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Aerco KC Series Operation And Maintenance Manual
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APPENDIX H
I-2
P1
P2
P3
P4
P5
P6
SHELL HARNESS
CONNECTOR
(19 PIN)
INTERLOCK HARNESS
CONNECTOR
(16 PIN)
EXT. SENSOR/COMM
HARNESS CONNECTOR
(24 PIN)
GAS TRAIN HARNESS
CONNECTOR
(9 PIN)
A/F VALVE
HARNESS
CONNECTOR
(16 PIN)
SENSOR
HARNESS
CONNECTOR
(7 PIN)
TO INPUT/OUTPUT (I/O) BOX
KC1000 CO
NTROL PANEL RE
AR
VIEW
101
103
Table of Contents
Default Chapter
3
Table of Contents
3
Section 1 - SAFETY PRECAUTIONS
7
Safety Precautions
7
Warnings & Cautions
7
Emergency Shutdown
8
Manual Gas Shutoff Valve
8
Prolonged Shutdown
8
Section 2 - INSTALLATION PROCEDURES
9
Heater Clearance
9
Installation
9
Receiving the Unit
9
Unpacking
9
Inlet and Outlet Location
10
Installation
10
Lifting Lug Location
10
Setting the Unit
10
Water Inlet and Outlet Piping
10
Condensate Piping
11
Pressure/Temperature Relief and Drain Valve
11
System Recirculation
11
Test Hose Bib
11
Condensate Drain Assembly Location
12
Gas Supply Piping
12
Gas Supply Pressure Regulator
12
Gas Supply Regulator and Manual Shut - off Valve Location
12
AC Power Box Location
13
Electrical Supply
13
Iri Gas Train Kit
13
Analog in
14
Aux Sensor in
14
Electrical Requirements
14
Field Control Wiring
14
Exhaust Switch in
15
Interlocks
15
Ma out
15
Shield
15
Combustion Air
16
Flue Gas Vent Installation
16
I/O Box Wiring
16
Combustion Air from Inside the Building
17
Combustion Air from Outside the Building
17
Sealed Combustion
17
Section 3 - CONTROL PANEL OPERATING PROCEDURES
19
Control Panel Description
19
Control Panel Front View
19
Control Panel Operating Procedures
19
Introduction
19
Operating Controls, Indicators and Displays
20
Control Panel Menus
21
Menu Processing Procedure
21
Menu Structure
22
Operating Menu
22
Setup Menu
22
Configuration Menu
23
Safety Shut-Off Valve
25
Start Sequence
25
Tuning Menu
25
Air/Fuel Valve in Purge Position
26
Blower Proof Switch
26
Air/Fuel Valve in Ignition Position
27
Start/Stop Levels
27
Initial Start- up
29
Initial Start- up Requirements
29
Required Tools and Instrumentation
29
Section 4 - INITIAL START-UP
29
Tools and Instrumentation for Combustion Calibration
29
Differential Regulator Adjustment Tool Installation
30
Installing the Differential Regulator Adjustment Tool
30
Natural Gas Combustion Calibration
30
Preparing the Flue Vent Probe Hole
30
Air Shutter Locking Nut Location
32
Propane Air Differential Pressure Taps
33
Propane Combustion Calibration
33
Unit Reassembly
33
Minimum Load Adjustment
34
Setting the Outlet Water Temperature Setpoint
34
Temperature Control Calibration
34
Maximum Load Adjustment
35
Over-Temperature Limit Switch Adjustments
35
Over Temperature Limit Switch Location
36
High Gas Pressure Test
37
Low Gas Pressure Fault Test
37
Section 5 - SAFETY DEVICE TESTING PROCEDURES
37
Testing of Safety Devices
37
High Gas Pressure Switch
38
Low Water Level Fault Test
38
Temperature Limit Switch Setting
38
Water Temperature Fault Test
38
Delayed Interlock
39
Flame Fault Test
39
Interlock Tests
39
Remote Interlock
39
Air Flow Fault Test
40
Blower Proof Switch Location and Wiring
40
SSOV Actuator Cover Screw Location
40
Ssov Proof of Closure Switch
40
Air/Fuel Valve Cover Location
41
Air/Fuel Valve Purge and Ignition Switch Locations
41
Ignition Switch Open During Ignition
41
Purge Switch Open During Purge
41
Safety Pressure Relief Valve Test
42
Maintenance Schedule
43
Section 6 - MAINTENANCE
43
Spark Ignitor
43
Flame Detector
44
Spark Ignitor and Flame Detector Location
44
BTU Transmitter Assembly
45
Btu Transmitter Pump Lubrication
45
BTU Transmitter Pump Oil Port Locations
45
Combustion Calibration
45
Safety Device Testing
45
BTU Transmitter Pump Disassembly
46
BTU Transmitter Disassembly
47
Compression Fitting Locations
47
BTU Transmitter Hot Water Tube Disassembly
48
BTU Transmitter Pump Compression Fitting Locations
48
BTU Transmitter Shell Components
49
Impeller Housing Disassembly
49
Manifold and Exhaust Tubes
49
Burner Disassembly Diagram
50
Grounding Terminal Location
50
Blower Proof Switch Wire Location
51
Exhaust Sensor Connector Location
51
Air/Fuel Valve Inlet Hose Clamp
52
Feedback Tube and Air/Fuel Valve to Differential Regulator Bolts
52
Manifold Nut and Bolt Locations
53
Propane Units
53
Heat Exchanger Inspection and Cleaning
54
Inspecting the Heat Exchanger
54
Propane Air Regulator Measuring Taps
54
Carbon Water Heater Head Configuration
55
Cleaning the Heat Exchanger
55
SS Water Heater Head Configuration
55
Cleaning Procedure
56
Hydroskrub Pumping System Set-Up Diagram for KC-1000
56
Pumping System Set-Up Directions
56
Calcium Carbonate Spot Test
57
Condensate Drain Assembly
57
Ph Trend Charting
57
Testing Hydroskrub Effectiveness
57
Low Water Cutoff Probe and Brass Coupling
58
Low Water Cutoff Probe Inspection and Cleaning
58
Hydraulic Zero Needle Valve Adjustment (C-More Control Box)
59
Hydraulic Zero Needle Valve Adjustment Instructions
59
Defining Flame Strength
60
Determining Flame Strength
60
Flame Strength Measurment
60
Instructions for Measuring Flame Strength
60
Check for the Following During the Reading
61
Troubleshooting Guide
63
Kc1000 Water Heater Troubleshooting Table
64
Water Heater Menu Item Descriptions
73
Configuration Menu
75
Tuning Menu
76
Startup, Status and Fault Messages
77
Fault Messages
78
Temperature Sensor Resistance Chart
81
Water Heater Default Settings
83
Parts List
87
Kc1000 Control Panel Exploded View
101
Kc1000 Control Panel Rear View
102
Other manuals for Aerco KC Series
User Manual
118 pages
Installation, Operation & Maintenance Instructions
113 pages
4
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Aerco KC Series Specifications
General
Brand
Aerco
Model
KC Series
Category
Water Heater
Language
English
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