AERCO KC1000 Boiler equipped with C-More version 3.04 User Manual

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

Text mode
Original mode

Printed in U.S.A.

REVISED, JUNE 24, 2010

Instruction

No.

GF-109

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-10

-1324 and above

Patent No. 4,852,524

Table of contents

Document Outline

CONTENTS
- 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
SECTION 1 - SAFETY PRECAUTIONS
SECTION 2 - INSTALLATION PROCEDURES
- 2.1 RECEIVING THE UNIT
- 2.2 UNPACKING
- 2.3 INSTALLATION
- 2.4 GAS SUPPLY PIPING
- 2.5 ELECTRICAL SUPPLY
  - 2.5.1 ELECTRICAL REQUIREMENTS
- 2.6 MODE OF OPERATION AND FIELD CONTROL WIRING
- 2.7 I/O BOX CONNECTIONS
- 2.8 AUXILIARY RELAY CONTACTS
- 2.9 FLUE GAS VENT INSTALLATION
- 2.10 COMBUSTION AIR
  - 2.10.1 COMBUSTION AIR FROMOUTSIDE THE BUILDING
  - COMBUSTION AIR FROM INSIDE THE BUILDING
  - 2.10.3 SEALED COMBUSTION
SECTION 3 - CONTROL PANEL OPERATING PROCEDURES
- 3.1 INTRODUCTION
- 3.2 CONTROL PANEL DESCRIPTION
- 3.3 CONTROL PANEL MENUS
  - 3.3.1 Menu Processing Procedure
- 3.4 OPERATING MENU
- 3.5 SETUP MENU
- 3.6 CONFIGURATION MENU
- 3.7 TUNING MENU
- 3.8 START SEQUENCE
- 3.9 START/STOP LEVELS
SECTION 4 - INITIAL STARTUP
- 4.1 INITIAL START- UP REQUIREMENTS
- 4.2 TOOLS AND INSTRUMENTATION REQUIRED FOR COMBUSTION CALIBRATION
- 4.3 COMBUSTION CALIBRATION
- 4.4 PROPANE COMBUSTION CALIBRATION
- 4.5 UNIT REASSEMBLY
- 4.6 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS
SECTION 5 - MODE OF OPERATION
- 5.1 INTRODUCTION
- 5.2 INDOOR/OUTDOOR RESET MODE
- 5.3 CONSTANT SETPOINT MODE
  - 5.3.1 SETTING THE SETPOINT
- 5.4 REMOTE SETPOINT MODES
  - 5.4.1 REMOTE SETPOINT FIELD WIRING
  - 5.4.2 REMOTE SETPOINT STARTUP
- 5.5 DIRECT DRIVE MODES
  - 5.5.1 DIRECT DRIVE FIELD WIRING
  - 5.5.2 DIRECT DRIVE STARTUP
- 5.6 BOILER MANAGEMENT SYSTEM (BMS)
  - 5.6.1 BOILER MANAGEMENT SYSTEM EXTERNAL FIELD WIRING
  - 5.6.2 BOILER MANAGEMENT SYSTEM SETUP AND STARTUP
- 5.7 COMBINATION CONTROL SYSTEM (CCS)
  - 5.7.1 COMBINATION CONTROL SYSTEM FIELD WIRING
  - 5.7.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP
SECTION 6 - SAFETY DEVICE TESTING PROCEDURES
- 6.1 TESTING OF SAFETY DEVICES
- 6.2 LOW GAS PRESSURE TEST
- 6.3 HIGH GAS PRESSURE TEST
- 6.4 LOW WATER LEVEL FAULT TEST
- 6.5 WATER TEMPERATURE FAULT TEST
- 6.6 INTERLOCK TESTS
  - 6.6.1 REMOTE INTERLOCK
  - 6.6.2 DELAYED INTERLOCK
- 6.7 FLAME FAULT TEST
  - - Figure 6.4
      - Manual Leak Detection Valve
- 6.8 AIR FLOW FAULT TEST
- 6.9 SSOV PROOF OF CLOSURE SWITCH
- 6.10 PURGE SWITCH OPEN DURING PURGE
- 6.11 IGNITION SWITCH OPEN DURING IGNITION
  - - Figure 6.9
      - Air/Fuel Valve Purge and Ignition Switch Locations
- 6.12 SAFETY PRESSURE RELIEF VALVE TEST
SECTION 7 - MAINTENANCE
- 7.1 MAINTENANCE SCHEDULE
- 7.2 SPARK IGNITOR
- 7.3 FLAME DETECTOR
- 7.4 COMBUSTION CALIBRATION
- 7.5 SAFETY DEVICE TESTING
- 7.6 MANIFOLD AND EXHAUST TUBES
- 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
SECTION 8 - TROUBLESHOOTING GUIDE
- 8.1 INTRODUCTION
SECTION 9 - RS232 COMMUNICATION
- 9.1 INTRODUCTION
- 9.2 RS232 COMMUNICATION SETUP
- 9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
- 9.4 DATA LOGGING
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
APPENDIX I
APPPENDIX J
STANDARD WARRANTY