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
    • 2.3.1 SETTING THE UNIT
    • 2.3.2 SUPPLY AND RETURN PIPING
    • 2.3.3 PRESSURE RELIEF & DRAIN VALVE INSTALLATION
    • 2.3.4 TEMPERATURE/PRESSURE INDICATOR
    • 2.3.5 CONDENSATE PIPING
  • 2.4 GAS SUPPLY PIPING
    • 2.4.1 GAS SUPPLY PRESSURE REGULATOR
    • 2.4.2 MANUAL GAS SHUTOFF VALVE
    • 2.4.3 IRI GAS TRAIN
  • 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
    • 2.10.3 SEALED COMBUSTION
    • 2.10.4 TEMPORARY COMBUSTION AIR FILTERING DURING CONSTRUCTION
• 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
    • 4.2.1 REQUIRED TOOLS AND INSTRUMENTATION
    • 4.2.2 INSTALLING THE SUPPLY GAS MANOMETER
    • 4.2.3 PREPARING THE FLUE VENT PROBE HOLE
    • 4.2.4 INSTALLING THE DIFFERENTIAL REGULATOR ADJUSTMENT TOOL
  • 4.3 NATURAL GAS 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
    • 5.2.1 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)
    • 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
• SECTION 9 - RS232 COMMUNICATION
• 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
• APPENDIX K - RECOMMENDED SPARE PARTS
• WARRANTIES