AERCO KC1000 Low NOx Boiler equipped with C-More 2003 User Manual

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

REVISED JANUARY, 2009

No.

Instructio

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

Installation, Operation

& Maintenance Instructions

KC Series
Gas Fired
Low NOx
Boiler System

GF-109LN

Natural Gas and Propane Fired,

Condensing and Forced Draft Hot Water Boiler

970,000 BTU/HR Input (Natural Gas)

1,000,000 BTU/HR Input (Propane)

Applicable to Serial Numbers G-03-807 and above

Patent No. 4,852,524

Table of contents

Document Outline

Telephone Support
TABLE OF CONTENTS
FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
SECTION 2 - INSTALLATION PROCDURES
- 2.1 RECEIVING THE UNIT
- 2.2 UNPACKING
- 2.3 INSTALLATION
- 2.4 GAS SUPPLY PIPING
- 2.5 ELECTRICAL SUPPLY
  - 2.5.1 ELECTRICAL REQUIREMENMTS
- 2.6 MODE OF OPERATION AND FIELD CONTROL WIRING
  - 2.6.1 CONSTANT SETPOINT MODE
  - 2.6.2 INDOOR/OUTDOOR RESET MODE
  - 2.6.3 BOILER MANAGEMENT SYSTEM MODE
  - 2.6.4 REMOTE SETPOINT AND DIRECT DRIVE MODES
  - 2.6.5 COMBINATION MODE
- 2.7 I/O BOX CONNECTIONS
  - 2.7.1 OUTDOOR SENSOR IN
  - 2.7.2 AUX SENSOR IN
  - 2.7.3 ANALOG IN
  - 2.7.4 B.M.S. (PWM) IN
  - 2.7.5 SHIELD
  - 2.7.6 mA OUT
  - 2.7.7 RS-485 COMM
  - 2.7.8 EXHAUST SWITCH IN
  - 2.7.9 INTERLOCKS
  - 2.7.9.1 REMOTE INTERLOCK IN
  - 2.7.9.2 DELAYED INTERLOCK IN
  - 2.7.10 FAULT RELAY
- 2.8 AUXILIARY RELAY CONTACTS
- 2.9 FLUE GAS VENT INSTALLATION
- 2.10 COMBUSTION AIR
  - 2.10.1 COMBUSTION AIR FROM OUTSIDE THE BUILDING
  - 2.10.2 COMBUSTION AIR FROM INSIDE THE BUILDING
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 START-UP
- 4.1 INITIAL START- UP REQUIREMENTS
- 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
- 4.3 NATURAL GAS COMBUSTION CALIBRATION
- 4.4 PROPANE COMBUSTION CALIBRATION
- 4.5 UNIT REASSEMBLY
- 4.6 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS
  - - - Over Temperature Limit Switch Location
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 BMS 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
- 6.1 TESTING OF SAFETY DEVICES
- 6.2 LOW GAS PRESSURE FAULT 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
- 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
- 6.12 SAFETY PRESSURE RELIEF VALVE TEST
SECTION 7 - MAINTENANCE
- 7.1 MAINTENANCE SCHEDULE
- 7.2 SPARK IGNITER
- 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
- 7.8 CONDENSATE DRAIN ASSEMBLY
SECTION 8 - TROUBLESHOOTING GUIDE
- 8.1 INTRODUCTION
APPENDIX A - BOILER MENU ITEM DESCRIPTIONS
APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES
APPENDIX C - TEMPERATURE SENSOR RESISTANCE CHART
APPENDIX D - INDOOR/OUTDOOR RESET RATIO CHARTS
APPENDIX E - BOILER DEFAULT SETTINGS
APPENDIX F - DIMENSIONAL AND PART DRAWINGS
APPENDIX G - PIPING DRAWINGS
APPENDIX H - WIRING SCHEMATICS
APPENDIX I - KC1000 CONTROL PANEL VIEWS
APPENDIX J - KC1000 LOW NOx DUAL-FUEL SWITCH-OVER INSTRUCTIONS
WARRANTIES