AERCO KC1000 Boiler July 2011 - Manual (Page 45)

SAFETY DEVICE TESTING
6-1
SECTION 6-SAFETY DEVICE TESTING PROCEDURES
6.1 TESTING OF SAFETY DEVICES
Periodic testing of all controls and safety devices
is required to insure that they are operating as
designed. Precautions must be taken while tests
are being performed to protect against bodily
injury and property damage.
Systematic and thorough testing of the operating
and safety controls should be performed on a
scheduled basis, or whenever a control compo-
nent has been serviced or replaced. All testing
must conform to local jurisdictions or codes such
as ASME CSD-1.
NOTE:
MANUAL and AUTO modes are required to
perform the following tests. For a complete
explanation of these modes, see Section 3.
NOTE:
It will be necessary to remove the sheet
metal covers and cap from the unit to
perform the following tests.
WARNING!
ELECTRICAL VOLTAGES IN THIS
SYSTEM INCLUDE 120 AND 24 VOLTS
AC. POWER MUST BE REMOVED PRIOR
TO PERFORMING WIRE REMOVAL OR
OTHER TESTING PROCEDURES THAT
CAN RESULT IN ELECTRICAL SHOCK.
6.2 LOW GAS PRESSURE FAULT TEST
1. Shut off the gas supply to the unit.
2. Install a 0-16” W.C. manometer in the gas
pipe assembly below the low gas pressure
switch. (See Fig. 6.1)
3. Open the gas supply to the unit and depress
the CLEAR button to clear any fault
messages..
4. Place the unit in Manual Mode and fire the
unit at a valve position between 25% and
30%.
5. Slowly close the manual gas supply valve
while monitoring the gas pressure. The unit
should fault and shutdown on LOW GAS
PRESSURE when the manometer indicates
approximately 6.5” W.C.
6. Open the gas supply to the unit and press
the CLEAR button on the Control Box.
7. The unit should restart.
1/4" NPT PLUG
(INSTALL
MANOMETER
HERE)
SSOV
Figure 6.1
1/8” Pipe Plug Position for Manometer
Installation
NOTE:
After faulting the unit, the fault message will
be displayed and the fault indicator light will
flash until the CLEAR button is pressed.
6.3 HIGH GAS PRESSURE TEST
1. Start the unit in manual mode and fire
between 25% and 30%.
2. Remove either wire # 150 or wire #151 from
the high gas pressure switch. See Fig. 6.2.
3. The unit should shut down on a HIGH GAS
PRESSURE FAULT.
4. Reconnect the wire previously removed from
the high gas pressure switch and depress
the CLEAR button.
5. The unit should restart.