal is hooked up.
Hook up if not installed.
If installed, check polarity.
Measure signal level.
Check continuity of wiring between source and boiler.
2. Check signal at source to ensure it is isolated.
3. Check DIP switch on PMC board to ensure it is set correctly for
the type of signal being sent. Check control signal type set in
Configuration Menu.
1. Check open/close indicator window of Safety Shut-Off Valve
(SSOV) and ensure that the SSOV is fully closed. If not fully
closed, replace the valve and or actuator.
Close gas shut-off valve downstream of SSOV. Install a
manometer or gauge in a gas test port between the SSOV and
the gas shut off valve. If a gas pressure reading is observed
replace the SSOV valve and or actuator.
8-8
TROUBLESHOOTING
TABLE 8-1. BOILER TROUBLESHOOTING – Continued
FAULT INDICATION
(continued)
SSOV FAULT
DURING PURGE
SSOV FAULT
DURING RUN
SSOV RELAY
FAILURE
SSOV
SWITCH OPEN
PROBABLE CAUSES
2. Defective Flame Detecto
See SSOV SWITCH OPEN
2. Replace Flame Detector.
1. SSOV switch closed for 15 seconds
during run.
1. SSOV relay failed on board.
1. Replace or adjust microswitch in SSOV actuator. If fault
persists, replace actuator.
1. Press CLEAR button and restart unit. If fault persists, replace
Ignition/Stepper (IGST) Board.
1. Actuator not allowing for full closure
of gas valve
1. Observe operation of the Safety Shut-Off Valve (SSOV) through
indicator on the Valve actuator and ensure that the valve is fully
and not partially closing.
2. If the SSOV never closes, it may be powered continuously. Close
the gas supply and remove power from the unit. Refer fault to
qualified service personnel.
3. Remove the electrical cover from the SSOV and check switch
continuity. If the switch does not show continuity with the gas
valve closed, either adjust or replace the switch or actuator.
4. Ensure that the SSOV Proof of Closure switch is correctly wired.
1. Refer to GF-112 and perform Stepper Test (para. 6.3.5) to
ensure stepper motor rotates properly between the 0% (fully
closed) and 100% (fully open) positions. Verify that the FIRE
RATE bargraph and the dial on the Air/Fuel Valve track each
other to indicate proper operation. If operation is not correct,
perform the Stepper Feedback Calibration (GF-112, para. 6.2.1).
2. Check that the Air/Fuel Valve is connected to the Control Box.
3. .Inspect for loose connections between the Air/Fuel Valve motor
and the wiring harness.
4. Replace stepper motor.
2. SSOV powered when it should not be
3. Defective Switch or Actuator
STEPPER MOTOR
FAILURE
4. Incorrectly wired switch.
1. Air/Fuel Valve out of calibration.
2. Air/Fuel Valve unplugged.
3. Loose wiring connection to the
stepper motor.
4. Defective Air/Fuel Valve stepper
motor.
5. Defective Power Supply Board or
fuse
6. Defective IGST Board
8-9
CORRECTIVE ACTION
5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not
steady ON, replace Power Supply Board.
6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF
every second. If not, replace IGST Board.
APPENDIX A
BOILER MENU ITEM DESCRIPTIONS
MENU LEVEL & OPTION
DESCRIPTION
OPERATING MENU
Active Setpoint
This is the setpoint temperature to which the
control is operating when operating in the
Constant Setpoint, Remote Setpoint or Outdoor
Reset Mode. When in the Constant Setpoint
Mode, this value is equal to the Internal Setpoint
setting in the Configuration Menu. When in the
Remote Setpoint Mode, this value is the setpoint
equivalent to the remote analog signal supplied to
the unit. When in the Outdoor Reset Mode, this is
the derived value from the charts in Appendix D.
Aux Temp
For monitoring purposes only
Outdoor Temp
Displayed only if an outdoor sensor is installed and
enabled in the Configuration Menu.
Fire Rate In
Indicates desired input fire rate. This will normally
be the same as the fire rate shown on the bargraph (fire rate out) when the boiler is operating.
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
999,999.
Fault Log
Displays information on the last 9 faults.
A-1
APPENDIX A
BOILER MENU ITEM DESCRIPTIONS - Continued
MENU LEVEL & OPTION
DESCRIPTION
SETUP MENU
Password
Allows password to be entered.
Once the valid password (159) is entered, options in
the Setup, Configuration and Tuning Menus can be
modified.
Language
English Only
Time
Displays time from 12:00am to 11:59pm.
Date
Displays dates from 01/01/00 to 12/31/99
Unit of Temp
Permits selection of temperature displays in
degrees Fahrenheit (°F) or degrees Celsius (°C).
Default is °F.
Comm Address
For RS-485 (MODBUS) communications (0 to 255).
Default address is 0. RS-232 should have its own
(programmable) password.
Baud Rate
Allows communications Baud Rate to be set (2400
to 19.2K). Default is 9600.
Software Version
Identifies the current software version of the control
box.
CONFIGURATION MENU
A-2
Internal Setpoint
Allows internal setpoint to be set . Default is 130°F.
Unit Type
Allows selection of Boiler or Water Heater. Default
is Boiler.
Unit Size
Sets unit size from 0.5 to 3.0 MBTUs. Default is 1.0
MBTU.
Boiler Mode
It allows selection of: Constant Setpoint, Remote
Setpoint, Direct Drive, Combination, or Outdoor
Reset Mode. Default is Constant Setpoint Mode.
Remote Signal
Used to set the type of external signal which will be
used when operating in the Remote Setpoint, Direct
Drive or Combination Mode. The factory default is
4-20 mA/1-5V.
Bldg Ref Temp
Allows the building reference temperature to be set
when operating a boiler in the Outdoor Reset Mode.
Default is 70°F.
APPENDIX A
BOILER MENU ITEM DESCRIPTIONS - Continued
MENU LEVEL & OPTION
DESCRIPTION
Reset Ratio
Permits setting of Reset Ratio when operating boiler
in the Outdoor Reset Mode. Reset Ratio is
adjustable from 0.1 to 9.9. Default is 1.2.
Outdoor Sensor
Allows outdoor sensor function to be enabled or
disabled. Default is Disabled.
System Start Tmp
If outdoor sensor is enabled in the Configuration
Menu, this menu item allows the system start
temperature to be set from 30°F to 100°F. Default
is 60°F.
Setpoint Lo Limit
Used to set the minimum allowable setpoint (40°F to
Setpoint Hi Limit). Default is 60°F
Setpoint Hi Limit
Used to set the maximum allowable setpoint
(Setpoint Lo Limit to 240°F). Default is 200°F.
Temp Hi Limit
Used to set the maximum allowable outlet
temperature (40°F to 240°F). Any temperature
above this setting will turn off the unit. The
temperature must then drop 5°F below this setting
to allow the unit to run. Default Temp Hi Limit is
215°F.
Max Fire Rate
Sets the maximum allowable fire rate for the unit
(40% to 100%). Default is 100%.
Pump Delay Timer
Specifies the amount of time (0 to 30 min.) to keep
the pump running after the unit turns off. Default is
zero.
Aux Start On Dly
Specifies the amount of time to wait (0 to 120 sec.)
between activating the Aux Relay (due to a demand)
and checking the pre-purge string to start the boiler.
Default is 0 sec.
Failsafe Mode
Allows the Failsafe mode to be set to either
Constant Setpoint or Shutdown. Default is
Shutdown.
mA Output
Can be set to allow this output to monitor Setpoint,
Outlet Temperature, Fire Rate Out or be set to OFF.
Default is OFF.
Lo Fire Timer
Specifies how long (2 to 120 sec.) to remain in the
low fire position after ignition, before going to the
desired output. Default is 2 sec.
A-3
APPENDIX A
BOILER MENU ITEM DESCRIPTIONS - Continued
MENU LEVEL & OPTION
DESCRIPTION
Setpt Limiting
Allows Setpoint Limiting to be enabled or disabled.
Default is disabled.
Setpt Limit Band
If Setpoint Limiting is enabled, this menu item allows
the Setpt Limit Band to be set from 0°F to 10°F.
Default is 5°F.
TUNING MENU
A-4
Prop Band
Generates a fire rate based on the error that exists
between the setpoint temperature and the actual
outlet temperature. If the actual error is less than
the proportional band setting (1 to 120°F), the fire
rate will be less than 100%. If the error is equal to
or greater than the proportional band setting, the fire
rate will be 100%. Default is 70°F.
Integral Gain
This sets the fraction of the output, due to setpoint
error, to add or subtract from the output each minute
to move towards the setpoint. Gain is adjustable
from 0.00 to 2.00. Default is 1.00.
Derivative Time
This value (0.0 to 2.00 min.) responds to the rate of
change of the setpoint error. This is the time that
this action advances the output. Default is 0.0 min.
Reset Defaults?
Allows Tuning Menu options to be reset to their
Factory Default values.
APPENDIX B
STARTUP, STATUS AND FAULT MESSAGES
STARTUP AND STATUS MESSAGES
MESSAGE
DISABLED
HH:MM pm MM/DD/YY
STANDBY
DEMAND DELAY
XX sec
PURGING
XX sec
IGNITION TRIAL
XX sec
FLAME PROVEN
WARMUP
XX sec
WAIT
DESCRIPTION
Displayed if ON/OFF switch is set to OFF. The display also
shows the time and date that the unit was disabled.
Displayed when ON/OFF switch is in the ON position, but
there is no demand for heat. The time and date are also
displayed.
Displayed if Demand Delay is active.
Displayed during the purge cycle during startup. The
duration of the purge cycle counts up in seconds.
Displayed during ignition trial of startup sequence. The
duration of cycle counts up in seconds.
Displayed after flame has been detected for a period of 2
seconds. Initially, the flame strength is shown in %. After 5
seconds has elapsed, the time and date are shown in place
of flame strength.
Displayed for 2 minutes during the initial warmup only.
Prompts the operator to wait.
B-1
APPENDIX B
FAULT MESSAGES
FAULT MESSAGE
HIGH WATER TEMP
SWITCH OPEN
LOW WATER
LEVEL
LOW GAS
PRESSURE
HIGH GAS
PRESSURE
INTERLOCK
OPEN
DELAYED
INTERLOCK OPEN
AIRFLOW FAULT
DURING PURGE
PRG SWTCH OPEN
DURING PURGE
IGN SWTCH OPEN
DURING IGNITION
IGN SWTCH CLOSED
DURING PURGE
PRG SWTCH CLOSED
DURING IGNITION
AIRFLOW FAULT
DURING IGN
AIRFLOW FAULT
DURING RUN
SSOV
SWITCH OPEN
SSOV FAULT
DURING PURGE
SSOV FAULT
DURING IGN
SSOV FAULT
DURING RUN
SSOV RELAY
FAILURE
FLAME LOSS
DURING IGN
FLAME LOSS
DURING RUN
HIGH EXHAUST
TEMPERATURE
LOSS OF POWER
B-2
FAULT DESCRIPTION
The High Water Temperature Limit Switch is open.
The Water Level Control board is indicating low water level.
The Low Gas Pressure Limit Switch is open.
The High Gas Pressure Limit Switch is open.
The Remote Interlock is open.
The Delayed Interlock is open.
The Blower Proof Switch opened during purge.
The Purge Position Limit switch on the air/fuel valve opened
during purge.
The Ignition Position Limit switch on the air/fuel valve opened
during ignition.
The Ignition Position Limit switch on the air/fuel valve closed
during purge.
The Purge Position Limit switch on the air/fuel valve closed
during ignition.
The Blower Proof Switch opened during ignition.
The Blower Proof Switch opened during run.
The SSOV switch opened during standby.
The SSOV switch opened during purge.
The SSOV switch closed or failed to open during ignition.
The SSOV switch closed for more than 15 seconds during
run.
A failure has been detected in one of the relays that control
the SSOV.
The Flame signal was not seen during ignition or lost within 5
seconds after ignition.
The Flame signal was lost during run.
The High Exhaust Temperature Limit Switch is closed.
A power loss had occurred. The time and date when power
was restored is displayed.
APPENDIX B
FAULT MESSAGES - Continued
FAULT MESSAGE
RESIDUAL
FLAME
HEAT DEMAND
FAILURE
IGN BOARD
COMM FAULT
DIRECT DRIVE
SIGNAL FAULT
REMOTE SETPT
SIGNAL FAULT
OUTDOOR TEMP
SENSOR FAULT
OUTLET TEMP
SENSOR FAULT
FFWD TEMP
SENSOR FAULT
HIGH WATER
TEMPERATURE
LINE VOLTAGE
OUT OF PHASE
STEPPER MOTOR
FAILURE
NETWORK COMM
FAULT
FAULT DESCRIPTION
The Flame signal was seen for more than 60 seconds during
standby.
The Heat Demand Relays on the Ignition board failed to
activate when commanded.
A communication fault has occurred between the PMC board
and Ignition board.
The direct drive signal is not present or is out of range.
The remote setpoint signal is not present or is out of range.
The temperature measured by the Outdoor Air Sensor is out
of range.
The temperature measured by the Outlet Sensor is out of
range.
The temperature measured by the FFWD Sensor is out of
range.
The temperature measured by the Outlet Sensor exceeded
the Temp Hi Limit setting.
The High AC voltage is out of phase from the low AC voltage.
The stepper motor failed to move the valve to the desired
position.
The RS-485 network information is not present or is
corrupted.
B-3
APPENDIX C
Temperature Sensor Resistance Chart
(Balco)
C-1
APPENDIX D
INDOOR/OUTDOOR RESET RATIO CHARTS
Header Temperature for a Building Reference Temperature of 50F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
-5F
-10F
-15F
-20F
50
53
56
59
62
65
68
71
74
77
80
83
86
89
92
50
54
58
62
66
70
74
78
82
86
90
94
98
102
106
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
50
56
62
68
74
80
86
92
98
104
110
116
122
128
134
50
57
64
71
78
85
92
99
106
113
120
127
134
141
148
50
58
66
74
82
90
98
106
114
122
130
138
146
154
162
50
59
68
77
86
95
104
113
122
131
140
149
158
167
176
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
50
60
72
83
94
105
116
127
138
149
160
171
182
193
204
50
62
74
86
98
110
122
134
146
158
170
182
194
206
218
Header Temperature for a Building Reference Temperatrure of 60F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
-5F
-10F
-15F
-20F
60
63
66
69
72
75
78
81
84
87
90
93
96
99
102
105
108
60
64
68
72
76
80
84
88
92
96
100
104
108
112
116
120
124
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
150
156
60
67
74
81
88
95
102
109
116
123
130
137
144
151
158
165
172
60
68
76
84
92
100
108
116
124
132
140
148
156
164
172
180
188
60
69
78
87
96
105
114
123
132
141
150
159
168
177
186
195
204
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
60
71
82
93
104
115
126
137
148
159
170
181
192
203
214
60
72
84
96
108
120
132
144
156
168
180
192
204
216
D-1
APPENDIX D
Header Temperature for a Building Reference Temperature of 65F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
65
60
55
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
65
68
71
74
77
80
83
86
89
92
95
98
101
104
107
110
113
116
65
69
73
77
81
85
89
93
97
101
105
109
113
117
121
125
129
133
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
65
71
77
83
89
95
101
107
113
119
125
131
137
143
149
155
161
167
65
72
79
86
93
100
107
114
121
128
135
142
149
156
163
170
177
201
65
73
81
89
97
105
113
121
129
137
145
153
161
169
177
185
193
218
65
74
83
92
101
110
119
128
137
146
155
164
173
182
191
200
209
65
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
65
76
87
98
109
120
131
142
153
164
175
186
197
208
219
65
77
89
101
113
125
137
149
161
173
185
197
209
Header Temperature for a Building Reference Temperature of 70F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
-5F
-10F
-15F
-20F
70
73
76
79
82
85
88
91
94
97
100
103
106
109
112
115
118
121
124
70
74
78
82
86
90
94
98
102
106
110
114
118
122
126
130
134
138
142
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
70
76
82
88
94
100
106
112
118
124
130
136
142
148
154
160
166
172
178
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
182
189
196
70
78
86
94
102
110
118
126
134
142
150
158
166
174
182
190
198
206
214
70
79
88
97
106
115
124
133
142
151
160
169
178
187
196
205
214
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
70
81
92
103
114
125
136
147
158
169
180
191
202
213
70
82
94
106
118
130
142
154
166
178
190
202
214
D-2
APPENDIX D
Header Temperature for a Building Reference Temperature of 75F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
75F
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
-5F
-10F
-15F
75
78
81
84
87
90
93
96
99
102
105
108
111
114
117
120
123
126
129
75
79
83
87
91
95
99
103
107
111
115
119
123
127
131
135
139
143
147
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
75
81
87
93
99
105
111
117
123
129
135
141
147
153
159
165
171
177
183
75
82
89
96
103
110
117
124
131
138
145
152
159
166
173
180
187
194
201
75
83
91
99
107
115
123
131
139
147
155
163
171
179
187
195
203
211
219
75
84
93
102
111
120
129
138
147
156
165
174
183
192
201
210
219
75
85
95
105
115
125
135
145
155
165
175
185
195
205
215
75
86
97
108
119
130
141
152
163
174
185
196
207
218
75
87
99
111
123
135
17
159
171
183
195
207
219
Header Temperature for a Building Reference Temperature of 80F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
80F
75F
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
-5F
-10F
80
83
86
89
92
95
98
101
104
107
110
113
116
119
122
125
128
131
134
80
84
88
92
96
100
104
108
112
116
120
124
128
132
136
140
144
148
152
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
80
86
92
98
104
110
116
122
128
134
140
146
152
158
164
170
176
182
188
80
87
94
101
108
115
122
129
136
143
150
157
164
171
178
185
192
199
206
80
88
96
104
112
120
128
136
144
152
160
168
176
184
192
200
208
216
80
89
98
107
116
125
134
143
152
161
170
174
188
197
206
215
80
90
100
110
120
130
140
150
160
170
180
190
200
210
80
91
102
113
124
135
146
157
168
179
190
201
212
80
92
104
116
128
140
152
164
176
188
200
212
D-3
APPENDIX D
Header Temperature for a Building Reference Temperature of 90F
RESET RATIO
Air
Temp
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
90F
85F
80F
75F
70F
65F
60F
55F
50F
45F
40F
35F
30F
25F
20F
15F
10F
5F
0F
90
93
96
99
102
105
108
111
114
117
120
123
126
129
132
135
138
141
144
90
94
98
102
106
110
114
118
122
126
130
134
138
142
146
150
154
158
162
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
90
96
102
108
114
120
126
132
138
144
150
156
162
168
174
180
186
192
198
90
97
104
111
118
125
132
139
146
153
160
167
174
181
188
195
202
209
216
90
98
106
114
122
130
138
146
154
162
170
178
186
194
202
210
218
90
99
108
117
126
135
144
153
162
171
180
189
198
207
216
90
100
110
120
130
140
150
160
170
180
190
200
210
90
101
112
123
134
145
156
167
178
189
200
90
102
114
126
138
150
162
174
186
198
210
D-4
APPENDIX E
BOILER DEFAULT SETTINGS
MENU & OPTION
FACTORY DEFAULT
Setup Menu
Password
0
Language
English
Unit of Temp
Comm Address
Baud Rate
Fahrenheit
0
9600
Configuration Menu
Internal Setpt
130°F
Unit Type
Boiler
Unit Size
1.0 MBTU
Boiler Mode
Remote Signal
(If Mode = Remote Setpoint, Direct Drive or
Combination)
Constant Setpoint
4 – 20 mA /1-5V
Bldg Ref Temp
(If Boiler Mode = Outdoor Reset)
70°F
Reset Ratio
(If Boiler Mode = Outdoor Reset)
1.2
Outdoor Sensor
System Start Tmp
(If Outdoor Sensor = Enabled)
Disabled
60°F
Setpt Lo Limit
60°F
Setpt Hi Limit
Temp Hi Limit
200°F
Max Fire Rate
215°F
100%
Pump Delay Timer
0 min
Aux Start On Dly
0 sec
Failsafe Mode
mA Output
Lo Fire Timer
Setpt Limit Band (If Setpt Limiting = Enabled)
Shutdown
Off
2 sec
5°F
Tuning Menu
Prop Band
70°F
Integral Gain
1.00
Derivative Time
0.0 min
E-1
APPENDIX F
F-1
APPENDIX F
F-2
APPENDIX F
F-3
APPENDIX F
F-4
APPENDIX F
F-5
APPENDIX F
F-6
APPENDIX G
G-1
APPENDIX G
G-2
APPENDIX G
G-3
APPENDIX H
H-1
ECO
2
3
4
6
REVISIONS
SEE SHEET ONE
237
7
236
5
235
8
238
240
241
242
243
244
245
9 10 11 12 13 14 15
239
THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL, INC. THEY ARE ISSUED IN STRICT CONFIDENCE AND
SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER.
REV
J1
1
234
8
233
13
232
DATE
247
16 1
246
2
BY
4
251
5
252
6
253
8
7
254
CK'D
J3
B
ORIGINAL
DWG. SIZE
16-PIN CONNECTOR
CHECKED BY:
DRAWN BY:
226
MD
LS3
LS4
J2
1
2
DATE:
DATE:
061302
ALL DIMENSIONS ARE AFTER FINISH OR PLATING
4
220
LS2
3
221
6
MAT'L SPEC.:
TITLE
7
216
8 7 6
LS1
5
219
16 15 14 13 12 11 10 9
ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE
AS FOLLOWS UNLESS OTHERWISE SPECIFIED
XX ±.015 XXX ± .005 FRACTIONS 1/32± ANGLES ±1°
DIAMETERS ON A COMMON AXIS .005 TOTAL
PERPENDICULARITY/PARALLELISM/FLATNESS .003 TOTAL
THIRD ANGLE PROJECTION
INPUT/OUTPUT BOX
3
250
2
231
1
2
OUTDOOR AIR SENSOR IN
SENSOR COMMON IN
3
4
AUX SENSOR IN
5
+
6
CO SENSOR IN
7
FLOW SENSOR IN
+
9
+
10
-
OXYGEN SENSOR IN
11
SENSOR EXCIT. (12 VDC)
12
+
14
+
ANALOG IN
16
SHIELD
15
-
BMS (PWM) IN
-
1
2
+
ANALOG OUT
4
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
IN
1
3
-
+
GND
RS-485 IN
1
A
2
B
3
A
LONWORKS
B
OUT
1 2 3
4
1
CONTROL BOX CONNECTORS
3
C
N.C.
AUX
7
6
NOT USED
5
N.O.
2
FAULT
N.O.
RELAY
1
C
N.C.
RELAY
8
215
213
3
212
211
2 1
9 10 11 12
214
5 4
7
6
NOT USED
5
4
SHEET 2 OF 2
161613
DWG. NO.:
GAS FIRED BOILER SYSTEM
WIRING SCHEMATIC
(KC 1000)
159 PARIS AVE, NORTHVALE, N.J.
INTERNATIONAL INC.
IN
OUT
DELAYED INTLK
3
EXHAUST TEMP
2
IN
OUT
1
IN
OUT
REMOTE INTLK
H-2
24-PIN CONNECTOR
C
REV
APPENDIX H
APPENDIX I
KC1000 CONTROL PANEL EXPLODED VIEW
I-1
APPENDIX I
KC1000 CONTROL PANEL REAR VIEW
I-2
APPENDIX J
KC1000 LOW NOx DUAL-FUEL
SWITCH-OVER INSTRUCTIONS
The KC1000 Low NOx Boiler is shipped from the factory configured for either natural gas or
propane operation, as specified on the Sales Order. However, if required, the unit’s operating
configuration can be easily switched from natural gas to propane (or vice-versa) by performing a
simple change to the spring contained in the unit’s differential regulator.
The extra spring required to switch from natural gas to propane, or from propane to natural gas
is included with the unit accessories (see Chapter 2, para. 2.2). Units configured for natural gas
operation include a zinc-plated regulator spring, part no. 124803. Units configured for propane
operation include a brown painted spring, part no. 122548.
The following instructions provide the steps necessary 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 counterclockwise. Remove the installed zinc-plated regulator spring (124803) used for Natural
Gas operation. DO NOT DISCARD THE REMOVED SPRING.
5. Install the brown painted spring (122548) required for Propane operation.
6. Replace the regulator adjustment screw. Rotate the screw clockwise to a depth of 1-1/2
inches from the top of the regulator housing.
7. Upon completion of the spring change, perform the combustion calibration procedures in
Section 4 of this Instruction Manual.
FIGURE 1. REGULATOR SPRING REPLACEMENT
J -1
INTERNATIONAL, INC.
STANDARD WARRANTY:
Gas-Fired Hydronic Boiler
Model KC-1000GWB & PWB (Propane)
PRESSURE VESSEL: 10 YEARS NON-PRORATED
The shell shall carry a non-prorated 10 year guarantee from shipment against leakage due to
thermal shock, mechanical defects or workmanship. The shell will not be covered for waterside
corrosion.
HEAT EXCHANGER TUBES/COMBUSTION CHAMBER: 5 YEARS
The heat exchanger/combustion chamber shall carry a 5 year, non-prorated, warranty from
shipment against any condensate corrosion, thermal stress failure, mechanical defects or
workmanship. Operation of the boiler using contaminated air will void the warranty. The heat
exchangers combustion chamber shall not be warranted from failure due to scaling, liming,
corrosion, or erosion due to water or installation conditions. AERCO will repair, rebuild or
exchange, at its option the heat exchanger/combustion chamber for the warranted time period.
“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 ignitor and flame detector, are conditionally
guaranteed against any failure for 18 months from shipment.
AERCO shall accept no responsibility if such item has been improperly installed, operated, or
maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or
repairs to the item.
The warranty as set forth on the back page of the Operations & Maintenance Manual is in lieu
of and not in addition to any other express or implied warranties in any documents, or under
any law. No salesman or other representative of AERCO has any authority to expand
warranties beyond the face of the said warranty and purchaser shall not rely on any oral
statement except as stated in the said warranty. Any modifications to this warranty must be
done in writing by an Officer of AERCO. AERCO MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER
EXPRESS OR IMPLIED WARRANTIES. AERCO disclaims all responsibility for any special,
incidental or consequential damages. any claim relating to the product must be filed with
AERCO not later than 14 days after the event giving rise to such claim. Any claims relating to
this product shall be limited to the sale price of the product at the time of sale. The sale of the
product is specifically conditioned upon acceptance of these terms.
03/01/05
W-1
(C102.0)
INTERNATIONAL, INC.
STANDARD WARRANTY:
Gas-Fired Hydronic Boiler
Model KC-1000GWB & PWB (Propane)
CONDITIONS OF WARRANTY
Should an AERCO gas-fired (natural gas or propane only) water heater or hydronic boiler fail
for any of the above reasons within the specified time period from the date of original
shipment(s), AERCO shall at its option modify, repair or exchange the defective item. AERCO
shall have the option of having the item returned, FOB its factory, or to make field replacements
at the point of installation. In no event shall AERCO be held liable for replacement labor
charges or for freight or handling charges.
AERCO shall accept no responsibility if such item has been improperly installed, operated, or
maintained or if the buyer has permitted any unauthorized modification, 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 the item's return
address, register number and factory authorized RGA number.
Warranty coverage for all components and equipment mentioned in said warranty are not valid
unless the water heater or hydronic boiler is started up by a factory certified SST (Service,
Start-Up and Troubleshooting) Technician and an AERCO start-up sheet is completed.
This warranty coverage is only applicable within the United States and Canada. All other
geographical areas carry a standard warranty of 18 months from date of shipment or 12 months
from startup, whichever comes first.
03/01/05
W-2
(C102.1)