Document Outline

• KC-B-Cover-OCT-09
  • Telephone Support
  • Direct to AERCO Technical Support
• KC-B-TOC-11-10-08.GR
  • 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
• KC-B-Foreword-10-2-06-J
• KC-B-CH1-2-27-07
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• KC-B-Ch2-11-25-08.GR
  • 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
  • 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
    • 2.7.1 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
• KC-B-Ch3-11.25.08.GR
  • 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-B-Ch3-11-11-09
  • 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-B-Ch4-2-5-07
  • 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
  • 4.2.4 INSTALLING THE DIFFERENTIAL REGULATOR ADJUSTMENT TOOL
    • Figure 4.3
      • Differential Regulator Adjustment Tool Installation
  • 4.3 NATURAL GAS COMBUSTION CALIBRATION
    • 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
• KC-B-Ch4-GF109--10-09-09-dsg-bb
  • 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
• KC-B-Ch5-GF109--10-05-09-dsg-bb
  • Section 5 - MODE OF OPERATION
    • 5.1 INTRODUCTION
    • 5.2 INDOOR/OUTDOOR RESET MODE
      • 5.2.1 RESET RATIO
      • 5.2.2. BUILDING REFERENCE TEMPERATURE
      • 5.2.3 OUTDOOR AIR TEMPERATURE SENSOR INSTALLATION
      • 5.2.4 INDOOR/OUTDOOR STARTUP
    • 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) MODE
      • 5.6.1 BMS EXTERNAL FIELD WIRING
    • 5.7 COMBINATION CONTROL SYSTEM (CCS)
      • 5.7.1 COMBINATION CONTROL SYSTEM FIELD WIRING
      • 5.7.2 COMBINATION CONTROL SYSTEM SETUP AND STARTUP
• KC-B-Ch6-3-5-07
  • SECTION 6-SAFETY DEVICE TESTING PROCEDURES
    • Figure 6.1
      • 1/8” Pipe Plug Position for Manometer Installation
    • 6.3 HIGH GAS PRESSURE TEST
      • Figure 6.2
      • Figure 6.3
        • Temperature Limit Switch Setting
    • 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
      • Figure 6.5
        • Blower Proof Switch Location and Wiring
    • 6.9 SSOV PROOF OF CLOSURE SWITCH
      • Figure 6.6
        • SSOV Actuator Cover Screw Location
    • 6.10 PURGE SWITCH OPEN DURING PURGE
      • Figure 6.7
        • Air/Fuel Valve Cover Location
    • 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
• KC-B-Ch7-GF109--10-05-09-dsg-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
  • 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
  • CONDENSATE DRAIN ASSEMBLY
• 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.
• KC-B-App A-11-25-08.GR
• KC-B-App-B-GF109--10-01-09-dsg-bb
• KC-B-App-C
• KC-B-App-D
• KC-B-App-E-FEB-06
• KC-B-App-F--4-23-07
• KC-B-App-G
• KC-B-App-H-JULY-06
• KC-B-App-I-12-27-08
• KC-BLR-WARRANTY-J
• KC-B-Cover-OCT-09.pdf
  • Telephone Support
  • Direct to AERCO Technical Support