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Aerco KC Series Installation, Operation & Maintenance Instructions Manual

Gas fired installation, operation & maintenance instructions water heating system
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Download this manual See also: Operation & Maintenance Manual, Installation, Operation & Maintenance Instructions Manual
Instruction
GF-105
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
KC Series
Gas Fired
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
1,000,000 BTU/HR Input
Applicable to Serial Numbers G-01-026 and above
Patent No. 4,852,524
REVISED 12/30/04
Printed in U.S.A.

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  • Page 1: Maintenance Instructions

    Instruction GF-105 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions KC Series Gas Fired Water Heating System Natural Gas or Propane Fired, Condensing and Forced Draft Hot Water Heater 1,000,000 BTU/HR Input Applicable to Serial Numbers G-01-026 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-105 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER Operating & Maintenance Instructions FOREWORD Section 1 SAFETY PRECAUTIONS--------------------------------1 Section 2 INSTALLATION PROCEDURES-----------------------2 Receiving the Unit Field Control Wiring Unpacking Flue Gas Vent Installation Installation Combustion Air Gas Supply Piping...
  • Page 4 CONTENTS Section 6 MAINTENANCE REQUIREMENTS-------------------29 Maintenance Schedule BTU Transmitter Pump Spark Ignitor Lubrication Flame Detector BTU Transmitter Assembly Combustion Calibration Manifold and Exhaust Tubes Safety Device Testing Heat Exchanger Inspection Section 7 TROUBLESHOOTING-----------------------------------39 Gas Pressure Fault Flame Fault Exhaust Temperature Fault Air Pressure Fault Water Level Fault System Fault...
  • Page 5 FOREWORD Foreword The AERCO KC Hot Water Heating System is a true industry advance that meets the needs of today’s energy and environmental concerns. Designed for use in any potable water heating system, it provides constant temperature water regardless of flow rate. It’s small space requirements and venting capabilities allows installations without normal restrictions yet with maximum flexibility.

  • Page 6: Safety Precautions

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

  • Page 7: Installation Procedures

    INSTALLATION PROCEDURES SECTION 2 - INSTALLATION PROCEDURES The freight carrier should be notified immediately 2.1 RECEIVING THE UNIT if any damage is detected. The following Each KC unit is shipped as a single crated unit. accessories come standard with each unit and The shipping weight is approximately 1500 lb.
  • Page 8 The locations of the 2" NPT cold water inlet and These are the minimum clearance dimensions hot water outlet piping connections are shown in required by AERCO. Local building codes may Figure 2.4. Flow rates through the unit are require more clearance and take precedence.
  • Page 9 INSTALLATION PROCEDURES for startup and testing. It should be a minimum maintenance. Recirculation flow rates must be kept to 8 gpm or less. In a multiple unit of 3/4". It cannot be omitted (See Fig. 2.4a) installation, each unit must be tied into the system recirculation system.
  • Page 10 Figure 2.5 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 started. WARNING !
  • Page 11 National Electrical Code and/or with any AERCO. applicable local codes. 2.5 ELECTRIC SUPPLY AERCO Gas Fired Equipment Electrical Power The electrical wiring diagram is shown in Figure Wiring Guide (GF-1060) must be consulted in 2.8. Conduit should be run from the knockouts...

  • Page 12: Field Control Wiring

    SHIELD Figure 2.10 Field Control Box Wiring 2.7 FLUE GAS VENT INSTALLATION FIELD AERCO Gas Fired Venting and Combustion Air CONTROL WIRING Guide, GF-1050, must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification.

  • Page 13: Combustion Air

    If the maximum allowable optional Inlet Air Adapter # GM-18917 available equivalent lengths of piping are exceeded, the from AERCO. This Adapter bolts directly on to unit will not operate properly or reliably. the air inlet of the unit blower. See installation instructions with Adapter.

  • Page 14: Water Level Test And Reset Switches

    CONTROL PANEL OPERATING PROCEDURES SECTION 3- CONTROL PANEL OPERATING PROCEDURES The following is a guide to the operation of the • unit’s control panel. Initial startup of this unit must 2- eight segment LED displays • be performed by factory trained startup personnel. 5 indicator status lights •...
  • Page 15 CONTROL PANEL OPERATING PROCEDURES The third LED, “ON”, indicates the status of the menu parameter are listed within this section. For start relay, (Fig. 3.2). The start relay is internal to more data concerning the minimum and the controller and is part of the start string for the maximum range, and factory defaults of menu unit.
  • Page 16 CONTROL PANEL OPERATING PROCEDURES NOTE: To access the percent of firing rate press the Changing the setpoint will only be INDEX button while in the primary menu until recognized when the unit is in the automatic " (Pct) is displayed in the lower LED. Use the mode.
  • Page 17 CONTROL PANEL OPERATING PROCEDURES For a complete explanation of the secondary menu parameters see the Appendix A of this manual. 3.5 THE ANNUNCIATOR CIRCUIT The annunciator consists of the annunciator circuit board, the front panel LCD display, and 4 function switches (see Fig. 3.8). The annunciator circuit board is the interface between the LCD display and the combustion safeguard system.
  • Page 18 CONTROL PANEL OPERATING PROCEDURES LCD display on the front of the control panel. LOW WATER The unit water level is " LEVEL below the probe level. They are labeled CLEAR, , and AUX. REMOTE The interlock terminals, The MAIN display is used during normal operation DISABLED in the relay box, are not of the unit.

  • Page 19: On\Off Switch

    CONTROL PANEL OPERATING PROCEDURES 3.6 THE COMBUSTION SAFEGUARD 3.7 WATER LEVEL TEST and RESET CONTROLLER SWITCHES The Combustion Safeguard is responsible for The water level switches are located on the left monitoring the safety components during the start side of the panel (see Fig. 3.10). When depressed sequence, and after flame is established.
  • Page 20 CONTROL PANEL OPERATING PROCEDURES 3.9 START SEQUENCE When the unit is in the standby mode, and there is a demand for hot water, the following will occur: 1. Upon demand the temperature controller’s ON status indicator will light. 2. The combustion safeguard’s PILOT LED lights, and the blower contactor energizes, starting the blower.

  • Page 21: After Flame

    CONTROL PANEL OPERATING PROCEDURES from the ignition transformer and the MAIN LED lights of the combustion safeguard. At this point, the annunciator will display FLAME PROVEN. The unit, in the automatic mode, is released to modulate through the PID controls. 3.10 AFTER FLAME Once the control signal has gone below the stop level (see section 3.12 for Stop Level explanation),...

  • Page 22: Initial Start

    6 to complete 8. * Digital multimeter with 10 amp and volt the initial unit start-up. capability An AERCO Gas Fired Startup Sheet included *Although not necessary for actual start-up with each KC-1000 must be completed for each procedures, recommended for troubleshooting.
  • Page 23 INITIAL START-UP 1/4" NPT PLUG (INSTALL MANOMETER HERE) SSOV Figure 4.3 Differential Regulator Adjustment Tool Figure 4.1 Installation 1/8” Gas Plug Location 4.2.3 INSTALLING THE DIFFERENTIAL 4.2.2 PREPARING THE FLUE VENT REGULATOR ADJUSTMENT TOOL PROBE HOLE 1. Remove the cap from the differential If the unit has been installed using the pressure regulator (see Fig.
  • Page 24 Table 1. Repeat adjustment until oxygen is contact the local AERCO representative in within the specified range. your area. Running the unit on insufficient gas pressure will void the warranty 10.
  • Page 25 INITIAL START-UP clockwise, 1/4-1/2 turns, to increase gas Open the shutter 1/4” to 1/2”, to increase the flow. oxygen level then tighten the nuts. 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.

  • Page 26: Unit Reassembly

    Table 1. 28. Continue this procedure until all oxygen levels are within the ranges specified in Tables 1,2, and 3. 29. Record all readings on the AERCO start-up sheet provided with each unit. Proceed to Section 4.5. 4.4 PROPANE COMBUSTION...

  • Page 27: Temperature Control Calibration

    INITIAL START-UP 8. Replace the unit’s panels and hood. 4.6.2 MINIMUM LOAD ADJUSTMENT 1. Place the control in the secondary menu by 9. Remove the combustion analyzer probe simultaneously pressing and ENTER. from the vent hole. Seal the probe hole and replace the vent connection cover.

  • Page 28: Over Temperature Limit Switch

    11. If the outlet temperature does not maintain pressing and ENTER. setpoint after a reasonable amount of time and adjustment contact your local AERCO 2. Press INDEX until Pct is displayed. This is representative. the unit’s percentage of firing rate.
  • Page 29 INITIAL START-UP F water temperature. Do NOT attempt to adjust it’s set point. To adjust the lower over temperature switch limit switch: 1. Remove the wing nut from the top center of the shell cap. Lift the cap off the shell. 2.
  • Page 30 SAFETY DEVICE TESTING SECTION 5-SAFETY DEVICE TESTING PROCEDURES 5.1 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 31: Safety Device Testing

    SAFETY DEVICE TESTING 9. Open the water shut-off valve in the supply 2. Once the unit is firing, close the manual piping to the unit. leak-detection valve. This is the valve located between the safety shut off valve 10. Press the LOW WATER LEVEL RESET and the differential gas pressure regulator button to reset the low water cutoff and (See Fig.

  • Page 32: Purge Interlocks Fault Test

    SAFETY DEVICE TESTING 2. Disconnect wire #17 from the air pressure 6. Clear the annunciator. Turn the ON/OFF switch located on the air/fuel valve (See Fig. switch to the OFF position. 5.4). 3. Restore AC power to the unit. SSOV ACTUATOR 4.

  • Page 33: Safety Pressure Relief Valve Test

    SAFETY DEVICE TESTING 10. Restore AC power to the unit. 20. Reconnect wire #62 to the ignition position switch 11. Start the unit. 21. Replace the air/fuel valve cover. WARNING! 22. Restore AC power to the unit THIS IS A 120 VOLT AC COMBUSTION 23.
  • Page 34 MAINTENANCE SECTION 6 – MAINTENANCE To inspect/replace the Ignitor 6.1 MAINTENANCE SCHEDULE 1. Put the green ON/OFF button on the control The KC1000 requires regular routine panel, to the OFF position and disconnect maintenance to keep up efficiency and AC power to the unit. Disconnect the plastic reliability.
  • Page 35 MAINTENANCE Prior to reinstalling the ignitor, an anti-seize compound must be applied to the ignitor 6. Replace the rear cover panels or left side threads. panel. Replace the condensate cup to drain tubing. Reinstall the ignitor using the ignitor removal 6.4 COMBUSTION CALIBRATION tool.
  • Page 36 MAINTENANCE 6.7 BTU TRANSMITTER ASSEMBLY NOTE: The BTU Transmitter is a crucial part of the It is not necessary to disconnect the unit’s temperature control system. It must be electrical wires to the pump inspected and kept free of scale and debris in order for the unit to maintain accurate outlet water temperatures.
  • Page 37 MAINTENANCE 12. Loosen the compression fitting holding the 13. Remove the compression fitting at the top of hydraulic zero and control orifice tube the impeller housing and remove the assembly to the pump’s impeller housing, impeller housing, (See Fig. 6.7). (See Fig.
  • Page 38 MAINTENANCE NOTE: Compression fittings are nickel-plated and should be replaced only with nickel-plated fittings. Do not use brass fittings 6.8 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, the exhaust manifold, and/or the condensate cup.
  • Page 39 MAINTENANCE Figure 6.11 Grounding Terminal Location 9. Loosen the hose clamp at the air/fuel valve Figure 6.13 outlet and slide the clamp back towards the Exhaust Sensor Connector Location burner, (see Fig. 6.12). 13. Disconnect the air/fuel valve wire harness, 10.
  • Page 40 MAINTENANCE 19. Remove the flue venting from the exhaust manifold. 20. Removing the exhaust manifold insulation will prevent it from being damaged and will make it easier to handle the exhaust manifold once it is removed. Using a 7/16” wrench or socket remove the 3 bolts and fender washers securing the insulation to the exhaust manifold.
  • Page 41 Remove the upper head and upper the older is a concave head. head-liner, (See Fig. 6.19). 6. Inspect and clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head. AERCO recommends that NEW gaskets be used when reassembling.
  • Page 42 6. Inspect and clean the heat exchanger by warranty. thoroughly before reassembling the upper head. 7. Clean all gasket surfaces thoroughly. AERCO recommends that NEW gaskets be used when reassembling the upper head to the unit shell.
  • Page 43 MAINTENANCE Figure 6.20 Concave Style Head 8. Place the shell gasket then the release gasket on top of the shell ring and align the gasket holes with those in the flange. 9. Place the upper head liner (dimple facing in/down) on top of the gasket, with all holes aligned.

  • Page 44: Troubleshooting

    10” to 12” W.C. cannot be In the event that a fault cannot be remedied, obtained, proceed to Step 8. contact your local AERCO Representative or the factory for Technical Assistance. 4. If static pressure is already 10” to 12” W.C.
  • Page 45 5. If there is no continuity and the exhaust Contact a qualified service technician or your temperature fault will not clear, combustion local AERCO representative for more calibrate the unit as per Section 4.4. information. 7.3 LOW WATER LEVEL 7.2 HIGH EXHAUST TEMPERATURE...
  • Page 46 TROUBLESHOOTING 5. If 12 VAC is read on the AC voltmeter, 6. If there is no continuity repair as necessary. disconnect power to the unit and ground the If there is continuity, replace the low water probe to the unit shell. level circuit.
  • Page 47 6. Remove the unit cap. Disconnect and remove the header sensor. 13. If the over temperature fault does not clear 7. Allow the sensors to cool to ambient consult your local AERCO representative or temperature. contact aqualified service technician. 8. Referring to the Temperature Sensor Chart in Appendix C of this manual, measure the 7.4.3 BTU TRANSMITTER PUMP...
  • Page 48 TROUBLESHOOTING 10. Place the entire length of the sensors in a are shorted or in an open circuit condition, water bath of known temperature. Measure which may indicate a wiring problem. the resistance of the probe, and determine the corresponding temperature from the 20.
  • Page 49 TROUBLESHOOTING 2. If the gas supply valves were open, restart 4. Remove the actuator portion from the valve the unit. body and inspect for signs of leaking hydraulic fluid. 3. Remove the cover to the Air Fuel Valve. Ensure that the Air Fuel Valve rotates to the 5.
  • Page 50 TROUBLESHOOTING 20. Restore electrical power to the unit and restart the unit. 6. Start the unit. 21. If the safety shutoff valve still does not open, 7. At ignition, an arc should be observed. It proceed to section 7.7.8. should last for approximately 15 seconds. 22.
  • Page 51 TROUBLESHOOTING 21. If wires #12 and #29 have continuity, inspect the pin on wire #12 in the 9-pin connector for 7. If 345 VAC is not observed, disconnect proper insertion or signs of wear electrical power to the unit. 22. Inspect the connector on wire #29 at the AC 8.
  • Page 52 TROUBLESHOOTING 3. If a rumbling sound is heard when 7.6 LOCKOUT RUN AIR FLOW approaching firing rates above 75%, A LOCKOUT RUN AIR FLOW indicates that the combustion calibrate the unit as per section air pressure while running is too low for 4 of this manual.
  • Page 53 TROUBLESHOOTING 7. Referring to system schematic 161412 in 7.7.6 Air/Fuel Valve Open Proving Appendix F, locate wire #17 and #24 and Switch check both for continuity. 7.7.7 Air Fuel Valve not Rotating 8. Check the switch end of wires #17 and #24 Recommended Troubleshooting for loose connections.
  • Page 54 3. If the Annunciator displays the message open while the unit is firing. (Refer to PURGE INTLK OPEN and the air\fuel valve AERCO GF-1050 for sizing.) does not rotate, proceed to section 7.7.7. 3. If the combustion air supply is okay, remove wires #17 and #24 from the blower proof 4.
  • Page 55 17. If 120VAC is not present proceed to section 24. Restart the unit. If the condition persists, 7.7.5. contact a certified Aerco Service personnel or your local Aerco representative. 7.7.7 AIR/FUEL VALVE NOT ROTATING 1. Disconnect electrical power to the unit.
  • Page 56 16. Measure the DC voltage again it should be approximately 3 volts DC during PURGE 13. If the system fault persists contact your and 1 to 1.3 volts during ignition. local AERCO representative for further assistance. 17. If the voltage is correct replace the stepper motor driver board.
  • Page 57 APPENDICES APPENDIX A Temperature Controller Menus APPENDIX B Temperature Controller Quick Programming Guide APPENDIX C Temperature Sensor Resistance Chart APPENDIX D Mode of Operation Default Settings APPENDIX E Dimensional & Parts Drawings APPENDIX F Piping Drawings APPENDIX G Wiring Schematics APPENDIX H Control Box isometric drawing...
  • Page 59 APPENDIX A PRIMARY MENU ITEM DESCRIPTIONS tout This is the actual outlet water 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 500,000 BTU gas input while a 75 % signal equals approximately 750,000 BTU...
  • Page 60 APPENDIX A Secondary Menu Item Description 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. Displays the current outlet water tout temperature of the heater. Displays the temperature of the BTU transmitter sensor.
  • Page 61 APPENDIX A This is minimum load adjust used during OFSt a water heater temperature calibration. It adjusts the controller’s linear offset relative to the temperature of the BTU transmitter sensor. Similar to SEnS it is adjusted when the controllers output is less than 30%.
  • Page 62 APPENDIX A Turns the outlet sensor feedback ON or OFF. Used during factory calibration of the BTU transmitter. Feedback should always be in the ON position during normal operation. Addr This displays the address for the controller. It is used for external communication with a computer.
  • Page 63 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 paramters, and how to make changes to them. • PRIMARY MENU to SECONDARY MENU Press ENTER and the ⇑ arrow key. The display will indicate: •...
  • Page 64 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 ⇓...
  • Page 65 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: •...
  • Page 66 APPENDIX C viii...
  • Page 67 APPENDIX D WATER HEATER DEFAULT SETTINGS MENU LEVEL DESCRIPTION OF CODE0 FACTORY & CODE DEFAULT PRIMARY MENU tout OUTLET TEMPERATURE ACTUAL PERCENTAGE OF FIRING ACTUAL setp UNIT’S SETPOINT TEMPERATURE auto AUTOMATIC\MANUAL MODE AUTO ON SECONDARY MENU func MODE OF OPERATION FDFO tout OUTLET TEMPERATURE...
  • Page 68 APPENDIX D bp 7 bp_8 BREAK POINT 8 bp 8 bp_9 BREAK POINT 9 bp 9 bp_A BREAK POINT bp A bp_B BREAK POINT bp B SECURE MENU SECr SECURITY LEVEL Func MODE OF OPERATION fDfO gAin GAIN PROPORTIONAL BAND 5000 Lofi LOW FIRE...
  • Page 69 APPENDIX E...
  • Page 70 APPENDIX E...
  • Page 71 APPENDIX E xiii...
  • Page 72 APPENDIX E...
  • Page 73 APPENDIX F...
  • Page 74 APPENDIX F...
  • Page 75 APPENDIX F xvii...
  • Page 76 APPENDIX F xviii...
  • Page 77 APPENDIX F...
  • Page 78 APPENDIX F FLOOR FLOOR...
  • Page 79 APPENDIX G...
  • Page 80 APPENDIX G xxii...
  • Page 81 APPENDIX H 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 H 123280-W1 WATER HEATER TEMPERATURE CONTROLLER 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 xxiv...
  • Page 84 HEAT EXCHANGERS • WATER HEATERS • BOILERS HEAT RECLAMATION SYSTEMS • CONTROL VALVES STEAM GENERATORS HOT WATER SYSTEMS AERCO INTERNATIONAL, INC. • 159 PARIS AVE. • NORTHVALE, N.J. 07647 201-768-2400 • TELEX 135450 • FAX 201-768-7789 Visit Us at www.aerco.com...

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