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Aerco KC Series Installation, Operation & Maintenance Instructions Manual

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See also: User Manual , Installation, Operation & Maintenance Instructions Manual
Instruction
GF-109
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
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
Applicable to Serial Numbers G-10-1324 and above
Patent No. 4,852,524
REVISED, JUNE 24, 2010
Printed in U.S.A.

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  • Page 1: Maintenance Instructions

    Instruction GF-109 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions 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 Applicable to Serial Numbers G-10-1324 and above 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-109 - THE AERCO KC1000 GAS FIRED BOILER Operating & Maintenance Instructions FOREWARD SECTION 1 – SAFETY PRECAUTIONS Para. Subject Page Para. Subject Page Warnings & Cautions Prolonged Shutdown Emergency Shutdown SECTION 2 – INSTALLATION PROCEDURES Para. Subject Page Para.
  • Page 4 CONTENTS SECTION 6 – SAFETY DEVICE TESTING PROCEDURES Para. Subject Page Para. Subject Page Testing of Safety Devices Air Flow Fault Test Low Gas Pressure Fault Test SSOV Proof of Closure Switch High Gas Pressure Fault Test 6.10 Purge Switch Open During Low Water Level Fault Test Purge Water Temperature Fault Test...
  • 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 20:1 modulating turndown ratio for natural gas units and 14:1 for propane units.

  • Page 7: Warnings & Cautions

    SEALED TO PREVENT LEAKAGE addition to all the requirements included in this OF COMBUSTION PRODUCTS INTO AERCO Instruction Manual, the installation of LIVING SPACES. units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 WARNING! (National Fuel Gas Code Publication No.

  • Page 8: Emergency Shutdown

    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.
  • Page 9 SAFETY PRECAUTIONS Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

  • Page 11: Receiving The Unit

    INSTALLATION SECTION 2 - INSTALLATION PROCEDURES 2.1. RECEIVING THE UNIT immediately if any damage is detected. The following accessories come standard with each Each KC1000 Boiler is shipped as a single unit and are packed separately within the unit’s crated unit. The crated unit shipping weight is packing container approximately 1500 pounds.

  • Page 12: Installation

    Figure 2.1. requirements must be given. All piping must The minimum clearance dimensions, required by include ample provision for expansion. AERCO, are listed below. Local building codes may require more clearance and take If installing a Combination Control (CCP) precedence...
  • Page 13 INSTALLATION Every boiler plant must have a source of make- The relief piping must be full size without up water to it. As with any closed loop hydronic reduction. No valves, restrictions, or other system, air elimination and expansion equip- blockages should be allowed in the discharge ment must be provided as part of the overall line.

  • Page 14: Gas Supply Piping

    Pressure /Temperature Gauge Installation Figure 2.6 Condensate Drain System Location 2.4. GAS SUPPLY PIPING The AERCO Gas Fired Equipment Gas Compo- nents and Supply Design Guide (GF-1030) must be consulted before any gas piping is designed or Figure 2.5b started.

  • Page 15: Electrical Supply

    8.9” W.C. for IRI gas trains at maximum 2.5 ELECTRICAL SUPPLY BTU input (1,000,000 BTU/HR) for natural gas The AERCO Gas Fired Equipment Electrical and propane installations. The supply gas Power Wiring Guide, (GF-1060), must be regulator must be of sufficient capacity volume,...

  • Page 16: Mode Of Operation And Field

    INSTALLATION 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. POWER BOX Figure 2.9 AC Power Wiring Diagram...
  • Page 17 RS485 strip. Polarity must be maintained and the shield Modbus signaling to the Boiler. BMS II must be connected only at the AERCO BMS. Model 5R5-384 can utilize only RS485 The boiler end of the shield must be left floating.
  • Page 18 (Direct Drive Mode) of the Boiler. These formats are: 2.7.1 OUTDOOR SENSOR IN An outdoor air temperature sensor (AERCO Part 4 to 20 mA/1 to 5 Vdc No. 122790) will be required mainly for the Indoor/Outdoor Reset mode of operation. It can...
  • Page 19 (such as AERCO Part (ungrounded) signals. Connections between the No. 123463) that closes (trips) at 500 source and the Boiler’s I/O Box must be made using twisted shielded pair of 18 –22 AWG wire 2.7.9 INTERLOCKS...
  • Page 20 AERCO GF-1050, Venting and Combustion Air water-tight vent materials specified in Guide. 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"...
  • Page 21 The free area must special Inlet Air Adapter # GP-18917 available take into account restrictions such as louvers from AERCO. This adapter bolts directly on to and bird screens. the air inlet of the unit’s blower. See installation 2.10.2 COMBUSTION AIR FROM INSIDE...

  • Page 23: 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 Boiler using the BOILER. STARTING THE UNIT WITHOUT Control Panel mounted on the front of the unit.

  • Page 24: Section 8 – 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: Lights when RS-232 communication is occurring COMM Lights when the unit is being controlled using the front panel MANUAL keypad.

  • Page 25: 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 26: Operating Menu

    CONTROL PANEL OPERATING PROCEDURES 3. Continue pressing the MENU key until the desired menu is displayed. NOTE: 4. With the desired menu displayed, press the following paragraphs provide brief ▲ or ▼ arrow key. The first option in the descriptions of the options contained in each selected menu will be displayed.
  • Page 27 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 28 CONTROL PANEL OPERATING PROCEDURES 3.6. CONFIGURATION MENU NOTE: The Configuration Menu shown in Table 3-4 The Configuration Menu settings shown in permits adjustment of the Internal Setpoint Table 3-4 are Factory-Set in accordance (Setpt) temperature regardless of whether the valid password has been entered. Setpt is with the requirements specified for each required for operation in the Constant Setpoint...
  • Page 29 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Default Setpt Lo Limit 40°F Setpt Hi Limit 60°F Setpt Hi Limit Setpt Lo Limit 220°F 200°F Temp Hi Limit 40°F 240°F 210°F Max Valve Position...
  • Page 30 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 31 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 32 CONTROL PANEL OPERATING PROCEDURES Table 3-6. Relationship Between Air/Fuel Valve Position and Energy Input of a Unit Running on Natural Gas Valve position, 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...

  • Page 33: Initial Startup Requirements

    6. 7/16" open end wrench and small adjustable wrenches. An AERCO Gas Fired Startup Sheet included with each KC-1000 must be completed for each 7. Tube of silicone adhesive unit for warranty validation and a copy must be returned promptly to AERCO at: *For propane fired units: an additional 8"...
  • Page 34 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. For propane units, refer to paragraph 4.4 for some additional setup procedures unique to propane units.
  • Page 35 If 8.5” W.C. for FM gas trains or 8.9” W.C. for IRI gas trains cannot be obtained at the 100% valve position, 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 10.
  • Page 36 INITIAL START-UP 22. If the measured oxygen reading is below the NOTE: oxygen range in Table 3, loosen the two In the following step, adjust the valve position to bolts that secure the inlet air shutter to the 13% for natural gas, or 16% for propane. unit using a 7/16”...
  • Page 37 Tables 1, 2 and 3. NOTE: After an adjustment is made to the air regulator, 30. Record all readings on the AERCO start-up the cap must be replaced and securely tightened sheet provided with each unit. Proceed to to obtain an accurate reading paragraph 4.5.
  • Page 38 INITIAL START-UP 6. Remove all of the manometers and barbed fittings and reinstall the pipe plugs using a suitable thread compound. 7. Remove the combustion analyzer probe from the vent hole. Seal the probe hole and replace the vent connection cover. 8.

  • Page 39: Mode Of Operation

    MODE OF OPERATION SECTION 5 - MODE OF OPERATION is expected. The sensor must be shielded from 5.1 INTRODUCTION the sun's direct rays, as well as from direct following paragraphs provide detailed impingement by the elements. If a cover or descriptions of the six different modes of shield is used, it must allow free air circulation.
  • Page 40 AERCO representative be NOTE: contacted. For a complete listing of factory defaults and descriptions of temperature related If a voltage, rather than current signal is used to functions, see Appendices A and E.
  • Page 41 4-20 mA/1-5 Vdc preset with settings that work well in most applications. It is suggested that an AERCO 0-20 mA/0-5 Vdc representative be contacted, prior to changing any temperature related function settings. For...
  • Page 42 RS485 This mode of operation is factory preset and the Modbus signaling to the Boiler. BMS II AERCO BMS controls the air/fuel valve position. Model 5R5-384 can utilize only RS485 There are no setup instructions for each signaling to the Boiler.

  • Page 43: Combination Control System

    100% valve applications. It is suggested that AERCO be position, the BMS will then ask the Combination contacted prior to changing settings other than Control Panel for the domestic boilers to become the unit’s setpoint. For a complete listing of space-heating boilers.

  • Page 45: Section 6 – Safety Device Testing Procedures

    SAFETY DEVICE TESTING SECTION 6-SAFETY DEVICE TESTING PROCEDURES 6. Open the gas supply to the unit and press 6.1 TESTING OF SAFETY DEVICES 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 46: Safety Device Testing

    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. The unit is now ready for operation.
  • Page 47 SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS 6.7 FLAME FAULT TEST The unit is equipped with two interlock circuits 1. Place the ON/OFF switch in the OFF called the Remote Interlock and Delayed Inter- position. lock. Terminal connections for these circuits are located in the I/O Box and are labeled REMOTE 2.
  • Page 48 SAFETY DEVICE TESTING Figure 6.4 Manual Leak Detection Valve 6.8 AIR FLOW FAULT TEST 1. Start the unit in manual mode and set the valve position between 25% and 30%. Figure 6.5 Blower Proof Switch Location and Wiring 2. Once the unit has proved flame, remove either wire #154 or #155 from the blower 6.9 SSOV PROOF OF CLOSURE proof switch (see Fig.
  • Page 49 SAFETY DEVICE TESTING Figure 6.6 SSOV Actuator Cover Screw Location Figure 6.7 Air/Fuel Valve Cover Location 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 and set the valve position between 25% and 30%.
  • Page 50 SAFETY DEVICE TESTING 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 valve position between 25% and 30%. 2. Remove the air/fuel valve cover (Fig. 6.7) by rotating cover counterclockwise...
  • Page 51 MAINTENANCE SECTION 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE To inspect/replace the Ignitor : The unit requires regular routine maintenance to keep up efficiency and reliability. For best opera- 1. Set the ON/OFF switch on the control panel tion and life of the unit, the following routine to the OFF position and disconnect AC maintenance procedures should be carried out in power from the unit.
  • Page 52 MAINTENANCE 10. Replace the rear cover panels or right side 7.4 COMBUSTION CALIBRATION panel. Replace the condensate cup to drain Combustion settings must be checked at the tubing. intervals shown in Table 7-1 as part of the maintenance requirements. Refer to Section 4 for the combustion calibration instructions.
  • Page 53 MAINTENANCE 5. Remove the flame detector and ignition 11. Lower the burner while sliding the air hose cable wires from the flame detector and off the air/fuel valve. Remove the burner ignitor contactor. Remove the ignitor and through the rear of the unit. flame detector per paragraphs 7.2, and 7.3.
  • Page 54 MAINTENANCE 20. To prevent damage to and for easier 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.
  • Page 55 MAINTENANCE 7.6.1 PROPANE UNITS 7.7 HEAT EXCHANGER WATER SIDE For propane units it will be necessary to remove INSPECTION the air mix assembly in addition to the Per CSD-1, the water side of the heat exchanger components outlined in Section 7.6. Proceed as requires an inspection.
  • Page 56 MAINTENANCE 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).

  • Page 57: Section 9 – Rs232 Communication

    Refer 6. If the fault cannot be corrected using the to Section 9 of this manual for detailed RS232 information provided in the Troubleshooting communication set-up and procedures. Tables, contact your local AERCO Repre- sentative.

  • Page 58: Troubleshooting

    TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped running due to thermal 1. Check combustion blower for signs of excessive heat or high DURING IGNITION or current overload current drain that may trip thermal or current overload devices. 2.
  • Page 59 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED 1. Delayed Interlock Jumper not 1. Check for a jumper properly installed across the delayed INTERLOCK OPEN installed or removed. interlock terminals in the I/O box. 2.
  • Page 60 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FLAME LOSS 1. Worn Flame Detector or cracked 1. Remove and inspect the Flame Detector for signs of wear or DURING RUN ceramic. cracked ceramic. Replace if necessary. 2.
  • Page 61 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH WATER TEMP 1. Faulty Water temperature switch. 1. Test the temperature switch to insure it trips at its actual water SWITCH OPEN temperature setting. 2. Incorrect PID settings. 2.
  • Page 62 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge DURING PURGE (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 63 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1. Check hot and neutral in AC Power Box to ensure they are not LINE VOLTAGE 1. Line and Neutral switched in AC reversed OUT OF PHASE Power Box.
  • Page 64 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 5. Defective IGST Board 5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. PRG SWTCH OPEN 1.
  • Page 65 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defective Flame Detecto 2. Replace Flame Detector. SSOV FAULT See SSOV SWITCH OPEN DURING PURGE SSOV FAULT 1. SSOV switch closed for 15 seconds 1. Replace or adjust microswitch in SSOV actuator. If fault DURING RUN during run.
  • Page 67 Enter. the Operating, Setup, Configuration and 4. “Welcome to Aerco” will appear in the laptop Tuning Menus. (The Calibration and or “dumb terminal” display with a listing of Diagnostic Menus should only be used the following available entry choices: by Factory-Trained service personnel).
  • Page 68 RS232 COMMUNICATION (c) Menu changes will be stored in non- within the C-More Control Panel. Events such volatile memory. as power-up, ignition and turn-off are time stamped. Data logged while the unit is running 9. To redisplay the menu and view the option are run-length encoded.
  • Page 69 RS232 COMMUNICATION Table 9-1. 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 9-2. Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time...
  • Page 71 APPENDIX A APPENDIX A - BOILER 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, Remote Setpoint or Outdoor Reset Mode.
  • Page 72 APPENDIX A 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.
  • Page 73 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) 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.
  • Page 74 APPENDIX A APPENDIX A - BOILER 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 75 APPENDIX A APPENDIX A - BOILER 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 77 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 78 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 79 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 81 APPENDIX C Temperature Sensor Resistance Chart (Balco)
  • Page 83 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 Temperatrure of 60F RESET RATIO Temp -10F -15F -20F...
  • Page 84 APPENDIX D Header Temperature for a Building Reference Temperature of 65F RESET RATIO Temp Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F...
  • Page 85 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 86 APPENDIX D Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp...
  • Page 87 APPENDIX E BOILER 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 Boiler Unit Size 1.0 MBTU Boiler Mode Constant Setpoint Remote Signal 4 –...
  • Page 88 APPENDIX E BOILER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Configuration Menu --Continued Network Timeout 30 seconds Hi DB Setpt En Demand Offset Deadband High Deadband Low Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min...
  • Page 89 APPENDIX F...
  • Page 90 APPENDIX F...
  • Page 91 APPENDIX F...
  • Page 92 HIGH PRESS. GAS SWITCH GP-122412 123863 1/8" NPT BALL VALVE OTHER PARTS ITEM PART NO. DESCRIPTION GP-122406 BURNER & AIR/FUEL VALVE O-RING AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER BOILER PARTS LIST 44 45 PL-A-139 041304 DWN.BY DATE SCALE (SH.
  • Page 93 APPENDIX F CPLG. W/PLUG SIGHT PORT AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER BOILER PARTS LIST PL-A-139 041304 DWN.BY DATE SCALE (SH. 2 OF 2) APPD. DATE...
  • Page 94 APPENDIX F...
  • Page 95 APPENDIX F...
  • Page 97 APPENDIX G...
  • Page 98 APPENDIX G...
  • Page 99 APPENDIX H...
  • Page 100 APPENDIX H...
  • Page 101 APPENDIX I KC1000 CONTROL PANEL EXPLODED VIEW...
  • Page 102 APPENDIX I KC1000 CONTROL PANEL REAR VIEW...
  • Page 103 DESCRIPTION PART NUMBER C-More Control Box 181198 Burner Assembly, Natural Gas GM-20874 Burner Assembly, Propane GM-20933 NOTES: 1. If boiler is installed in the State of Kentucky, contact your local AERCO Sales Representative for Temperature Switch rated for 200°F max.

  • Page 105: Warranties

    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 106 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.

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