Aerco KC Series Equipped with C-More Controller for Mass Manual de usuario Pagina 1

Printed in U.S.A. REVISED 12/10 AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 20

SAFETY PRECAUTIONS 1-4 2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall

INSTALLATION 2-1 `SECTION 2 - INSTALLATION 2.1 RECEIVING THE UNIT Each KC1000 Heater is shipped as a single crated unit. The shipping weight is app

INSTALLATION 2-2 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Fig 2.1 These are the minimum c

INSTALLATION 2-3 Shut-off valves and union conections must be installed in the inlet and outlet lines for main-tenance. The use of dielectric unions

INSTALLATION 2-4 Figure 2.4b Pressure/Temperature Relief and Drain Valve Installation Location 2.3.6 CONDENSATE PIPING The KC Heater is designed t

INSTALLATION 2-5 Figure 2.6 Gas Supply Regulator and Manual Shut -Off Valve Location All pipe should be de-burred and internally cleared of any sc

INSTALLATION 2-6 2.5 ELECTRICAL SUPPLY The AERCO Gas Fired Equipment Electrical Power Wiring Guide, (GF-1060), must be consulted in addition to the

INSTALLATION 2-7 GAS SHUT-OFFVALVEI/O BOXBLOWER Figure 2.9 Input/Output (I/O) Box Location 2.6.1 OUTDOOR AIR SENSOR IN Not applicable to Water Heat

INSTALLATION 2-8 INTL’K IN. Both interlocks, described below, are factory wired in the closed position. NOTE: Both the Delayed Interlock and Remot

INSTALLATION 2-9 2.7 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-1050, must be consulted before any flue or com

Printed in U.S.A. REVISED 12/10 AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 20

CONTROL PANEL OPERATING PROCEDURES 3-1 SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION The information in this Section provides a

CONTROL PANEL OPERATING PROCEDURES 3-2 Table 3-1. Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 Fo

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

CONTROL PANEL OPERATING PROCEDURES 3-4 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu wil

CONTROL PANEL OPERATING PROCEDURES 3-5 NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Ou

CONTROL PANEL OPERATING PROCEDURES 3-6 Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Intern

CONTROL PANEL OPERATING PROCEDURES 3-7 3.7. TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change

CONTROL PANEL OPERATING PROCEDURES 3-8 (a) Blower relay energizes and turns on blower. (b) Air/Fuel Valve rotates to the full-open purge position a

CONTROL PANEL OPERATING PROCEDURES 3-9 STEPPERMOTORDETAIL "A"DIAL(DETAIL “A”)BLOWERBURNER25 Figure 3-6. Air/Fuel Valve In Ignition Position

CONTENTS i GF-111 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER Operating & Maintenance Instructions FOREWARD A Section 1 – SAFETY PRECAUTI

INITIAL START-UP 4-1 SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the KC-1000 Water Heater is comprised

INITIAL START-UP 4-2 SSOV1/4" NPT PLUG(INSTALLMANOMETERHERE) Figure 4.1 1/4” Gas Plug Location 4.2.3 PREPARING THE FLUE VENT PROBE HOLE 1. I

INITIAL START-UP 4-3 NOTE: On initial start-up, or return to service from a fault condition, the unit will remain at a 29% valve position for two-minu

INITIAL START-UP 4-4 17. If necessary, repeat the adjustment until the oxygen level is within the range specified in Table 1. 18. Replace the regu

INITIAL START-UP 4-5 NOTE: Adjust the inlet air shutter only at 100% valve position. Do not adjust the differential pressure regulator. 25. Change

INITIAL START-UP 4-6 5. Reinstall the regulator cap and gasket on the regulator. Tighten the cap using a screwdriver or wrench. 6. Remove all of

INITIAL START-UP 4-7 7. Press the CHANGE key. The display will begin to flash. 8. Raise or lower the minimum load adjustment in increments of one

INITIAL START-UP 4-8 OVER-TEMPERATURESWITCHES209TEMPERATURE SWITCH DETAILS137HARNESS136FROM SHELLNCNCCNOC25OVER TEMP. SWITCH(SEE DETAIL) Figure 4.6

SAFETY DEVICE TESTING 5-1 SECTION 5 - SAFETY DEVICE TESTING PROCEDURES 5.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety dev

CONTENTS ii Section 5 – SAFETY DEVICE TESTING PROCEDURES 5-1 Para. Subject Page 5.1 Testing of Safety Devices 5-1 5.2 Low Gas Pressure Fault Test 5-

SAFETY DEVICE TESTING 5-2 HIGH GASPRESSURE SWITCH Figure 5.2 High Gas Pressure Switch 5. 4 LOW WATER LEVEL FAULT TEST 1. Set the ON/OFF switch in

SAFETY DEVICE TESTING 5-3 5.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Inter-lock. Te

SAFETY DEVICE TESTING 5-4 5.8 AIR FLOW FAULT TEST 1. Start the unit in manual mode and set the valve position between 25% and 30%. 2. Once the uni

SAFETY DEVICE TESTING 5-5 5.10 PURGE SWITCH OPEN DURING PURGE 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode an

SAFETY DEVICE TESTING 5-6 5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Ve

MAINTENANCE 6-1 SECTION 6 – MAINTENANCE 6.1 MAINTENANCE SCHEDULE The KC1000 Heater requires regular routine maintenance to maintain efficiency

MAINTENANCE 6-2 SPARK IGNITORASSEMBLYBURNERSHELLFLAMEDETECTORSILICONEPLUG Figure 6.1 Spark Ignitor and Flame Detector Location Table 6-1. Maintenan

MAINTENANCE 6-3 2. Remove the left side panel from the unit. 3. Disconnect the flame detector lead wire and unscrew the flame detector and remove

MAINTENANCE 6-4 3. Shut the water inlet, outlet and recirculation valves to the unit. 4. Open the drain valve on the unit. 5. Slowly open the pre

MAINTENANCE 6-5 10. Carefully remove the lower tubing assembly taking care not to lose either the cold water or hot water mixing orifice, (See Fig. 6

FOREWORD A Foreword The AERCO KC Water Heating System is a true industry advance that meets the needs of today's energy and environment

MAINTENANCE 6-6 12. Remove the compression fitting at the top of the impeller housing and remove the impeller housing, (See Fig. 6.6). HOT WATER TUBE

MAINTENANCE 6-7 IMPELLER HOUSINGCOVER Figure 6.9 Impeller Housing Disassembly 19. Once the BTU transmitter has been inspected and cleaned, reassembl

MAINTENANCE 6-8 6. Remove the grounding terminal from the burner by loosening the upper screw and sliding the connector from the grounding rod, (See

MAINTENANCE 6-9 Figure 6.12 Exhaust Sensor Connector Location 13. Disconnect the air/fuel valve wiring harness connector from the control panel.

MAINTENANCE 6-10 Figure 6.14 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube betwe

MAINTENANCE 6-11 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. 6.16). 2

MAINTENANCE 6-12 Figure 6.17 Propane Air Regulator Measuring Taps 6.9 HEAT EXCHANGER INSPECTION AND CLEANING Inspecting the Heat Exchanger The wate

MAINTENANCE 6-13 10. Reassemble the cap screws and nuts through the upper head and shell ring. Cross tighten the nuts to approximately 75 ft./lb. tor

MAINTENANCE 6-14 Figure 6.19 – HydroSkrub Pumping System Set-Up Diagram for KC-1000 Pumping System Set-Up Directions 1. Turn off the water heater a

MAINTENANCE 6-15 strength is depleted (two pounds of deposits removed per gallon used) or the equipment is free from calcium and other water formed mi

MAINTENANCE 6-16 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/

MAINTENANCE 6-17 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-MORE CONTROL BOX) The Hydraulic Zero Needle Valve is factory set in new equipment an

6.13 FLAME STRENGTH MEASURMENT The flame sensor is a very important safety device. Its function is to sense the absence of a flame (over a certai

MAINTENANCE 6-19 Check for the following during the reading: • Measure the voltage in µA between the flame rod and the flame connector. If the flame

TROUBLESHOOTING 7-1 SECTION 7- TROUBLESHOOTING GUIDE7.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in is

TROUBLESHOOTING 7-2 KC1000 WATER HEATER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. B

TROUBLESHOOTING 7-3 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OP

TROUBLESHOOTING 7-4 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FFWD TEMP SENSOR FA

TROUBLESHOOTING 7-5 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 3. Defe

TROUBLESHOOTING 7-6 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED DURING

SAFETY PRECAUTIONS 1-1 SECTION 1 -- SAFETY PRECAUTIONS1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe al

TROUBLESHOOTING 7-7 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE OUT OF

TROUBLESHOOTING 7-8 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 3. Switc

TROUBLESHOOTING 7-9 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV FAULT DURING PU

APPENDIX A A-1 WATER HEATER MENU ITEM DESCRIPTIONS MENU LEVEL & FUNCTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint te

APPENDIX A A-2 WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be en

APPENDIX A A-3 WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows

APPENDIX A A-4 WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate

APPENDIX B STARTUP, STATUS AND FAULT MESSAGES STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DISABLED HH:MM pm MM/DD/YY Displayed if ON/OFF s

APPENDIX A FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is open. LOW WATER L

APPENDIX B FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during stan

SAFETY PRECAUTIONS 1-2 CAUTIONS! Must be observed to prevent equipment damage or loss of operating effectiveness. CAUTION! Many soaps used for gas p

APPENDIX C Temperature Sensor Resistance Chart (Balco)

APPENDIX D D-1 WATER HEATER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit C

APPENDIX D D-2 WATER HEATER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Tuning Menu Prop Band 8°F Integral Gain 1.60 Derivati

APPENDIX E E-1

APPENDIX E E-2 18(45.7)49 (124.5)57 (144.8)16-3/422-5/871-7/871-7/819 (48)15-1/2 (39.4)6 (15.2) I.D.FLUE CONN.3/4 (1.9) DIA.(ENCLOSURE)PRESS./TEMP.RE

APPENDIX E E-3 1/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.3/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.32GP-1226141293531GM-209341123581G

APPENDIX E E-4 1436351634715181716103329323130402413427 284943SEE DETAIL "A"EXPLODEDDETAIL "A"13121142958SEE DRAWING PL-A-134 FOR

APPENDIX E E-5 1 1/2" SAFETY SHUT-OFF VALVEDIFFERENTIAL PRESSURE REGULATOR W/ BROWN SPRINGBURNER/GAS VA. ADAPTOR23451GM-161095GAS COCKGP-122415G

APPENDIX E E-6 5413718166231/4"NPT x 3/8"OD TUBE 90° COMP. FTG.PUMP OUTLET TUBE1/4"NPT STREET ELBOW1/4"NPT CLOSE NIPPLE1/4"N

APPENDIX E E-7 1714J15159845111041312NORTHVALE, NJ 07647(SH. 2 OF 2)PL-A-134KC1000 WATER HEATERBTU TRANSMITTER ASSEMBLY(COMPLETE ASS’Y GM-20872)INT

SAFETY PRECAUTIONS 1-3 1. INSTALLATION OF CARBON MONOXIDE DETECTORSa. In the event that the side wall horizontally vented gas fueled equipment is in

APPENDIX E E-8 DWN.BYSCALEAPPD.KC1000 WATER HEATERIRI GAS TRAINSD-A-606030801PDRDATEDATENTSREV.DNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCO3/4"

APPENDIX F F-1

APPENDIX F F-2

APPENDIX G G-1 CLOSURE SWITCHPROOF OFGRNWHT60 Hz120 VAC IN20 ANEUGNDHOTNCCGNHGNDHGN123456123456789123456789101112131415123456789101112CONTROL BOX CONN

APPENDIX G G-2 CONTROL BOX CONNECTORSGAS FIRED BOILER SYSTEMWIRING SCHEMATIC1616131210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 2422

APPENDIX H H-1 V.F.D. Display ModuleP/N: 124527Display BoardP/N: 124365C.P.U. BoardP/N: 124364Low Water Cutoff BoardP/N: 124363Power Supply Boa

APPENDIX H H-2 P1P2P3P4P5P6SHELL HARNESSCONNECTOR(19 PIN)INTERLOCK HARNESSCONNECTOR(16 PIN)EXT. SENSOR/COMMHARNESS CONNECTOR(24 PIN)GAS TRAIN

03/01/05 W-1 (D102.0) STANDARD WARRANTY: Gas-Fired Water Heater INTERNATIONAL, INC. PRESSURE VESSEL: 10 YEARS NON-PRORATED T

03/01/05 W-2 (D102.1) STANDARD WARRANTY: Gas-Fired Water Heater INTERNATIONAL, INC. CONDITIONS OF WARRANTY Should an AERCO g