AERCO KC Standard to Low NOx Convertion Instructions - Manual

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INTERNATIONAL, INC.
159 PARIS AVENUE • NORTHVALE, NJ 07647 • PHONE 201-768-2400
TECHNICAL SERVICE BULLETIN
Date: 08/19/05 Number: 2005-03
Subject: KC1000 LOW NOx CONVERSION KIT INSTRUCTIONS
Page 1 of 42
1. INTRODUCTION
The KC1000 Low NOx Conversion Kit, Part No. 124918 contains all of the assemblies, cables and
attaching parts necessary to upgrade a KC1000 Boiler or Water Heater for Low NOx compliance.
When so equipped, the Boiler or Water Heater complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2.
• Texas Commission on Environmental Quality (TCEQ), Title 30, Chapter 117, Rule
117.465.
NOTE
These Conversion Kit instructions are applicable to all KC1000 units,
regardless of the Control System and/or Safety Shutoff Valve (SSOV) installed
on your unit. Unless otherwise specified, the descriptions and procedures
contained in this Service Bulletin apply to all Natural Gas KC1000 Water
Heater and Boiler configurations. If you are not certain of your current unit
configuration, contact your nearest AERCO Representative.
1.1 General Description
In order to comply with the above-mentioned low NOx emission standards, the existing KC Burner
Assembly must be replaced with a new Low NOx Burner Assembly and a Staged Ignition Assembly.
In addition, several other assemblies must be modified to ensure low NOx emissions.
The Low NOx Conversion procedures provided in this Service Bulletin are divided into the following
main categories:
• Equipment Removal
• Equipment Modification/Rework
• Equipment Replacement/Reinstallation
• Post-Installation Setup and Calibration
The procedures in each of these categories are presented in Sections 2 through 5 respectively.
The following paragraphs in this Section describe the contents of the Low NOx Conversion Kit and the
tools and test equipment required to perform all procedures in this Service Bulletin.