AERCO KC1000 Low NOx Boiler equipped with C-More 2003 - Manual (Page 33)

INITIAL START-UP
4-3
1. Open the supply and return valves to the unit
and ensure that the system pumps are
running.
2. Open the gas supply valve(s) to the unit.
3. If a lockup style regulator is installed as a
gas supply regulator, adjust the gas supply
until a reading of 12” W.C. static pressure is
obtained.
4. Set the ON/OFF switch to the OFF position.
Turn on AC power to the unit. The display
will show LOSS OF POWER and the time
and date.
5. Set the unit to the Manual Mode by pressing
the AUTO/MAN switch. A flashing Manual
Fire Rate message will be displayed with the
present rate in %. Also, the MANUAL LED
will light.
NOTE:
For a review of the control panel operating
procedures, refer to Section 3.
6. Adjust the rate to 0% by pressing the ▼
arrow key.
7. Set the ON/OFF switch to the ON position.
8. Change the firing rate to 25% using the ▲
arrow key. This will put the unit into the
starting sequence.
NOTE:
On initial start-up, or return to service from a
fault condition, the unit will remain at a 29% firing
rate for two-minutes, although the control signal
may indicate a greater input.
9. Following the warm-up period, increase the
firing rate in 20% increments while
monitoring the gas pressure after every
increase. If gas pressure dips below 8.8”
W.C. for FM gas trains and 9.2” for IRI gas
trains at any input firing rate percentage,
stop and raise the pressure. Once 100% is
reached, adjust the gas pressure for 8.8”
W.C. (FM) or 9.2” W.C. (IRI).
NOTE:
If 8.8” W.C. for FM gas trains or 9.2” W.C. for IRI
gas trains cannot be obtained at the 100% firing
rate, it will be necessary to stop calibration and
contact the local AERCO representative in your
area. Running the unit on insufficient gas
pressure will void the warranty
10. Once 8.8” W.C. or 9.2” W.C. is set at the
100% level change the firing rate to 30%.
Insert the combustion analyzer probe into
the stack.
NOTE:
Always approach a firing rate percentage from
the same direction, (i.e., 100% to 30%, 30% to
20%, etc.). Whenever going to an increased
firing rate from below (i.e., 20% to 30%), first go
above and then back down to the desired firing
rate. This is necessary due to hysteresis in the
air/fuel stepper motor. Hysteresis causes the
air/fuel valve to stop in a slightly different position
if the firing rate percentage is approached from
below or above. This results in a difference in
oxygen readings for the same firing rate
percentage causing unnecessary recalibration.
11. Allow enough time for the combustion
analyzer to settle. Compare the measured
oxygen level to the oxygen range for intake
air temperature in Table 1 (page 4-5). Also,
ensure that the carbon monoxide (CO) and
nitrogen oxide (NOx) readings do not
exceed the values shown.
12. If the measured oxygen level, CO and NOx
emissions are within the ranges shown in
Table 1, no adjustment is necessary.
Proceed to step 17.
13. If the measured oxygen level is below the
range in Table 1, rotate the differential
regulator adjustment tool counterclockwise
1/4 to 1/2 revolution to decrease gas flow.
14. Wait for the combustion analyzer to settle,
then compare the new oxygen reading to
Table 1. Repeat adjustment until oxygen is
within the specified range.
15. If the measured oxygen level is above the
oxygen range in Table 1, rotate the
differential regulator adjustment tool
clockwise 1/4 to 1/2 revolution to increase
gas flow.
16. Wait for the analyzer reading to settle, then
compare the new reading to Table 1. Repeat
adjustment until oxygen is within the
specified range.
NOTE:
Adjust only the differential regulator at 30%
control signal; do not adjust the air shutter.
17. Once the oxygen level is within the specified
range at 30%, change the firing rate to 16%.