AERCO KC1000 Boiler equipped with C-More 2002 User Manual

Kc series gas fired boiler system, Installation, operation & maintenance instructions, Gf-109

Text mode
Original mode

Printed in U.S.A.

REVISED, OCTOBER, 2010

Instruction

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-02-536 and above

Patent No. 4,852,524

GF-109

Table of contents

Document Outline

KC-B-Cover-OCT-09
- Telephone Support
- Direct to AERCO Technical Support
KC-B-TOC-11-10-08.GR
- FOREWARD A
- SECTION 1 – SAFETY PRECAUTIONS 1-1
- SECTION 2 – INSTALLATION PROCEDURES 2-1
- SECTION 3 – CONTROL PANEL OPERATING PROCEDURES 3-1
- SECTION 4 – INITIAL START-UP 4-1
- Section 5 – MODE OF OPERATION 5-1
- SECTION 6 – SAFETY DEVICE TESTING PROCEDURES 6-1
- SECTION 7 – MAINTENANCE 7-1
- SECTION 8 – TROUBLESHOOTING 8-1
- APPENDICES
- WARRANTIES W-1
KC-B-Foreword-10-2-06-J
KC-B-CH1-2-27-07
- 1.1 WARNINGS & CAUTIONS
- 1.2 EMERGENCY SHUTDOWN
- 1.3 PROLONGED SHUTDOWN
KC-B-Ch2-11-25-08.GR
- Figure 2.1. Boiler Clearances
- Figure 2.2
  - Lifting Lug Location
- Figure 2.3
  - Supply and Return Location
- Figure 2.4
  - Relief and Drain Valve Location
- Figure 2.5a
  - Pressure /Temperature Gauge Installation
- Figure 2.5b
  - Pressure/Temperature Gauge Installation
- Figure 2.6
  - Condensate Drain System Location
- Figure 2.7
  - Gas Supply Regulator and Manual Shut -Off Valve Location
- Figure 2.8
  - AC Power Box Location
  - AC Power Wiring Diagram
- Figure 2.10
  - Input/Output (I/O) Box Location
- 2.6.1 CONSTANT SETPOINT MODE
  - Figure 2.11
    - I/O Box Terminal Strip
- BOILER MANAGEMENT SYSTEM (BMS) MODE
- 2.6.4 REMOTE SETPOINT and DIRECT DRIVE MODES
- 2.6.5 COMBINATION MODE
- 2.7 I/O BOX CONNECTIONS
- 2.8 AUXILIARY RELAY CONTACTS
KC-B-Ch3-11.25.08.GR
- Section 3 - CONTROL PANEL OPERATING PROCEDURES
KC-B-Ch3-11-11-09
- Section 3 - CONTROL PANEL OPERATING PROCEDURES
KC-B-Ch4-2-5-07
- 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
  - Figure 4.1
    - 1/8” Gas Plug Location
- 4.2.3 PREPARING THE FLUE VENT PROBE HOLE
  - Figure 4.2
    - Analyzer Probe Hole Location
- 4.2.4 INSTALLING THE DIFFERENTIAL REGULATOR ADJUSTMENT TOOL
  - Figure 4.3
    - Differential Regulator Adjustment Tool Installation
- 4.3 NATURAL GAS COMBUSTION CALIBRATION
  - Air Shutter Locking Nut Location
- 4.4 PROPANE COMBUSTION CALIBRATION
  - Figure 4.5
    - Propane Air Differential Pressure Taps
- 4.6 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS
  - Figure 4.6
    - Over Temperature Limit Switch Location
KC-B-Ch4-GF109--10-09-09-dsg-bb
- 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
  - Figure 4.1
    - 1/8” Gas Plug Location
- 4.2.3 PREPARING THE FLUE VENT PROBE HOLE
  - Figure 4.2
    - Analyzer Probe Hole Location
- 4.3 NATURAL GAS COMBUSTION CALIBRATION
  - Figure 4.3
    - Differential Regulator
    - Air Shutter Locking Nut Location
- 4.4 PROPANE COMBUSTION CALIBRATION
  - Figure 4.5
    - Propane Air Differential Pressure Taps
- 4.6 OVER-TEMPERATURE LIMIT SWITCH ADJUSTMENTS
  - Figure 4.6
    - Over Temperature Limit Switch Location
KC-B-Ch5-GF109--10-05-09-dsg-bb
- Section 5 - MODE OF OPERATION
KC-B-Ch6-3-5-07
- SECTION 6-SAFETY DEVICE TESTING PROCEDURES
KC-B-Ch7-GF109--10-05-09-dsg-bb
- Figure 7.1
  - Spark Ignitor and Flame Detector Locations
- Figure 7.2
  - Grounding Terminal Location
- Figure 7.3
  - Burner Disassembly Diagram
- Figure 7.4
  - Exhaust Sensor Connector Location
- Figure 7.5
  - Blower Proof Switch Wire Locations
- Figure 7.6
  - Air/Fuel Valve Inlet Hose Clamp
- Figure 7.7
  - Feedback Tube and Air/Fuel Valve to Differential Regulator Bolts
- Figure 7.8
  - Manifold Nut and Bolt Locations
- Figure 7.9
  - Propane Unit Component Location
- HEAT EXCHANGER WATER SIDE INSPECTION
  - Figure 7.10
    - Heat Exchanger Supply and Return Locations
  - Figure 7.11
    - Heat Exchanger 2 ½ Inch Inspection Plug Location
- CONDENSATE DRAIN ASSEMBLY
KC-B-Ch8_09-29-10
- 8.1 INTRODUCTION
- 1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 475 o F and the exhaust sensor shows continuity replace the sensor.
- 2. If exhaust temperature is greater than 500 o F, check combustion calibration. Calibrate or repair as necessary.
  - 2. If there are two external wires on these terminals check any Energy Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning).
  - 3. Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational.
KC-B-App A-11-25-08.GR
KC-B-App-B-GF109--10-01-09-dsg-bb
KC-B-App-C
KC-B-App-D
KC-B-App-E-FEB-06
KC-B-App-F--4-23-07
KC-B-App-G
KC-B-App-H-JULY-06
KC-B-App-I-12-27-08
KC-BLR-WARRANTY-J
KC-B-Cover-OCT-09.pdf
- Telephone Support
- Direct to AERCO Technical Support