Watts AERCO KC Series User Manual
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Watts AERCO KC Series User Manual

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KC Series Gas Fired Boiler
GF-106
USER MANUAL
OMM-0008_0A
Applicable for Serial Numbers G-01-026 to G-09-XXX
KC Series
Gas Fired
Boiler System
-
Semi
Instantaneous, Condensing,
Forced Draft,
Natural Gas and Propane Fired, Hot
Water Boiler
1,000,000 BTU/HR Input
Patent No. 4,852,524
10/8/01
Printed in U.S.A.

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  • Page 1 KC Series Gas Fired Boiler GF-106 USER MANUAL OMM-0008_0A Applicable for Serial Numbers G-01-026 to G-09-XXX KC Series Gas Fired Boiler System Semi Instantaneous, Condensing, Forced Draft, Natural Gas and Propane Fired, Hot Water Boiler 1,000,000 BTU/HR Input Patent No. 4,852,524 10/8/01 Printed in U.S.A.
  • Page 2 Telephone Support Direct to Aerco technical support 8 to 5 pm EST, Monday through Friday) (800) 526-0288 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...

  • Page 3: Table Of Contents

    CONTENTS GF-106 THE AERCO KC1000 GAS FIRED BOILER Operating & Maintenance Instructions FOREWORD Section 1 SAFETY PRECAUTIONS---------------------------1 Section 2 INSTALLATION PROCEDURES------------------2 Receiving the Unit Enable/Disable Interlock Unpacking Fault Relay Wiring Installation Flue Gas Vent Installation Gas Supply Piping 2.10 Combustion Air Electrical Supply 2.11 Unit Initial Fill...
  • Page 4 CONTENTS Section 6 SAFETY DEVICE TESTING PROCEDURES---------------------------29 Testing of Safety Devices Flame Fault Test Gas Pressure Fault Test Air Pressure Fault Test Low Water Level Fault Test Purge Interlocks Fault Test Water Temperature Fault Test Safety Pressure Relief Valve Test Section 7 MAINTENANCE REQUIREMENTS----------------33 Maintenance Schedule...
  • Page 5 FOREWORD Foreword The AERCO KC 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 14:1 modulating turndown ratio.

  • Page 6: Safety Precautions

    SAFETY PRECAUTIONS SECTION 1 - SAFETY PRECAUTIONS Installing or operating personnel MUST, at WARNING ! all times, observe all safety regulations. The DO NOT USE MATCHES, CANDLES, following warnings are general and must be FLAMES, OR OTHER SOURCES OF given the same attention as specific IGNITION TO CHECK FOR GAS precautions included in these instructions.

  • Page 7: Installation Procedures

    INSTALLATION SECTION 2 - INSTALLATION PROCEDURES 2.1. RECEIVING THE UNIT immediately if any damage is detected. The following accessories come standard with each Each KC unit is shipped as a single crated unit. unit and are packed separately within the unit’s’ The shipping weight is approximately 1500 packing container pounds, and must be moved with the proper...
  • Page 8 INSTALLATION 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 more clearance and take precedence Minimum clearances required: Sides 24"...
  • Page 9 INSTALLATION Whether installing single or multiple units, install 2.3.4 TEMPERATURE/PRESSURE the piping and accessories as shown in the INDICATOR appropriate piping diagram located in the The unit is supplied with one of two styles of Appendix G.. For applications other than Temperature/Pressure Indicators that must be standard space heating, consult the AERCO installed in the tapping on the supply flange of...
  • Page 10 INSTALLATION Figure 2.6 Condensate Drain System Location Figure 2.5b Pressure/Temperature Gauge Installation CAUTION! 2.3.5 CONDENSATE PIPING Soaps used for gas pipe leak testing can be The KC Boiler is designed to condense and the corrosive to metals. Piping must be rinsed installation must have provisions for drainage to thoroughly with clean water after leak a suitable waste.
  • Page 11 INSTALLATION 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.
  • Page 12 INSTALLATION ELECTRICAL WIRING BOX FRAME Figure 2.9 SSOV Electrical Wiring Diagram ACTUATOR 2.6 MODE OF OPERATION and FIELD CONTROL WIRING The KC Boiler is available in several different BLOWER modes of operation. While each unit is factory configured and wired for a particular mode, Figure 2.8 some field wiring may be required to complete AC Wiring Box Location...

  • Page 13: Enable/Disable Interlock

    INSTALLATION 2.6.1 CONSTANT SETPOINT MODE 2.6.5 COMBINATION MODE No external field wiring connections other than With a Combination Mode unit, field wiring is electrical supply connectins are required for this between the unit’s field wiring box, the CCP mode. Although fault monitoring or (Combination Control Panel), and the BMS enable/disable interlocking wiring can be utilized (Boiler Management System).

  • Page 14: Flue Gas Vent Installation

    INSTALLATION 2.9 FLUE GAS VENT INSTALLATION take into account restrictions such as louvers and bird screens. The AERCO Venting and Combustion Air Guide, GF-1050, must be consulted before any flue or 2.10.2 COMBUSTION AIR FROM INSIDE inlet air venting is designed or installed. THE BUILDING Suitable, U/L approved, positive pressure, When combustion air is provided from within the...
  • Page 15 CONTROL PANEL OPERATING PROCEDURES SECTION 3- CONTROL PANEL OPERATING PROCEDURES The following is a guide to the operation of the 2- eight segment LED displays control panel. Initial start-up of this unit must be 5 indicator status lights performed by factory trained start-up personnel. Operation prior to initial start-up by factory 3 menu levels trained personnel will void the warranty.
  • Page 16 CONTROL PANEL OPERATING PROCEDURES The third LED, “ON”, indicates the status of the For more data concerning the minimum and start relay, (see Fig. 3.2). The start relay is maximum range, and factory defaults of menu internal to the controller and is part of the start parameters, see Appendix E of this manual.
  • Page 17 CONTROL PANEL OPERATING PROCEDURES To access the percent of firing rate press the INDEX button while in the primary menu until NOTE: (Pct) is displayed in the lower LED. Use the Changing the setpoint will only be arrow key to increase or decrease the recognized when the unit is in the automatic percentage of firing rate.
  • Page 18 CONTROL PANEL OPERATING PROCEDURES These displays are accessed using the four membrane switches located directly under the LCD display on the front of the control panel. They are labeled CLEAR, , and AUX. Figure 3.7 Auto/Manual Display with Manual On 3.4 THE SECONDARY MENU The secondary menu is primarily related to temperature control.
  • Page 19 CONTROL PANEL OPERATING PROCEDURES The number of times The combustion the controller has LOCKOUT RUN safeguard is locked out. # CYCLES = completed it’s start The exhaust gas “DATE” “TIME” HI EXHAUST cycle, and the time temperature has TEMP and date exceeded 500º...

  • Page 20: On\Off Switch

    CONTROL PANEL OPERATING PROCEDURES activated. The unit at this point is in standby mode and ready to run. Figure 3.9 Combustion Safeguard Status Indicator LED Location Figure 3.10 3.7 WATER LEVEL TEST and RESET Water Level Test and Reset Switch Locations SWITCHES 3.9 STARTING SEQUENCE The water level switches are located on the left...
  • Page 21 CONTROL PANEL OPERATING PROCEDURES FROM CONNECTOR PROOF OF CLOSURE SWITCH SAFETY SHUT-OFF VALVE Figure 3.13 Blower Proof Switch Location Figure 3.11 8. Once the combustion safeguard detects Proof of Closure Switch Location flame, its flame LED lights. Power is removed from the ignition transformer and the MAIN LED lights of the combustion safeguard.

  • Page 22: After Flame

    CONTROL PANEL OPERATING PROCEDURES 3.10 AFTER FLAME Once the control signal has gone below the stop level (see section 3.12 for Stop Level explanation), the temperature controller’s green ON light extinguishes, indicating there is no longer a call for heat. This signals the combustion safeguard to shut down the burner.
  • Page 23 INITIAL START-UP SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS To properly perform combustion calibration, the proper instruments and tools must be used and The initial start-up of the KC-1000 boiler is correctly installed on the unit. The following comprised of the following steps: sections outline the necessary tools and instrumentation as well as their installation.
  • Page 24 INITIAL START-UP 1/4" NPT PLUG (INSTALL MANOMETER HERE) SSOV Figure 4.3 Differential Regulator Adjustment Tool Installation Figure 4.1 4.2.3 INSTALLING THE DIFFERENTIAL 1/8” Gas Plug Location REGULATOR ADJUSTMENT TOOL 4.2.2 PREPARING THE FLUE VENT 1. Remove the cap from the differential pressure regulator (see Fig.
  • Page 25 INITIAL START-UP 30%. Insert the combustion analyzer probe 3. Using the 16” manometer installed as per into the stack. Section 4.2.1, adjust the gas supply regulator until a reading of 12” W.C. static NOTE: pressure is obtained. Always go to a percentage of firing rate from the same direction, (i.e., 100% to 30% or 4.
  • Page 26 INITIAL START-UP 16. Wait for the analyzer reading to settle, then 23. Wait for the analyzer to settle then compare compare the new reading to Table 1. Repeat the new oxygen reading to Table 3. Repeat adjustment until oxygen is within the the inlet air shutter adjustment until the specified range.
  • Page 27 INITIAL START-UP specified range. Firmly tighten the inlet air shutter locking nuts when finished. NOTE: After an adjustment is made to the air NOTE: regulator, the cap must be put back on Adjust the inlet air shutter only at 100% securely to obtain an accurate reading firing rate.

  • Page 28: Over Temperature Limit Switch

    INITIAL START-UP 9. Remove the combustion analyzer probe from the vent hole. Seal the probe hole and replace the vent connection cover. 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.
  • Page 29 MODE OF OPERATION SECTION 5- MODE OF OPERATION The following is a detailed description of the circulation. The sensor may be mounted up to KC1000’s six modes of operation. Each unit is two hundred feet from the unit. shipped from the factory tested and configured in the mode of operation it was ordered.
  • Page 30 MODE OF OPERATION 5.2 CONSTANT SETPOINT MODE MENU FUNCTION SETTING Constant setpoint mode of operation is when a non-changing, fixed, header temperature is Secondary Lore desired. Common uses of this mode of operation Secondary FUNC Cont include water source heat pump loops, and shell Primary Auto and tube heat exchangers for potable hot water...

  • Page 31: Boiler Management System

    MODE OF OPERATION 5. Follow the above directions to change back 5.4.2 4 to 20 MA DIRECT DRIVE to remote mode. STARTUP Since this mode of operation is factory preset NOTE: and the percentage of firing rate is being The unit automatically defaults to remote externally controlled there are no startup instructions necessary.

  • Page 32: Combination Control System

    MODE OF OPERATION from an external source, the following functions 5.6 COMBINATION CONTROL SYSTEM must be correctly set. (CCP) MENU FUNCTION SETTING A Combination Control System is when enough units are installed to cover the space-heating Secondary Lore load on the design day. However one or more of Secondary FUNC Cont...

  • Page 33: Using The Outside Air Sensor Feature

    MODE OF OPERATION 5.6.1 COMBINATION CONTROL SYSTEM 4. Press ENTER to accept the change. FIELD WIRING Wiring for this system is between the BMS 5. Follow the above directions to change back panel, the CCP and terminals 2 and 3 in the to remote mode.
  • Page 34 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.
  • Page 35 SAFETY DEVICE TESTING 8. Open the water shut-off valve in the return piping to the unit to fill the shell. 6.5 FLAME FAULT TEST 1. Start the unit. 9. Open the water shut-off valve in the supply piping to the unit. 2.
  • Page 36 SAFETY DEVICE TESTING 5. The unit should shutdown and display the 1. Disconnect AC power from the unit. message “SYSTEM FAULT PURGE INTERLOCKS”. 2. Disconnect wire #17 from the air pressure switch located on the air/fuel valve (See Fig. 6. Clear the Annunciator. Turn the ON/OFF 6.4).
  • Page 37 SAFETY DEVICE TESTING 9. Disconnect wire #60 from the air/fuel valve 19. Disconnect AC power from the unit. open position switch. This is the switch closest to the blower (See Fig. 6.7). 20. Reconnect wire #62 to the ignition position switch.
  • Page 38 MAINTENANCE SECTION 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE 2. Disconnect the plastic tubing from the condensate cup to drain and remove the The unit requires regular routine maintenance to rear cover panels from the unit. Access to keep up efficiency and reliability. For best the spark ignitor may also be gained by operation and life of the unit, the following removing the unit’s right side panel...
  • Page 39 MAINTENANCE 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,...
  • Page 40 MAINTENANCE Figure 7.2 Grounding Terminal Location 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. 7.3). Figure 7.4 8. Using two 9/16” wrenches remove the 3/8"- Exhaust Sensor Connector Location 16 hex nuts and bolts on the gas inlet pipe 13.
  • Page 41 MAINTENANCE insulation. Using a 7/16” wrench or socket, remove the 3 bolts and fender washers securing the insulation to the exhaust manifold. 21. Loosen the three 1-1/16” nuts that hold the manifold. Remove the two side nuts. DO NOT REMOVE THE FRONT NUT (See Fig. 7.8).
  • Page 42 MAINTENANCE 26. Beginning with the manifold, reinstall all the components in the reverse order that they were removed. 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 Section 7.6. Proceed as follows: 1.
  • Page 43 APPENDIX A PRIMARY MENU ITEM DESCRIPTIONS This is the actual outlet water tout temperature of the heater. It is designated by the code (tout). Percentage of firing rate is a number, in percent, that is related to the input BTU’s of the unit. For instance a 50% signal equals approximately a 500,000 BTU gas input while a 75 % signal equals approximately a 750,000 BTU...
  • Page 44 APPENDIX A SECONDARY MENU ITEM DESCRIPTIONS CONSTANT SETPOINT This indicates the mode of operation the FUNC temperature controller is in. Common modes are Oart, indoor\outdoor reset, Cont, constant setpoint, and FDFO for a water heater. This menu item turns the outside air enable\disable feature on or off.
  • Page 45 APPENDIX A This is the derivative rate in % /.1°/sec. This adjusts response time to temperature changes at the outlet of the unit. This displays the address for the Addr controller. It is used for external communication with a computer. This changes the local/remote status of LOre the controller.
  • Page 46 APPENDIX A SECONDARY MENU ITEM DESCRIPTIONS INDOOR-OUTDOOR RESET MODE This displays the mode of the FUNC temperature controller . Common modes are Oart, indoor\outdoor reset, Cont, constant setpoint, and FDFO for a water heater. REFT This is the building reference temperature.
  • Page 47 APPENDIX A This is the Proportional Band in F for the feedback of the controller. This feature is useful in correcting outlet temperature errors when under steady load conditions. This is the integral rate, in minutes, for the feedback of the controller. It is adjusted with the .
  • Page 48 TROUBLESHOOTING SECTION 8- TROUBLESHOOTING GUIDE This troubleshooting section is intended to serve 3. If the static pressure to the unit is lower than as a guideline to determining and solving faults 10” W.C., readjust the supply regulator until on the KC1000. Whenever a fault occurs, it’s output is between 10”...
  • Page 49 TROUBLESHOOTING 3. Replace the low gas pressure switch if it necessary to replace the gas supply does not show continuity. regulator with a lock up style. Consult your local AERCO representative for more 4. If there is no continuity, check for loose information.
  • Page 50 TROUBLESHOOTING 2. Remove the unit cap and remove wire #25 from the water level probe. 8.2.1 EXHAUST TEMPERATURE SENSOR WARNING! Start the unit and wait for the HI EXHAUST TEMP. message to display. THIS WIRE HAS A POTENTIAL OF 12 VAC.
  • Page 51 TROUBLESHOOTING...
  • Page 52 TROUBLESHOOTING 8.3.3 WATER LEVEL CIRCUIT Often in a boiler system, supply water temperatures can vary and may be higher than the system design temperature. Check the 1. Remove AC power from the unit. actual outlet water temperature of the unit and ensure that the lower temperature switch is 20 2.
  • Page 53 TROUBLESHOOTING 9. Check the pins of the 15 pin connector for 8.5.1 FLAME FAULT WHILE FIRING proper insertion or wear. 1. Install a DC voltmeter in the flame test jacks located on the front of the combustion 10. If the connectors, pins, and continuity are safeguard and start the unit.
  • Page 54 TROUBLESHOOTING fault still persists, check the ignition circuit 14. Disconnect the 9 pin connector from the as per Section 8.5.6. control panel, and remove the cover from 7. If the flame fault still persists after checking the AC wiring box. the above, measure the flame detector lead voltage as per Section 8.5.7.
  • Page 55 TROUBLESHOOTING 8.5.5 FLAME DETECTOR 11. If the ignition cable is okay, remove the ignition transformer cover plate. 1. Disconnect AC power to the unit. 12. Referring to system schematic 161413 in 2. Remove the flame detector as per Section Appendix H, locate wires #12 and #29. 7.3.
  • Page 56 TROUBLESHOOTING 29. Reconnect AC power to the unit and start the unit. 8.5.8 RESIDUAL FLAME Once the KC1000 has stopped firing, it 30. If the flame fault still persists, replace the continues to monitor the flame circuit. If a combustion safeguard. residual flame exists, the unit will indicate a LOCKOUT fault.
  • Page 57 TROUBLESHOOTING 4. If the blower starts but the Annunciator 10. If 120VAC is measured, check the blower displays LOW AIR FLOW, proceed to capacitor using an analog ohmmeter or Section 8.6.4. substitute the capacitor. 5. If the unit has sealed combustion air ducted 11.
  • Page 58 TROUBLESHOOTING 4. If the blower starts, and the message 8.6.5 SOLID STATE RELAY SYSTEM FAULT LOW AIR PRESSURE is displayed, proceed to section 8.7.3 1. Referring to Appendix I,Item #17, open the 5. If the unit does not fire, and the message control box and locate the solid state relay.
  • Page 59 TROUBLESHOOTING 4. Connect an ohmmeter across the blower 4. If the air/fuel valve rotates to its full open proof switch and start the unit. position and engages the air/fuel valve open proving switch, and the Annunciator still 5. The blower proof switch should show displays SYSTEM FAULT, PURGE continuity while the blower is running.
  • Page 60 TROUBLESHOOTING 14. If there is no continuity, replace the actuator valve open, proving switch, noting their or switch. location. (The air/fuel valve open proving switch, is the one closest to the blower.) 15. Start the unit. If the unit sequence resumes 7.
  • Page 61 TROUBLESHOOTING 5. If the air/fuel valve does not rotate or is 8.8.8 AIR/FUEL VALVE IGNITION extremely difficult to rotate, replace the POSITION SWITCH air/fuel valve. 1. Disconnect AC power to the unit. 6. Disconnect the 12 pin connector from the 2.
  • Page 62 APPENDIX B TEMPERATURE CONTROLLER QUICK REFERENCE PROGRAMMING GUIDE The following is a “How To” guide that quickly shows how to access menu levels and their parameters, and how to make changes to them. PRIMARY MENU to SECONDARY MENU Press ENTER and the arrow key.
  • Page 63 APPENDIX B NOTE: The temperature controller defaults back to the PRIMARY menu from the SECONDARY menu or the SECURE menu if there is no activity in either of those menus after 4 minutes. TO CHANGE TO THE SECURE MENU While in the primary menu press the INDEX key and arrow key.
  • Page 64 APPENDIX B SECURE MENU TO THE MAIN MENU While in the SECURE menu press INDEX and the arrow key. This will place you in the SECONDARY menu. Press INDEX and the arrow key again, to return to the MAIN menu. The display will indicate: SCROLLING THROUGH MENU ITEMS To scroll through Menu items in a menu level, Press INDEX.
  • Page 65 APPENDIX C...
  • Page 66 APPENDIX D INDOOR\OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Temp -10F -15F -20F Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp -10F -15F -20F Header Temperature for a Building Reference Temperature of 65F...
  • Page 67 APPENDIX D RESET RATIO Temp Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F...
  • Page 68 APPENDIX D Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F...
  • Page 69 APPENDIX D Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp xiii...
  • Page 70 APPENDIX E BOILER DEFAULT SETTINGS CONSTANT SET POINT MODE MENU LEVEL DESCRIPTION OF CODE FACTORY & CODE DEFAULT PRIMARY MENU tout OUTLET TEMPERATURE ACTUAL PERCENTAGE OF FIRING RATE ACTUAL setp UNIT’S SETPOINT TEMPERATURE airt OUTSIDE AIR TEMPERATURE ACTUAL auto AUTOMATIC\MANUAL MODE AUTO ON SECONDARY MENU func...
  • Page 71 APPENDIX E BOILER DEFAULT SETTINGS INDOOR /OUTDOOR RESET MODE MENU LEVEL DESCRIPTION OF CODE DEFAULT & CODE VALUE PRIMARY MENU tout OUTLET TEMPERATURE ACTUAL PERCENTAGE OF FIRE RATE ACTUAL SEtP UNIT’S SETPOINT TEMPERATURE Airt OUTSIDE AIR TEMPERATURE ACTUAL Auto AUTO\MANUAL MODE AUTO ON SECONDARY MENU Func...
  • Page 72 APPENDIX F...
  • Page 73 APPENDIX F xvii...
  • Page 74 APPENDIX F xviii...
  • Page 75 APPENDIX F...
  • Page 76 APPENDIX G...
  • Page 77 APPENDIX G...
  • Page 78 APPENDIX H xxii...
  • Page 79 APPENDIX H xxiii...
  • Page 80 APPENDIX H xxiv...
  • Page 81 APPENDIX I 123446 FAN GUARD 123402 #6-32 X 3/8 LG PAN HEAD MACH. SCREW 123459 #6-32 X 2 LG PAN HEAD MACH. SCREW 123452 #8-32 X 5/16 LG PAN HEAD MACH. SCREW 123437 #6-32 X 5/8 LG PAN HEAD MACH. SCREW 123389 LINE FILTER 123436...
  • Page 82 APPENDIX I PARTS LIST 123280-B_ TEMPERATURE CONTROLLER (NEED STYLE NUMBER ) 123803 SOLID STATE TIMER-ARTISAN CORP(123469 FOR SSAC INC.) 123438 CIRCUIT BREAKER 123391 RELAY BOARD 123390 STATUS ANNUNCIATOR ITEM PART NUMBER DESCRIPTION PARTS LIST...

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