Aerco KC1000 Boiler equipped with C-More 2002 Bedienungsanleitung

Printed in U.S.A. REVISED, OCTOBER, 2010 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey,

APPENDIX F F-4 14636451635341549175218293343313230404114223727 28CPLG. W/PLUGSIGHT PORT535413PARTS LISTNORTHVALE, NJ 07647INTERNATIONAL, INC.PL-A-1

APPENDIX F F-5 1 1/2" SAFETY SHUT-OFF VALVEDIFFERENTIAL PRESSURE REGULATOR W/ BROWN SPRINGBURNER/GAS VA. ADAPTOR23451GM-161095GAS COCKGP-122415

APPENDIX F F-6 HIGH GASPRESSURE SWITCHPN: GP-122412REV.KC1000 BOILER IRI GAS TRAIN030801PDRDWN.BY DATENTSSCALEAPPD. DATESD-A-584FNORTHVALE, NJ 0764

APPENDIX G G-1

APPENDIX G G-2

APPENDIX H H-1 CLOSURE SWITCHPROOF OFGRNWHT60 Hz120 VAC IN20 ANEUGNDHOTNCCGNHGNDHGN123456123456789123456789101112131415123456789101112CONTROL BOX CONN

APPENDIX H H-2 CONTROL BOX CONNECTORSGAS FIRED BOILER SYSTEMWIRING SCHEMATIC1616131210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 2422

APPENDIX I I-1 CONNECTOR BOARDP/N 124366POWER SUPPLY BOARDP/N 124362LOW WATER CUTOFF BOARD P/N 124363PMC BOARDP/N 124364IGNITION/STEPPER BOARD

APPENDIX I I-2 P1P2P3P4P5P6SHELL HARNESSCONNECTOR(19 PIN)INTERLOCK HARNESSCONNECTOR(16 PIN)EXT. SENSOR/COMMHARNESS CONNECTOR(24 PIN)GAS TRAIN

03/01/05 W-1 (C102.0) STANDARD WARRANTY: Gas-Fired Hydronic Boiler Model KC-1000GWB & PWB (Propane) INTERNATIONAL, INC. PR

INSTALLATION 2-1 SECTION 2 - INSTALLATION PROCEDURES 2.1. RECEIVING THE UNIT Each KC1000 Boiler is shipped as a single crated unit. The crated

03/01/05 W-2 (C102.1) STANDARD WARRANTY: Gas-Fired Hydronic Boiler Model KC-1000GWB & PWB (Propane) INTERNATIONAL, INC. CO

INSTALLATION 2-2 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Figure 2.1. The minimum clearanc

INSTALLATION 2-3 Figure 2.3 Supply and Return Location Whether installing single or multiple units, install the piping and accessories as shown i

INSTALLATION 2-4 SHELLCAPPARTIAL TOP VIEW OF BOILERFOR INSTALLATION OF PRESS./TEMP. GAUGEPART NO. 122994-1 (PRESS. RANGE 0 – 75 PSI)SYSTEMSUPPLY1/2&q

INSTALLATION 2-5 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

INSTALLATION 2-6 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. Con

INSTALLATION 2-7 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.

INSTALLATION 2-8 (Direct Drive Mode) of the Boiler. These formats are: 4 to 20 mA/1 to 5 Vdc 0 to 20 mA/0 to 5 Vdc PWM – (Pulse Width Modulated sig

INSTALLATION 2-9 voltage rather than current is selected as the drive signal, a DIP switch must be set on the CPU Board located inside the Control B

Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday) (800) 526-0288 AERCO In

INSTALLATION 2-10 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 faul

CONTROL PANEL OPERATING PROCEDURES 3-1 SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION The information in this Section provides a

CONTROL PANEL OPERATING PROCEDURES 3-2 Table 3-1. Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 Fo

CONTROL PANEL OPERATING PROCEDURES 3-3 Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM NO. CONTROL, INDICATOR OR DISPLAY F

CONTROL PANEL OPERATING PROCEDURES 3-4 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu wil

CONTROL PANEL OPERATING PROCEDURES 3-5 NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Out

CONTROL PANEL OPERATING PROCEDURES 3-6 Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Intern

CONTROL PANEL OPERATING PROCEDURES 3-7 3.7. TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change

CONTROL PANEL OPERATING PROCEDURES 3-8 3. With all required safety switches closed, a purge cycle will be initiated and the following events will occ

CONTROL PANEL OPERATING PROCEDURES 3-9 STEPPERMOTORDETAIL "A"DIAL(DETAIL “A”)BLOWERBURNER25 Figure 3-6. Air/Fuel Valve In Ignition Positio

CONTENTS i GF-109 - THE AERCO KC1000 GAS FIRED BOILER Operating & Maintenance Instructions FOREWARD A SECTION 1 – SAFETY PRECAUTIONS 1-1 Para

CONTROL PANEL OPERATING PROCEDURES 3-1 SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION The information in this Section provides a

CONTROL PANEL OPERATING PROCEDURES 3-2 Table 3-1. Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 Fo

CONTROL PANEL OPERATING PROCEDURES 3-3 Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM NO. CONTROL, INDICATOR OR DISPLAY F

CONTROL PANEL OPERATING PROCEDURES 3-4 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu wil

CONTROL PANEL OPERATING PROCEDURES 3-5 NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Out

CONTROL PANEL OPERATING PROCEDURES 3-6 Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Intern

CONTROL PANEL OPERATING PROCEDURES 3-7 3.7. TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change

CONTROL PANEL OPERATING PROCEDURES 3-8 3. With all required safety switches closed, a purge cycle will be initiated and the following events will occ

CONTROL PANEL OPERATING PROCEDURES 3-9 STEPPERMOTORDETAIL "A"DIAL(DETAIL “A”)BLOWERBURNER25 Figure 3-6. Air/Fuel Valve In Ignition Positio

CONTENTS ii SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1 Para. Subject Page 6.1 Testing of Safety Devices 6-1 6.2 Low Gas Pressure Fault Test 6-

INITIAL START-UP 4-1 SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the KC-1000 Boiler is comprised of the

INITIAL START-UP 4-2 SSOV1/4" NPT PLUG(INSTALLMANOMETERHERE) Figure 4.1 1/8” Gas Plug Location 4.2.3 PREPARING THE FLUE VENT PROBE HOLE 1. I

INITIAL START-UP 4-3 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)

INITIAL START-UP 4-4 12. If the measured oxygen level is within the range in Table 1, no adjustment is necessary. Proceed to step 17. 13. If the mea

INITIAL START-UP 4-5 22. If the measured oxygen reading is above the oxygen range in Table 3, loosen the two 7/16" locking nuts securing the inl

INITIAL START-UP 4-6 4.5 UNIT REASSEMBLY Once combustion calibration is set properly, the unit can be reassembled for permanent operation as follow

INITIAL START-UP 4-1 SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the KC-1000 Boiler is comprised of the

INITIAL START-UP 4-2 SSOV1/8" NPT PLUG(INSTALLMANOMETERHERE) Figure 4.1 1/8” Gas Plug Location 4.2.3 PREPARING THE FLUE VENT PROBE HOLE 1. I

INITIAL START-UP 4-3 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

FOREWORD A Foreword The AERCO KC boiler is a true industry advance that meets the needs of today's energy and environmental concerns. De

INITIAL START-UP 4-4 NOTE: Adjust only the differential regulator at 30% control signal; do not adjust the air shutter. 19. When the oxygen level is

INITIAL START-UP 4-5 NOTE: Adjust the inlet air shutter only at 100% firing rate. Do not adjust the differential pressure regulator. 28. Change the f

INITIAL START-UP 4-6 7. Remove the combustion analyzer probe from the vent hole. Seal the probe hole and replace the vent connection cover. 8. R

MODE OF OPERATION 5-1 SECTION 5 - MODE OF OPERATION 5.1 INTRODUCTION The following paragraphs provide detailed descriptions of the six different

MODE OF OPERATION 5-2 11. Press the CHANGE key. The display will begin to flash. 12. Use the ▲ and ▼ arrow keys to select the reset ratio determi

MODE OF OPERATION 5-3 If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to

MODE OF OPERATION 5-4 If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to

MODE OF OPERATION 5-5 5.7 COMBINATION CONTROL SYSTEM (CCS) NOTE Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5

SAFETY DEVICE TESTING 6-1 SECTION 6-SAFETY DEVICE TESTING PROCEDURES 6.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety devi

SAFETY DEVICE TESTING 6-2 HIGH GASPRESSURE SWITCH Figure 6.2 High Gas Pressure Switch 6.4 LOW WATER LEVEL FAULT TEST 1. Set the ON/OFF switch in

SAFETY DEVICE TESTING 6-3 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Inter-lock. Te

SAFETY DEVICE TESTING 6-4 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

SAFETY DEVICE TESTING 6-5 6.10 PURGE SWITCH OPEN DURING PURGE 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode an

SAFETY DEVICE TESTING 6-6 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accor-dance with ASME Boiler and Pressure V

MAINTENANCE 7-1 SECTION 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliabilit

MAINTENANCE 7-2 SPARK IGNITORASSEMBLYBURNERSHELLFLAMEDETECTORSILICONEPLUG Figure 7.1 Spark Ignitor and Flame Detector Locations 7.3 FLAME DETECTOR T

MAINTENANCE 7-3 6. Remove the grounding terminal from the burner by loosening the upper screw and sliding the connector from the grounding rod. (See

MAINTENANCE 7-4 Figure 7.6 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between

MAINTENANCE 7-5 7.6.1 PROPANE UNITS For propane units it will be necessary to remove the air mix assembly in addition to the components outlined in

MAINTENANCE 7-6 2-1/2" PLUG Figure 7.11 Heat Exchanger 2 ½ Inch Inspection Plug Location 7.8 CONDENSATE DRAIN ASSEMBLY KC Boilers contain a

SAFETY PRECAUTIONS 1-1 SECTION 1 -- SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe al

TROUBLESHOOTING 8-1 Chapter 8- TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel

TROUBLESHOOTING 8-2 TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blow

TROUBLESHOOTING 8-3 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1.

TROUBLESHOOTING 8-4 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FLAME LOSS DURING RUN 1.

TROUBLESHOOTING 8-5 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH WATER TEMP SWITCH OP

TROUBLESHOOTING 8-6 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED DURING P

TROUBLESHOOTING 8-7 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE OUT OF PHAS

TROUBLESHOOTING 8-8 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 5. Defective I

TROUBLESHOOTING 8-9 TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defective

TROUBLESHOOTING 8-10 6. Defective IGST Board 6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IG

SAFETY PRECAUTIONS 1-2 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figu

APPENDIX A A-1 BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperatu

APPENDIX A A-2 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered.

APPENDIX A A-3 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Reset Ratio Permits setting of Reset Ratio when op

APPENDIX A A-4 BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Setpt Limiting Allows Setpoint Limiting to be enable

APPENDIX B B-1 APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DEMAND DELAY XX sec

APPENDIX B B-2 TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge, o

APPENDIX B B-3 TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Out

APPENDIX C C-1 Temperature Sensor Resistance Chart (Balco)

SAFETY PRECAUTIONS 1-3 Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equi

APPENDIX D D-1 INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 0.6 0.8 1.0

APPENDIX D D-2 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 6

APPENDIX D D-3 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 7

APPENDIX D D-4 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

APPENDIX E E-1 BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Add

APPENDIX F F-1

APPENDIX F F-2 35 (89)49 (124)57 (145)47 (119)30-1/816-3/423-1/468-1/277-1/872-1/214-3/819 (48)22-1/4 (57)15-1/2 (39)293 (8)6 (15) I.D.FLUE CONN.3/4

APPENDIX F F-3 225146DESCRIPTIONQTYITEMPART NO.BLOWER PROOF SWITCH161002-144344 4537241138 39252623XX NOT SHOWN IN THE DRAWINGTEMP./PRESS. GAUGEDRAI