Document Outline

• KC-H-Cover-JUNE-24-2010_PN
  • UTelephone Support
  • Direct to AERCO Technical Support
• KC-H-TOC--1-7-10-bb
  • 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 – SAFETY DEVICE TESTING PROCEDURES 5-1
  • Section 6 – MAINTENANCE 6-1
  • Section 7 – TROUBLESHOOTING 7-1
  • Section 8 – RS232 COMMUNICATION 8-1
  • APPENDICES
  • WARRANTIES W-1
• KC-H-Fwd-GF111--10-07-09-dsg-bb
• KC-H-CH1-6-22-10
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• KC-H-Ch2--6-22-10
  • 2.1 RECEIVING THE UNIT
  • 2.2 UNPACKING
  • 2.3 INSTALLATION
    • 2.3.1 SETTING THE UNIT
    • Figure 2.2
      • Lifting Lug Location
        • 2.3.2 WATER INLET AND OUTLET PIPING
    • Figure 2.3
      • Inlet and Outlet Location
    • Figure 2.4b
      • Pressure/Temperature Relief and Drain Valve Installation Location
    • Figure 2.5
      • Condensate Drain Assembly Location
  • 2.4 GAS SUPPLY PIPING
    • Figure 2.6
      • Gas Supply Regulator and Manual Shut -Off Valve Location
        • 2.4.1 GAS SUPPLY PRESSURE REGULATOR
        • 2.4.2 MANUAL GAS SHUTOFF VALVE
        • 2.4.3 IRI GAS TRAIN KIT
  • 2.5 ELECTRICAL SUPPLY
    • Figure 2.7
    • AC Power Box Location
      • 2.5.1 ELECTRICAL REQUIREMENTS
    • Figure 2.8
      • AC Power Wiring Diagram
  • 2.6 FIELD CONTROL WIRING
    • Figure 2.9
      • Input/Output (I/O) Box Location
        • 2.6.10 FAULT RELAY
    • Figure 2.10 I/O Box Wiring
  • 2.7 FLUE GAS VENT INSTALLATION
  • 2.8 COMBUSTION AIR
    • 2.8.1 COMBUSTION AIR FROM OUTSIDE THE BUILDING
    • 2.8.2 COMBUSTION AIR FROM INSIDE THE BUILDING
    • 2.8.3 SEALED COMBUSTION
• KC-H-Ch3--7-9-10
  • 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
• KC-H-Ch4-GF111--10-06-09-dsg-bb-TEST
  • 4.1 INITIAL START- UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
    • 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
      • Figure 4.1
        • 1/4” 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 Pressure Regulator
      • Air Shutter Locking Nut Location
  • 4.4 PROPANE COMBUSTION CALIBRATION
    • Figure 4.5
    • Propane Air Differential Pressure Taps
  • 4.5 UNIT REASSEMBLY
  • 4.6 TEMPERATURE CONTROL CALIBRATION
    • 4.6.1 SETTING THE OUTLET WATER TEMPERATURE SETPOINT
    • 4.6.2 MINIMUM LOAD ADJUSTMENT
    • 4.6.3 MAXIMUM LOAD ADJUSTMENT
  • 4.7 OVER-TEMPERATURE LIMIT SWITCH ADJUSTMENTS
    • Figure 4.6
      • Over Temperature Limit Switch Location
• KC-H-Ch5--6-18-10
  • SECTION 5 - SAFETY DEVICE TESTING PROCEDURES
    • 5.1 TESTING OF SAFETY DEVICES
    • 5.2 LOW GAS PRESSURE FAULT TEST
      • Figure 5.1
        • 1/8” Pipe Plug Position for Manometer Installation
    • 5.3 HIGH GAS PRESSURE TEST
      • Figure 5.2
    • 5.4 LOW WATER LEVEL FAULT TEST
    • 5.5 WATER TEMPERATURE FAULT TEST
      • Figure 5.3
        • Temperature Limit Switch Setting
    • 5.6 INTERLOCK TESTS
      • 5.6.1 REMOTE INTERLOCK
      • 5.6.2 DELAYED INTERLOCK
    • 5.7 FLAME FAULT TEST
      • Figure 5.4
        • Manual Leak Detection Valve
    • 5.8 AIR FLOW FAULT TEST
      • Figure 5.5
        • Blower Proof Switch Location and Wiring
    • 5.9 SSOV PROOF OF CLOSURE SWITCH
      • Figure 5.6
        • SSOV Actuator Cover Screw Location
    • 5.10 PURGE SWITCH OPEN DURING PURGE
      • Figure 5.7
        • Air/Fuel Valve Cover Location
    • 5.11 IGNITION SWITCH OPEN DURING IGNITION
      • Figure 5.8
        • Air/Fuel Valve Purge and Ignition Switch Locations
    • 5.12 SAFETY PRESSURE RELIEF VALVE TEST
• KC-H-Ch6-GF111_12-09-10
  • 6.1 MAINTENANCE SCHEDULE
  • 6.2 Spark Ignitor
    • Figure 6.1
      • Spark Ignitor and Flame Detector Location
  • 6.3 Flame Detector
  • 6.4 COMBUSTION CALIBRATION
  • 6.5 SAFETY DEVICE TESTING
    • 6.6 BTU TRANSMITTER PUMP LUBRICATION
    • Figure 6.2
      • BTU Transmitter Pump Oil Port Locations
  • 6.7 BTU TRANSMITTER ASSEMBLY
    • Figure 6.3
      • BTU Transmitter Pump Disassembly
    • Figure 6.4
      • Compression Fitting Locations
    • Figure 6.5
      • BTU Transmitter Disassembly
    • Figure 6.6
      • BTU Transmitter Pump Compression Fitting Locations
    • Figure 6.7
      • BTU Transmitter Hot Water Tube Disassembly
    • Figure 6.8
      • BTU Transmitter Shell Components
    • Figure 6.9
      • Impeller Housing Disassembly
  • 6.8 MANIFOLD AND EXHAUST TUBES
    • Figure 6.10
      • Grounding Terminal Location
    • Figure 6.11
      • Burner Disassembly Diagram
    • Figure 6.12
      • Exhaust Sensor Connector Location
    • Figure 6.13
      • Blower Proof Switch Wire Location
      • (older style switch shown at left, newer style at right)
    • Figure 6.14
      • Air/Fuel Valve Inlet Hose Clamp
    • Figure 6.15
      • Feedback Tube and Air/Fuel Valve to Differential Regulator Bolts
    • Figure 6.16
      • Manifold Nut and Bolt Locations
        • 6.8.1 PROPANE UNITS
    • Figure 6.17
      • Propane Air Regulator Measuring Taps
  • 6.9 HEAT EXCHANGER INSPECTION AND CLEANING
  • 6.10 CONDENSATE DRAIN ASSEMBLY
  • 6.11 LOW WATER CUTOFF PROBE INSPECTION AND CLEANING
  • 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-More Control BOX)
  • 6.13 FLAME STRENGTH MEASURMENT
• KC-H-Ch7_09-29-10
  • SECTION 7- TROUBLESHOOTING GUIDE
    • 7.1 INTRODUCTION
  • 1. Inspect feed forward (BTU transmitter) sensor for loose or broken wiring.
  • 2. Check resistance of sensor to determine if it is within specification.
  • 1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 500 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.
  • KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued
  • KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued
  • KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued
• KC-H-CH8-GF-111--6-17-10_FIX
  • Section 8 - RS232 COMMUNICATION
    • INTRODUCTION
    • RS232 COMMUNICATION SETUP
    • MENU PROCESSING UTILIZING RS232 COMMUNICATION
    • DATA LOGGING
      • 8.4.1 Fault Log
      • 8.4.2 Operation Time Log
      • 8.4.3 Sensor Log
• KC-H-App-A--6-18-10
• KC-H-App-B-GF109--10-01-09-dsg-bb
• KC-H-App-C 05-05-09 dsg
  • Temperature Sensor Resistance Chart
• KC-H-App-D--6-29-10
  • WATER HEATER DEFAULT SETTINGS
• KC-H-App-E--6-18-10
• KC-H-App-F-11-30-06 dsg
  • Piping Drawings
• KC-H-App-G--6-17-10
  • SCHEMATICS
• KC-H-App-H-12-27-08 dsg
• KC-H-warranty dsg