AERCO KC1000 Boiler July 2011 - Manual (Page 15)

INSTALLATION
2-5
The location of the 1-1/4" inlet gas connection is
on the right side of the unit as shown in Figure
2.7.
All pipe should be de-burred and internally
cleared of any scale or iron chips before
installation. No flexible connectors or non-
approved gas fittings should be installed. Piping
should be supported from floor or walls only and
must not be secured to the unit.
A suitable piping compound, approved for use
with gas, should be used sparingly. Any excess
must be wiped off to prevent clogging of
components.
To avoid damage to the unit, when pressure
testing gas piping, isolate the unit from the
supply gas piping. At no time should there be
more than 14” W.C. the unit. Bubble test all
external piping thoroughly for leaks using a
soap and water solution or suitable equivalent.
The gas piping must meet all applicable codes.
2.4.1 GAS SUPPLY PRESSURE
REGULATOR
An external, in-line, supply gas regulator
(supplied by others) should be positioned as
shown in Figure 2.7. Union connections should
be placed in the proper locations to allow
maintenance of the regulator if required
NOTE:
An individual gas pressure regulator must
be installed upstream of each KC1000. The
regulator must regulate gas pressure to 8.5”
W.C. at 1,000,000 BTU/H for natural gas
and propane units .
The maximum static inlet pressure to the unit
must be no more than 14” water column.
Minimum gas pressure is 8.5” W.C. for FM gas
trains and 8.9” W.C. for IRI gas trains when the
unit is firing at maximum input. Gas pressure
should not exceed 10.5” W.C. at any time when
firing. Proper sizing of the gas supply regulator
in delivering the correct gas flow and outlet
pressure is mandatory. The gas supply pressure
regulator must maintain the gas pressure at a
regulated 8.5” W.C. minimum for FM gas trains
and 8.9” W.C. for IRI gas trains at maximum
BTU input (1,000,000 BTU/HR) for natural gas
and propane installations. The supply gas
regulator must be of sufficient capacity volume,
(1000 cfh), for the unit and should have no more
than 1" droop from minimum to full fire. The
supply gas regulator must also be rated to
handle the maximum incoming gas pressure to
it. When the gas supply pressure will not exceed
14” W.C. a non-lock up or flow through style
regulator may be used. When supply gas
pressure will exceed 14” W.C., a lock up style
regulator must be used. The gas supply
regulator must be propery vented to outdoors.
Consult the local gas utility for exact
requirements concerning venting of supply gas
regulators.
CAUTION!
A lockup style regulator must be used when
gas supply pressure exceeds 14” W.C.
2.4.2 MANUAL GAS SHUTOFF VALVE
A 1-1/4” manual gas shut-off valve is furnished
with each unit. The valve should be positioned
as shown in Figure 2.7. The manual gas shut-of
valve must be installed upstream of the supply
regulator in a readily accessible location.
Figure 2.7
Gas Supply Regulator and Manual Shut -Off
Valve Location
2.4.3 IRI GAS TRAIN KIT
The IRI gas train is an optional gas train
required in some areas by code or for insurance
purposes. The IRI gas train is factory pre-piped
and wired. (Refer to Appendix F, Drawing No.
SD-A-584).
2.5 ELECTRICAL SUPPLY
The AERCO Gas Fired Equipment Electrical
Power Wiring Guide, (GF-1060), must be
consulted in addition to the following material
before wiring to the unit is started. AC power
connection to the unit are made at the Power
Box.This box is located on the front right side of
the unit as shown in Figure 2.8. Conduit should