Aerco KC1000 Low NOx Boiler July 2011 Bedienungsanleitung

REVISED JULY 7, 2011 GF-109LN OMM-0019_0B KC Series Gas-Fired Low NOx Boiler USER MANUAL Applicable to Serial Numbers G-11-0695 and above KC

SAFETY PRECAUTIONS 1-4 (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wa

APPENDIX G G-1 CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVE *RELIEF VALVE *(NOTE 5)6''LINE SIZE BYPASSPRESSURE RE

APPENDIX G G-2 CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVE *RELIEF VALVE * PANELS AND COVERS. LOCATE GAS PRESSURE REGULA

APPENDIX G G-3 CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVERELIEF VALVESD-A-713BOILERS COMBINATION HEATING &KC LOW NOx S

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 H

APPENDIX J J-1 KC1000 LOW NOx DUAL-FUEL SWITCH-OVER INSTRUCTIONS The KC1000 Low NOx Boiler is shipped from the factory configured for either natu

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

APPENDIX K K-1 RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and opti

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

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 clearan

INSTALLATION 2-3 BOILERSUPPLYBOILERRETURN Figure 2.3 Supply and Return Location NOTE: The maximum working pressure for installations within the Pro

INSTALLATION 2-4 SHELLCAPPARTIAL TOP VIEW OF BOILERFOR INSTALLATION OF PRESS./TEMP. GAUGEPART NO. 122994-2 (PRESS. RANGE 0 – 200 PSI)PART NO. 12299

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 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 sh

INSTALLATION 2-7 removable side panel (see Fig. 2.10). Field wiring for each particular mode of operation is described in the following paragraphs.

INSTALLATION 2-8 2.6.3 BOILER MANAGEMENT SYSTEM (BMS) MODE NOTE BMS Model 168 can utilize either pulse width modulation (PWM) or RS485 Modbus signal

INSTALLATION 2-9 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 u

GF-109LN OMM-0019_0B KC Series Gas-Fired Low NOx Boiler USER MANUAL Telephone Support Direct to AERCO Technical Support (8am to 5 pm EST,

INSTALLATION 2-10 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 INT

INSTALLATION 2-11 from a clean area outdoors for the protection and longevity of the equipment. The more common methods of supplying combustion air

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 LE

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

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 3.6. CONFIGURATION MENU The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint

CONTROL PANEL OPERATING PROCEDURES 3-7 Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Defa

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

CONTROL PANEL OPERATING PROCEDURES 3-8 3.8. START SEQUENCE When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge s

CONTROL PANEL OPERATING PROCEDURES 3-9 154155AIR/FUEL VALVEBLOWER PROOFSWITCHTO FRAMEHARNESS Figure 3-5. Blower Proof Switch 5. Upon completion of

CONTROL PANEL OPERATING PROCEDURES 3-10 Table 3-6. Relationship Between Air/Fuel Valve Position and Energy Input of a Unit Running on Natural Gas Air/

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

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% valve position for two-min

INITIAL START-UP 4-4 15. Replace the regulator cap and cap gasket and wait for the analyzer reading to settle. 16. When the analyzer reading settl

INITIAL START-UP 4-5 BLOWEROUTLETBLOWERINLETSCREENSHUTTERSHUTTER LOCKING NUTS Figure 4.4 Air Shutter Locking Nut Location REMINDER: At 30% valve posi

INITIAL START-UP 4-6 5. Set the unit to the Manual Mode by pressing the AUTO/MAN switch. A flashing Manual Valve Position message will be display

INITIAL START-UP 4-7 14. Use a flat-tip screwdriver to adjust the differential pressure regulator. Turn the screwdriver: • counterclockwise to incre

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 4-8 22. Wait for the analyzer to settle and then compare the new oxygen reading to Table 6 (or 6A). Repeat the inlet air shutter

INITIAL START-UP 4-9 OVER-TEMPERATURESWITCHESSHELL SENSOR209TEMPERATURE SWITCH DETAILS137HARNESS136FROM SHELLNCNCCNOCLIQUID LEVEL SWITCHOVER TEMP. SWI

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 de

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 5R

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

FOREWORD A Foreword This system can be operated using natural gas or propane fuel. A simple spring change in the differential regulator and com

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 Figure 6.4 Manual Leak Detection Valve 6.8 AIR FLOW FAULT TEST 1. Start the unit in manual mode and set the valve positi

SAFETY DEVICE TESTING 6-5 SSOVACTUATORCOVERSSOVCOVERSCREW Figure 6.6 SSOV Actuator Cover Screw Location 6.10 PURGE SWITCH OPEN DURING PURGE 1. Set

SAFETY DEVICE TESTING 6-6 6.11 IGNITION SWITCH OPEN DURING IGNITION 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual

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 7.3 FLAME DETECTOR The flame detector assembly (124837) is located in the body of the burner (Figure 7.1). The flame detector may be

MAINTENANCE 7-3 7. Loosen the 1/4” NPT union on the low NOx staged ignition assembly (Figure 7.3). 8. Disconnect the staged ignition assembly 1

MAINTENANCE 7-4 19. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between the air/fuel valve and the differential pres

MAINTENANCE 7-5 RELIEF VALVEDRAIN VALVEREDUCING1/4" PLUGHOT WATERHOT WATERSUPPLY (OUTLET)RETURN (INLET)BUSHINGREDUCINGBUSHING Figure 7.9 Heat Ex

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. Blowe

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 SSOV FAULT DURING PURGE

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

RS232 COMMUNICATION 9-1 Section 9 - RS232 COMMUNICATION 9.1 INTRODUCTION The RS232 port on the front panel of the C-More Control Box (Figure 3-1)

RS232 COMMUNICATION 9-2 (c) Menu changes will be stored in non-volatile memory. 9. To redisplay the menu and view the option which was just changed

RS232 COMMUNICATION 9-3 Table 9-1. Sample Fault Log Display No. Fault Message Cycle Date Time 0 Direct Drive Signal Fau

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

APPENDIX A A-2 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to

APPENDIX A A-3 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Reset Ratio

APPENDIX A A-4 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Set

APPENDIX A A-5 APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a valv

SAFETY PRECAUTIONS 1-2 CAUTION Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean wat

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, or

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

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

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

SAFETY PRECAUTIONS 1-3 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipm

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 E E-2 BOILER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Configuration Menu --Continued Network Timeout 30 seconds

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 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(2)DIA.(ENCL

APPENDIX F F-4 225146DESCRIPTIONQTYITEM PART NO.BLOWER PROOF SWITCH161002-144337241138 39252623XX NOT SHOWN IN THE DRAWINGTEMP./PRESS. GAUGEDRAIN VA

APPENDIX F F-5 6364515491752182943313230404114223727 28CPLG. W/PLUGSIGHT PORT535413PARTS LISTNORTHVALE, NJ 07647INTERNATIONAL, INC.PL-A-145(SH. 2 OF

APPENDIX F F-6 REV.KC1000 LOW NOx BOILER IRI GAS TRAIN022305GSDWN.BY DATENTSSCALEAPPD. DATESD-A-660 CNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCOSSOV

APPENDIX F F-7 126115917108241413DO NOT CUT WIRESITEM NO. QTY. PART NO. DESCRIPTION1 1 124866 SOLENOID VALVE, 1/4" NPT2 1 122712 1/2" NPT,