AERCO KC1000 Boiler July 2011 User Manual

Kc series gas fired boiler system

REVISED JULY 7, 2011

GF-109

OMM-0016_0B

KC Series Gas-Fired Boiler

USER MANUAL

Applicable to Serial Number G-11-0695 and above

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

Patent No. 4,852,524

Table of contents

Document Outline

OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_01_KC-B-Cover_07-07-11
- Telephone Support
- Direct to AERCO Technical Support
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_02a_KC-B-TOC--1-7-10
- 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
- SECTION 9 – RS232 COMMUNICATION 9-1
- APPENDICES
- WARRANTIES W-1
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_02b_KC-B-Forewrd-10-2-06
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_03_KC-B-CH1_7-7-11
- 1.1 WARNINGS & CAUTIONS
- 1.2 EMERGENCY SHUTDOWN
- 1.3 PROLONGED SHUTDOWN
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_04_KC-B-Ch2_7-8-11
- 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
- 2.6.3 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
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_05_KC-B-Ch3--7-25-11
- Section 3 - CONTROL PANEL OPERATING PROCEDURES
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_06_KC-B-Ch4_6-29-10
- 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
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_07_KC-B-Ch5_6-14-10
- Section 5 - MODE OF OPERATION
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_08_KC-B-Ch_6-3-25-11
- SECTION 6-SAFETY DEVICE TESTING PROCEDURES
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_09_KC-B-Ch7_1-7-10-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
- 7.7 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
- 7.8 CONDENSATE DRAIN ASSEMBLY
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_10_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.
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_11_KC-B-CH9_6-8-10
- 9.1 INTRODUCTION
- 9.2 RS232 COMMUNICATION SETUP
- 9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
- 9.4 DATA LOGGING
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_12_KC-B-App A_3-25-11
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_13_KC-B-Ap-B_10-01-09
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_14_KC-B-App-C
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_15_KC-B-App-D
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_16_KC-B-App-E_3-25-11
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_17_KC-B-App-F_6-15-10
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_18_KC-B-App-G
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_19_KC-B-App-H-JULY-06
OMM-0016_0B_GF-109_KC BOILER_G-11-0695 and UP_20_KC-B-App-I-12-27-08
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