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KC Series Low NOx Gas-Fired Water Heater
GF-111LN
USER MANUAL
OMM-0029_0B
Applicable to Serial Numbers G-11-0694 and Above
KC Series
Low NOx
Gas Fired
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
1,000,000 BTU/HR Input
Patent No. 4,852,524
REVISED JULY 8, 2011

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Summary of Contents for Aerco KC Series

  • Page 1 KC Series Low NOx Gas-Fired Water Heater GF-111LN USER MANUAL OMM-0029_0B Applicable to Serial Numbers G-11-0694 and Above KC Series Low NOx Gas Fired Water Heating System Natural Gas or Propane Fired, Condensing and Forced Draft Hot Water Heater 1,000,000 BTU/HR Input Patent No.
  • Page 2 The information contained in this operation and maintenance manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.
  • Page 3: Table Of Contents

    CONTENTS GF-111LN - AERCO KC1000 GAS FIRED LOW NOx WATER HEATER Operating & Maintenance Instructions FOREWORD Section 1 – SAFETY PRECAUTIONS Para. Subject Page Para. Subject Page Warnings & Cautions Prolonged Shutdown Emergency Shutdown Section 2 – INSTALLATION PROCEDURES Para.
  • Page 4 CONTENTS Section 6 – MAINTENANCE Para. Subject Page Para. Subject Page Maintenance Schedule Heat Exchanger Inspection & Spark Ignitor Cleaning Flame Detector 6.10 Condensate Drain Assembly Combustion Calibration 6.11 Low Water Cutoff Probe Safety Device Testing Inspection and Cleaning 6-16 BTU Transmitter Pump 6.12 Hydraulic Zero Needle Valve...
  • Page 5: Warnings & Cautions

    3. If this heater was ordered with the optional VALVES. CAREFULLY DECREASE copper-lined, carbon steel shell, items 1 and ALL TRAPPED PRESSURES TO 2 Do Not Apply. (Contact your local AERCO ZERO BEFORE PERFORMING representative to verify heater shell material.
  • Page 6: Emergency Shutdown

    (LOCATED ON THE FRONT RIGHT turn off the electrical power supply to the SIDE OF THE UNIT UNDER THE AERCO heater and close the manual gas valve HOOD AND SHEET METAL SIDE located upstream the unit. The installer must PANEL) MUST BE INSTALLED AT identify the emergency shut-off device.
  • Page 7: Safety Precautions

    SAFETY PRECAUTIONS (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 1.
  • Page 8 SAFETY PRECAUTIONS Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:...
  • Page 9: Receiving The Unit

    INSTALLATION SECTION 2 - INSTALLATION freight carrier should notified 2.1 RECEIVING THE UNIT immediately if any damage is detected. The Each KC1000 Heater is shipped as a single following standard accessories are included with crated unit. The crated shipping weight is each unit and are packed separately within the approximately 1500 lb.
  • Page 10: Installation

    In multiple unit installations, it is important to optional copper-lined carbon steel shell (contact plan the position of each unit. Sufficient space your local AERCO Representative to verify), it is for piping connections and maintenance require- not shipped with, and does not require a flex ments must be given.
  • Page 11 INSTALLATION Shut-off valves and union conections must be installed in the inlet and outlet lines for maintenance. The use of dielectric unions is recommended. Install the piping and acces- sories as per the following drawings, located in Appendix F of this manual. •...
  • Page 12: Gas Supply Piping

    CONDENSATE CUP PLACED ON FLOOR Figure 2.6 Condensate Drain Assembly Location 2.4 GAS SUPPLY PIPING AERCO Gas Fired Equipment Gas Components and Supply Design Guide (GF-1030) should be consulted before any gas piping is designed or Figure 2.5 started. Pressure/Temperature Relief and Drain...
  • Page 13 INSTALLATION The location of the 1-1/4" inlet gas connection on the right side of the unit is shown in Figure Natural Gas: 2.7. The maximum static inlet pressure to the unit must be no more than 14” W.C. Minimum gas All pipe should be de-burred and internally pressure is 8.8”...
  • Page 14: Electrical Supply

    2.5 ELECTRICAL SUPPLY the authority having jurisdiction. In the absence The AERCO Gas Fired Equipment Electrical of such requirements, the installation shall Power Wiring Guide, (GF-1060), must be conform to National Electrical Code (NEC),...
  • Page 15 2.6.8 EXHAUST SWITCH IN the AUX SENSOR IN and SENSOR COMMON These terminals permit an external exhaust and must be similar to AERCO BALCO wire switch to be connected to the exhaust manifold sensor P/N 12449. A resistance chart for this of the heater.
  • Page 16 INSTALLATION locations for these interlocks (REMOTE INTL’K IN and DELAYED INTL’K IN). Both interlocks, 2.6.10 FAULT RELAY described below, are factory wired in the closed The fault relay is a single pole double throw position. (SPDT) relay having a normally open and NOTE: normally closed set of relay contacts that are Both the Delayed Interlock and Remote Interlock...
  • Page 17 Inlet Air Adapter # GP-18917 available fired equipment. Common sources of these from AERCO. This adapter bolts directly on to compounds are swimming pools, degreasing the air inlet of the unit’s blower. See installation compounds, plastic processing, and refrigerants.
  • Page 18 The adjustment screw on the Damper should be moved to the center of the slot position and tightened 1/2 turn past “finger-tight”. DO NOT over-tighten. See AERCO Venting Guide GF-1050 for further details. 6" MINIMUM COLD AIR DAMPER...
  • Page 19: Introduction

    CONTROL PANEL OPERATING PROCEDURES SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION WARNING: The information in this Section provides a guide DO NOT ATTEMPT TO DRY FIRE THE to the operation of the KC1000 Water Heater HEATER. STARTING THE UNIT WITHOUT using the Control Panel mounted on the front of A FULL WATER LEVEL CAN SERIOUSLY the unit.
  • Page 20: Section 7 – Troubleshooting

    CONTROL PANEL OPERATING PROCEDURES Table 3-1. Operating Controls, Indicators and Displays ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring MANUAL Lights when the unit is being controlled using the front panel keypad REMOTE Lights when the unit is being controlled by an external signal...
  • Page 21: Control Panel Menus

    CONTROL PANEL OPERATING PROCEDURES Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION ▲ (Up) Arrow When in one of the main menu categories (Figure 3-2), pressing this key will select the displayed menu category. If (Cont.) the CHANGE key was pressed and the menu item is flashing, pressing the ▲...
  • Page 22: Operating Menu

    CONTROL PANEL OPERATING PROCEDURES 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the NOTE: selected menu will be displayed. following paragraphs provide brief 5. Continue to press the ▲ or ▼ arrow key until descriptions of the options contained in each the desired menu option is displayed.
  • Page 23 CONTROL PANEL OPERATING PROCEDURES NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4). Table 3-2. Operating Menu Available Choices or Limits Menu Item Display Minimum Maximum...
  • Page 24 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Internal Setpt Lo Temp Limit Hi Temp Limit 130°F Unit Type KC Boiler, KC Boiler LN, KC Water BMK Boiler, BMK Boiler LN, Heater LN BMK Boiler Dual, KC Water Heater, KC Water Heater LN,...
  • Page 25 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Default Low Fire Timer 2 sec. 600 sec. 2 sec. Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0°F 10°F 5°F Network Timeout 5 Sec...
  • Page 26 CONTROL PANEL OPERATING PROCEDURES 3.8. START SEQUENCE 3. With all required safety switches closed, a When the Control Box ON/OFF switch is set to purge cycle will be initiated and the following the ON position, it checks all pre-purge safety events will occur: switches to ensure they are closed.
  • Page 27 CONTROL PANEL OPERATING PROCEDURES DIAL STEPPER (DETAIL “A”) MOTOR AIR/FUEL VALVE BLOWER PROOF SWITCH TO FRAME HARNESS Figure 3-5. Blower Proof Switch DETAIL "A" 5. Upon completion of the purge cycle, the Control Box initiates an ignition cycle and the following events occur: Figure 3-6.
  • Page 28 CONTROL PANEL OPERATING PROCEDURES Table 3-6. Relationship Between Air/Fuel Valve Position and Energy Input of a Unit Running on Natural Gas Air/Fuel Valve Energy Input Boiler Energy Input Position (BTU/Hr) (% of Full Capacity) (% Open) 50,000 (Stop Level) 89,000 191,000 311.000 460,000...
  • Page 29: Section 4 - Initial Start-Up

    Section 5 to complete wrenches. the initial unit start-up. 6. Tube of silicone adhesive An AERCO Gas Fired Startup Sheet included 4.2.2 INSTALLING THE SUPPLY GAS with each KC-1000 must be completed for each unit for warranty validation and a copy must be...
  • Page 30: Natural Gas Combustion

    INITIAL START-UP IMPORTANT The unit is shipped from the factory set up for either natural gas or propane, as specified by the Style No. on the Sales Order. If desired, the unit can be easily switched from one fuel type to 1/8"...
  • Page 31 100% valve position, it will be necessary to stop calibration and contact the local AERCO representative in 13. If the measured oxygen level is not within your area. Running the unit on insufficient gas the range listed in Table 1, remove the pressure will void the warranty.
  • Page 32 INITIAL START-UP 15. Replace the regulator cap and cap gasket 22. If the optional Cold Air Damper (P/N 99026) and wait for the analyzer reading to settle. is installed, compare the measured oxygen level with the levels in Table 3. If the Cold 16.
  • Page 33 INITIAL START-UP 30. Record all readings on the AERCO start-up BLOWER INLET sheet provided with each unit. Proceed to SCREEN paragraph when natural combustion calibration procedures completed. SHUTTER SHUTTER IMPORTANT LOCKING NUTS The unit is shipped from the factory set up for either natural gas or propane, as specified by the Style No.
  • Page 34 100°F 5.7% <100 ppm and contact the local AERCO representative in your area. Running the unit on insufficient gas * NOx readings corrected to 3% oxygen. pressure will void the warranty 12. If the measured oxygen level, CO and NOx emissions are within the ranges shown in Table 4, no adjustment is necessary.
  • Page 35 * NOx readings corrected to 3% oxygen. exceed values shown. adjustment should be necessary. Contact Table 6A AERCO if the oxygen, CO or NOx levels are Combustion Oxygen Levels for a 100% not within the specified ranges. Valve Position Without Cold Air Damper Inlet Air Oxygen...
  • Page 36 1. The unit must be in the Auto mode of Tables 4, 5 and 6 (or 6A). operation. 28. Record all readings on the AERCO start-up 2. The Outlet Feedback option in the Tuning sheet provided with each unit. Proceed to...
  • Page 37 INITIAL START-UP 5. Make small adjustments and allow time procedure in paragraph 4.6.3. If the unit is between adjustments for the outlet water not stabilized, proceed to step 5. temperature to stabilize. Press the MENU key and select the Tuning 6.
  • Page 38 FROM SHELL 11. If the outlet temperature does not maintain HARNESS setpoint after a reasonable amount of time and adjustment, contact your local AERCO representative. NOTE: After performing Temperature Calibration and TEMPERATURE SWITCH DETAILS prior to placing the water heater in service, be...
  • Page 39: Section 5 - Safety Device Testing Procedures

    SAFETY DEVICE TESTING SECTION 5 - SAFETY DEVICE TESTING PROCEDURES 5.1 TESTING OF SAFETY DEVICES 6. Open the gas supply to the unit and press the CLEAR button on the Control Box. Periodic testing of all controls and safety devices is required to insure that they are operating as 7.
  • Page 40 SAFETY DEVICE TESTING 10. After the shell is full, press the LOW WATER LEVEL RESET button to reset the low water cutoff. Press the CLEAR button to reset the FAULT LED and clear the error message. 11. Set the ON/OFF switch to the ON position. HIGH GAS The unit is now ready for operation.
  • Page 41 SAFETY DEVICE TESTING 5.6 INTERLOCK TESTS 5. Once the interlock connection is recon- nected, depress the CLEAR button. The unit is equipped with two interlock circuits unit should start. called the Remote Interlock and Delayed Inter- lock. Terminal connections for these circuits are located in the I/O Box and are labeled REMOTE 5.7 FLAME FAULT TEST INTL’K IN and DELAYED INTL’K IN.
  • Page 42 SAFETY DEVICE TESTING AIR/FUEL VALVE BLOWER PROOF SWITCH TO FRAME HARNESS Figure 5.4 Manual Leak Detection Valve 5.8 AIR FLOW FAULT TEST Figure 5.5 1. Start the unit in manual mode and set the Blower Proof Switch Location and Wiring valve position between 25% and 30%.
  • Page 43 SAFETY DEVICE TESTING VALVE COVER SSOV ACTUATOR COVER SSOV COVER SCREW Figure 5.6 SSOV Actuator Cover Screw Location Figure 5.7 Air/Fuel Valve Cover Location 5.10 PURGE SWITCH OPEN DURING PURGE 5.11 IGNITION SWITCH OPEN DURING IGNITION 1. Set the unit’s ON/OFF switch to the OFF position.
  • Page 44 SAFETY DEVICE TESTING STEPPER DIAL MOTOR PURGE IGNITION POSITION POSITION SWITCH SWITCH Figure 5.8 Air/Fuel Valve Purge and Ignition Switch Locations 5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the Safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.
  • Page 45: Section 6 - Maintenance

    MAINTENANCE SECTION 6 – MAINTENANCE 6.1 MAINTENANCE SCHEDULE The KC1000 Heater requires regular routine maintenance to maintain efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 6-1. Appendix I contains recommended spare parts lists for maintenance of the KC1000 Heater.
  • Page 46: Flame Detector

    Hard water deposits must be removed to prevent corrosion and leaking. Checking at more frequent intervals may be required to prevent scale buildup. See page 6-13 for information about removing scale deposits using AERCO HydroSkrub scale remover. 6.3 FLAME DETECTOR The flame detector (part no.
  • Page 47: Combustion Calibration

    MAINTENANCE Remove the left side panel from the unit. Disconnect the flame detector lead wire and unscrew the flame detector and remove it from the burner. 4. Inspect the detector thoroughly. If eroded, the detector should be replaced. A white coating is an indication of oxidation, which may be removed with an abrasive cloth (such as Scotch Brite).
  • Page 48 MAINTENANCE 4. Open the drain valve on the unit. 5. Slowly open the pressure relief valve to allow air-flow into the unit. 6. Fully drain the unit. 7. Disconnect electrical power from the unit. 8. Remove the 4 screws holding the BTU transmitter pump to the impeller housing. Remove and set the pump aside, (See Fig.
  • Page 49 MAINTENANCE 10. Carefully remove the lower tubing assembly taking care not to lose either the cold water or hot water mixing orifice, (See Fig. 6.5). 11. Loosen the compression fitting holding the hydraulic zero and control orifice tube assembly to the pump’s impeller housing, (See Fig.
  • Page 50 MAINTENANCE 12. Remove the compression fitting at the top of the impeller housing and remove the impeller housing, (See Fig. 6.6). HOT WATER TUBE COMPRESSION FITTING BALL VALVE Figure 6.7 BTU Transmitter Hot Water Tube Disassembly 13. Remove the compression fitting securing the pump outlet tube to the ball valve and remove the pump outlet tube.
  • Page 51: Manifold Exhaust Tubes

    MAINTENANCE IMPELLER HOUSING COVER Figure 6.9 Impeller Housing Disassembly 19. Once the BTU transmitter has been inspected and cleaned, reassemble in the reverse order. NOTE: Do not attempt to adjust the Hydraulic Zero Needle Valve. This is a factory-preset item. Refer to Figure 6.5.
  • Page 52 MAINTENANCE 6. Remove the grounding terminal from the burner by loosening the upper screw and sliding the connector from the grounding rod, (See Fig. 6.10). 7. 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, (See Fig.
  • Page 53 MAINTENANCE Figure 6.12 Exhaust Sensor Connector Location 13. Disconnect the air/fuel valve wiring harness connector from the control panel. 14. Disconnect wires #24 and #17 from the blower proof switch (See Fig. 6.13). To Frame Harness AIR/FUEL VALVE TO FRAME HARNESS BLOWER PROOF SWITCH...
  • Page 54 MAINTENANCE Figure 6.14 Air/Fuel Valve Inlet Hose Clamp 16. 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, (See Fig. 6.15). 17. 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, (See Fig.
  • Page 55 27. Beginning with the manifold, reinstall all the components in the reverse order that they were removed. Replace the o-ring seals removed with the air/fuel valve. AERCO recommends that NEW o-ring seals be used when reassembling.
  • Page 56 6. Inspect and, if necessary, clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head. Refer to heat exchanger cleaning steps on page 6.13. AERCO recommends that NEW gaskets be used when reassembling.
  • Page 57: Cleaning The Heat Exchanger

    Configuration Cleaning the Heat Exchanger Precautions: Please review MSDS, specifications, and our website www.aerco.com for additional information, or call technical service at (800) 526-0288. OTICE Mix the HydroSkrub with an equal volume of water to obtain a 50% concentration (11.5 gallons of each = 23 gallons total).
  • Page 58 MAINTENANCE Figure 6.19 – HydroSkrub Pumping System Set-Up Diagram for KC-1000 Pumping System Set-Up Directions 1. Turn off the water heater and close all isolation valves. 2. Drain at least half of the Heat Exchanger water-side volume. The KC-1000 heat exchanger holds a total volume of 23 gallons.
  • Page 59 MAINTENANCE strength is depleted (two pounds of deposits removed per gallon used) or the equipment is free from calcium and other water formed mineral deposits. 12. Periodically test the solution for effectiveness to determine if more HydroSkrub is needed—refer to “Testing hydroSkrob Effectiveness”...
  • Page 60 MAINTENANCE 6.11 LOW WATER CUTOFF PROBE INSPECTION AND CLEANING KC Heaters feature a Low Water Cutoff sensor probe (P/N 122843 as part of probe/capacitor assembly P/N 69126) which should be inspected and, if needed, cleaned every six months or replaced (if damaged) to ensure proper operation.
  • Page 61: Hydraulic Zero Needle Valve Adjustment (C-More Control Box)

    MAINTENANCE 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-MORE CONTROL BOX) The Hydraulic Zero Needle Valve is factory set in new equipment and should not be changed unless the BTU Transmitter is being replaced. If adjustment is necessary, the following procedure must be followed to assure optimum temperature control.
  • Page 62: Flame Strength Measurement

    When the flame is extinguished, there is a disruption of this electrical circuit, which the controller senses and so initiates shutdown procedures. This current is referred to by AERCO as the flame strength (also known as flame current or flame signal). CAUTION! There is a very low AC current used to energise the flame sensor when power is applied to the system (should be between 90 and 110 volts), so touching the energized sensor may cause a mild electric shock.
  • Page 63 MAINTENANCE • Measure the voltage in µA between the flame rod and the flame connector. If the flame senser is operating correctly, the reading will be between 3.4 µA and 12.0 µA. If there is a lower voltage reading or no voltage, check to make sure that the wires from the control module to the flame- sensing rod are correctly connected and ensure the the flame rod or the wire connected to it is grounded properly.
  • Page 65: Section 8 – Rs232 Communication

    Refer corrected. to Section 8 of this manual for detailed RS232 6. If the fault cannot be corrected using the communication set-up and procedures. information provided in the Troubleshooting Tables, please contact your local AERCO Representative.
  • Page 66: Troubleshooting

    TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped 1. Check combustion blower for signs of excessive heat or DURING IGNITION running due to high current drain that may trip thermal or current thermal or current overload devices.
  • Page 67 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED 1. Delayed Interlock Jumper 1. Check for a jumper properly installed across the INTERLOCK OPEN not installed or removed. delayed interlock terminals in the I/O box. 2.
  • Page 68 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FFWD TEMP 1. Loose or broken wiring. 1. Inspect feed forward (BTU transmitter) SENSOR FAULT sensor for loose or broken wiring. 2. Defective Sensor. 2. Check resistance of sensor to determine if it is within specification.
  • Page 69 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS 3. Defective High Gas 3. Remove the leads from the high gas pressure PRESSURE Pressure Switch switch and measure continuity across the common and normally closed terminals with (continued) the unit not firing.
  • Page 70 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED 1. Air/Fuel Valve not 1. Start the unit. The Air/Fuel Valve should rotate to DURING PURGE rotating the purge (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 71 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE 1. Line and Neutral 1. Check hot and neutral in AC Power Box to OUT OF PHASE switched in AC Power ensure they are not reversed Box.
  • Page 72 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 4. Defective Power Supply 4. Check DS1 & DS2 LEDs on Power Supply Board or fuse Board. If they are not steady ON, replace Power Supply Board. 5.
  • Page 73 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV FAULT 1. SSOV switch closed for 15 1. Replace SSOV actuator. DURING RUN seconds during run. SSOV RELAY 1. SSOV relay failed on 1. Ensure that Neutral and Earth Ground are FAILURE board.
  • Page 75: Menu Processing Utilizing

    Enter. the Operating, Setup, Configuration and “Welcome to Aerco” will appear in the laptop or Tuning Menus. (The Calibration and “dumb terminal” display with a listing of the Diagnostic Menus should only be used following available entry choices: by Factory-Trained service personnel).
  • Page 76: Data Logging

    RS232 COMMUNICATION (c) Menu changes will be stored in non- flame strength must change by more than 5%, volatile memory. or the run mode must change. At steady-state, the run-length is allowed to reach a maximum of To redisplay the menu and view the option 30 minutes before the record is logged.
  • Page 77 RS232 COMMUNICATION Table 8-1. Sample Fault Log Display Fault Message Cycle Date Time Direct Drive Signal Fault 1/10/02 8:42am Low Gas Pressure 7/04/01 5:29pm Loss of Power 1/01/01 11:50am Table 8-2. Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time...
  • Page 79 APPENDIX A APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint or Remote Setpoint Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu.
  • Page 80: Configuration Menu

    APPENDIX A APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set . Default is 130°F. Unit Type Allows selection of KC Boiler, KC Boiler LN, BMK Boiler, BMK Boiler LN, BMK Boiler Dual, KC Water Heater, KC Water Heater LN, Water Heater 2010 Unit Size...
  • Page 81 APPENDIX A APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS - CONTINUED MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH.
  • Page 82: Tuning Menu

    APPENDIX A APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a valve position 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 valve position will be less than 100%.
  • Page 83 APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DEMAND DELAY Displayed if Demand Delay is active. XX sec DISABLED Displayed if ON/OFF switch is set to OFF. The display also HH:MM pm, pm shows the time (am or pm) and date that the unit was MM/DD/YY...
  • Page 84 APPENDIX B TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof Switch opened during purge, DURING PURGE or air inlet is blocked. AIRFLOW FAULT The Blower Proof Switch opened during ignition. DURING IGN AIRFLOW FAULT The Blower Proof Switch opened during run. DURING RUN DELAYED The Delayed Interlock is open.
  • Page 85 APPENDIX B TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out SENSOR FAULT of range. OUTLET TEMP The temperature measured by the Outlet Sensor is out of SENSOR FAULT range: •...
  • Page 87 APPENDIX C Temperature Sensor Resistance Chart (Balco)
  • Page 89 APPENDIX D WATER HEATER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password Language English Unit of Temp Fahrenheit Comm Address Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type KC Water Heater LN Unit Size 1.0 MBTU Fuel Type Natural Gas Heater Mode...
  • Page 90 APPENDIX D WATER HEATER DEFAULT SETTINGS Continued MENU & OPTION FACTORY DEFAULT Tuning Menu Prop Band 8°F Integral Gain 1.60 Derivative Time 0.10 min Min Load Adj 0°F Max Load Adj 0°F FFWD Temp Outlet Feedback Feedback Gain 0.05 Breakpoint At 100% 77°F Breakpoint At 90% 81°F...
  • Page 91 APPENDIX E...
  • Page 92 APPENDIX E...
  • Page 93 APPENDIX E...
  • Page 94: Parts List

    * - NOT SHOWN IN THE DRAWING ** - INCLUDES LOWER AND UPPER BURNER GASKETS, IGNITOR, AND FLAME DETECTOR ASSEMBLY. *** - INCLUDES LOWER AND UPPER BURNER GASKETS, AND COMBUSTION CHAMBER LINER AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 LOW NOX KC1000 WATER HEATER PARTS LIST...
  • Page 95 APPENDIX E SEE DETAIL "A" DETAIL "A" EXPLODED SEE DRAWING PL-B-134 FOR AVAILABLE PARTS AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 LOW NOX KC1000 WATER HEATER PARTS LIST PL-A-144 DWN.BY DATE 022505 SCALE (SH. 2 OF 2) APPD. DATE...
  • Page 96 SEE TABLE 1 ORIFICE DISC GM-161212 HYD. ZERO & CONT. ORIFICE TUBE ASS'Y GP-122552 2"NPT 90° COLD WATER INLET ELBOW 123449 BTU TRANSMITTER SENSOR AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER BTU TRANSMITTER ASSEMBLY (COMPLETE ASS'Y GM-20872) DWN.BY DATE...
  • Page 97 APPENDIX E AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER BTU TRANSMITTER ASSEMBLY (COMPLETE ASS'Y GM-20872) 041304 DWN.BY DATE PL-A-134 SCALE (SH. 2 OF 2) APPD. DATE...
  • Page 98 APPENDIX E...
  • Page 99 APPENDIX E DO NOT CUT WIRES ITEM NO. QTY. PART NO. DESCRIPTION 124866 SOLENOID VALVE, 1/4" NPT 122712 1/2" NPT, FLEX, GAS HOSE, 12" LONG 123314 ELBOW, 1/4" NPT 9-43 REDUCER BUSHING, 1/2" TO 1/4" NPT 124933 UNION, 1/4" NPT 124934 1/4"...
  • Page 101 APPENDIX F...
  • Page 102 APPENDIX F...
  • Page 103 APPENDIX F...
  • Page 104 APPENDIX F...
  • Page 105 APPENDIX F...
  • Page 107 APPENDIX G...
  • Page 108 APPENDIX G...
  • Page 109 APPENDIX H LOW WATER CUTOFF BOARD P/N 124363 CONNECTOR BOARD PMC BOARD P/N 124366 P/N 124364 DISPLAY BOARD POWER SUPPLY BOARD P/N 124365 P/N 124362 IGNITION/STEPPER V.F.D. DISPLAY BOARD MODULE P/N 124361 P/N 124527 ENCLOSURE P/N 124951 FISH PAPER INSULATOR P/N 124960 FRONT FACE PLATE, KC1000...
  • Page 110 APPENDIX H TO INPUT/OUTPUT (I/O) BOX EXT. SENSOR/COMM INTERLOCK HARNESS HARNESS CONNECTOR CONNECTOR (24 PIN) (16 PIN) SENSOR A/F VALVE SHELL HARNESS GAS TRAIN HARNESS HARNESS HARNESS CONNECTOR CONNECTOR CONNECTOR CONNECTOR (19 PIN) (9 PIN) (7 PIN) (16 PIN) KC1000 CONTROL PANEL REAR VIEW...
  • Page 111: Kc1000 Low Nox Dual-Fuel

    APPENDIX I KC1000 LOW NOx DUAL-FUEL SWITCH-OVER INSTRUCTIONS The KC1000 Low NOx Heater 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.
  • Page 113: Recommended Spare Parts

    APPENDIX J RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List llustrations in Appendix E for the locations of the recommended and optional spare parts listed in the following Tables. Table J-1. Recommended Emergency Spare Parts DESCRIPTION PART NUMBER 120 VAC Single-Phase Blower 124935 Siemens SSOV Actuator - Used on:...
  • Page 115: Warranties

    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.
  • Page 116 International, Inc. 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.

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