Document Outline

• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_01_Cover_01-01-09
  • Telephone Support
  • Direct to AERCO Technical Support
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_02_TOC_3-28-11
  • FOREWORD 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 – SAFETY DEVICE TESTING PROCEDURES 5-1
  • Section 6 – MAINTENANCE 6-1
  • Section 7 – TROUBLESHOOTING 7-1
  • Section 8 – RS232 COMMUNICATION 8-1
  • APPENDICES
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_03_CH1_6-30-10
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_04_Ch2_6-30-10
  • 2.1 RECEIVING THE UNIT
  • 2.2 UNPACKING
  • 2.3 INSTALLATION
    • 2.3.1 SETTING THE UNIT
    • Figure 2.2
      • Lifting Lug Location
        • 2.3.2 WATER INLET AND OUTLET PIPING
    • Figure 2.3
      • Inlet and Outlet Location
    • Figure 2.4
      • Hose Bib Location
    • Figure 2.5
      • Pressure/Temperature Relief and Drain Valve Installation Location
    • Figure 2.6
      • Condensate Drain Assembly Location
  • 2.4 GAS SUPPLY PIPING
    • Figure 2.7
      • Gas Supply Regulator and Manual Shut -Off Valve Location
        • 2.4.2 MANUAL GAS SHUTOFF VALVE
        • 2.4.3 IRI GAS TRAIN KIT
  • 2.5 ELECTRICAL SUPPLY
    • Figure 2.8
      • AC Power Box Location
        • 2.5.1 ELECTRICAL REQUIREMENTS
    • Figure 2.9
      • AC Power Wiring Diagram
  • 2.6 FIELD CONTROL WIRING
    • Figure 2.10
      • Input/Output (I/O) Box Location
        • 2.6.10 FAULT RELAY
    • Figure 2.11 I/O Box Wiring
      • 2.8 COMBUSTION AIR
      • 2.8.1 COMBUSTION AIR FROM OUTSIDE THE BUILDING
      • 2.8.2 COMBUSTION AIR FROM INSIDE THE BUILDING
      • NOTE
    • Figure 2.12
      • Sealed Combustion Air Connection
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_05_Ch3_3-24-11
  • 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
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_06_Ch4_6-21-10
  • SECTION 4 - INITIAL START- UP
    • 4.1 INITIAL START- UP REQUIREMENTS
      • 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 Pressure Regulator
        • Air Shutter Locking Nut Location
    • 4.4 PROPANE COMBUSTION CALIBRATION
    • 4.5 UNIT REASSEMBLY
    • 4.6 TEMPERATURE CONTROL CALIBRATION
      • 4.6.1 SETTING THE OUTLET WATER TEMPERATURE SETPOINT
      • 4.6.2 MINIMUM LOAD ADJUSTMENT
      • 4.6.3 MAXIMUM LOAD ADJUSTMENT
    • 4.7 OVER TEMPERATURE LIMIT SWITCH ADJUSTMENTS
      • Figure 4.5
        • Over Temperature Limit Switch Location
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_07_Ch5_3-24-11
  • SECTION 5 - SAFETY DEVICE TESTING PROCEDURES
    • 5.1 TESTING OF SAFETY DEVICES
    • 5.2 LOW GAS PRESSURE FAULT TEST
      • Figure 5.1
        • 1/8” Pipe Plug Position for Manometer Installation
    • 5.3 HIGH GAS PRESSURE TEST
      • Figure 5.2
    • 5.4 LOW WATER LEVEL FAULT TEST
    • 5.5 WATER TEMPERATURE FAULT TEST
      • Figure 5.3
        • Temperature Limit Switch Setting
    • 5.6 INTERLOCK TESTS
      • 5.6.1 REMOTE INTERLOCK
      • 5.6.2 DELAYED INTERLOCK
    • 5.7 FLAME FAULT TEST
      • Figure 5.4
        • Manual Leak Detection Valve
    • 5.8 AIR FLOW FAULT TEST
      • Figure 5.5
        • Blower Proof Switch Location and Wiring
    • 5.9 SSOV PROOF OF CLOSURE SWITCH
      • Figure 5.6
        • SSOV Actuator Cover Screw Location
    • 5.10 PURGE SWITCH OPEN DURING PURGE
      • Figure 5.7
        • Air/Fuel Valve Cover Location
    • 5.11 IGNITION SWITCH OPEN DURING IGNITION
      • Figure 5.8
        • Air/Fuel Valve Purge and Ignition Switch Locations
    • 5.12 SAFETY PRESSURE RELIEF VALVE TEST
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_08_Ch6_12-09-10
  • 6.1 MAINTENANCE SCHEDULE
  • 6.2 Spark Ignitor
    • Figure 6.1
      • Spark Ignitor and Flame Detector Location
  • 6.3 Flame Detector
  • 6.4 COMBUSTION CALIBRATION
  • 6.5 SAFETY DEVICE TESTING
    • 6.6 BTU TRANSMITTER PUMP LUBRICATION
    • Figure 6.2
      • BTU Transmitter Pump Oil Port Locations
  • 6.7 BTU TRANSMITTER ASSEMBLY
    • Figure 6.3
      • BTU Transmitter Pump Disassembly
    • Figure 6.4
      • Compression Fitting Locations
    • Figure 6.5
      • BTU Transmitter Disassembly
    • Figure 6.6
      • BTU Transmitter Pump Compression Fitting Locations
    • Figure 6.7
      • BTU Transmitter Hot Water Tube Disassembly
    • Figure 6.8
      • BTU Transmitter Shell Components
    • Figure 6.9
      • Impeller Housing Disassembly
  • 6.8 MANIFOLD AND EXHAUST TUBES
    • Figure 6.10
      • Grounding Terminal Location
    • Figure 6.11
      • Burner Disassembly Diagram
    • Figure 6.12
      • Exhaust Sensor Connector Location
    • /
    • Figure 6.13
      • Blower Proof Switch Wire Location
      • (older style switch shown at left, newer style at right)
    • Figure 6.14
      • Air/Fuel Valve Inlet Hose Clamp
    • Figure 6.15
      • Feedback Tube and Air/Fuel Valve to Differential Regulator Bolts
    • Figure 6.16
      • Manifold Nut and Bolt Locations
        • 6.8.1 PROPANE UNITS
    • Figure 6.17
      • Propane Air Regulator Measuring Taps
  • 6.9 HEAT EXCHANGER INSPECTION AND CLEANING
  • 6.10 CONDENSATE DRAIN ASSEMBLY
  • 6.11 LOW WATER CUTOFF PROBE INSPECTION AND CLEANING
  • 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-More Control BOX)
  • 6.13 FLAME STRENGTH MEASURMENT
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_09_Ch7_3-28-11
  • 7.1 INTRODUCTION
  • 1. Inspect feed forward (BTU transmitter) sensor for loose or broken wiring.
  • 2. Check resistance of sensor to determine if it is within specification.
  • 1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 500 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.
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_10_CH8_6-20-10
  • Section 8 - RS232 COMMUNICATION
    • INTRODUCTION
    • RS232 COMMUNICATION SETUP
    • MENU PROCESSING UTILIZING RS232 COMMUNICATION
    • DATA LOGGING
      • 8.4.1 Fault Log
      • 8.4.2 Operation Time Log
      • 8.4.3 Sensor Log
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_11_App-A_6-18-10
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_12_App-B_10-01-09
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_13_App-C_05-06-09
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_14_App-D_3-24-11
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_15_App-E_6-18-10
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_16_App-F_05-06-09
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_17_App-G_05-06-09
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_18_App-H_12-27-08
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_19_App-I_05-06-09
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_20_App-J
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_21_warranty
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_04_Ch2_2-16-12.pdf
  • 2.1 RECEIVING THE UNIT
  • 2.2 UNPACKING
  • 2.3 INSTALLATION
    • 2.3.1 SETTING THE UNIT
    • Figure 2.2
      • Lifting Lug Location
        • 2.3.2 WATER INLET AND OUTLET PIPING
    • Figure 2.3
      • Inlet and Outlet Location
    • Figure 2.4
      • Hose Bib Location
    • Figure 2.5
      • Pressure/Temperature Relief and Drain Valve Installation Location
    • Figure 2.6
      • Condensate Drain Assembly Location
  • 2.4 GAS SUPPLY PIPING
    • Figure 2.7
      • Gas Supply Regulator and Manual Shut -Off Valve Location
        • 2.4.2 MANUAL GAS SHUTOFF VALVE
        • 2.4.3 IRI GAS TRAIN KIT
  • 2.5 ELECTRICAL SUPPLY
    • Figure 2.8
      • AC Power Box Location
        • 2.5.1 ELECTRICAL REQUIREMENTS
    • Figure 2.9
      • AC Power Wiring Diagram
  • 2.6 FIELD CONTROL WIRING
    • Figure 2.10
      • Input/Output (I/O) Box Location
        • 2.6.10 FAULT RELAY
    • Figure 2.11 I/O Box Wiring
      • 2.8 COMBUSTION AIR
      • 2.8.1 COMBUSTION AIR FROM OUTSIDE THE BUILDING
      • 2.8.2 COMBUSTION AIR FROM INSIDE THE BUILDING
      • NOTE
    • Figure 2.12
      • Sealed Combustion Air Connection
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_05_Ch3_2-16-11.pdf
  • 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
• OMM-0030_0B_GF-111LN_KC HEATER-LN _G-11-0694 and UP_08_Ch6_2-14-12.pdf
  • 6.1 MAINTENANCE SCHEDULE
  • 6.2 Spark IgnitEr
    • Figure 6.1
      • Spark Igniter and Flame Detector Location
  • 6.3 Flame Detector
  • 6.4 COMBUSTION CALIBRATION
  • 6.5 SAFETY DEVICE TESTING
    • 6.6 BTU TRANSMITTER PUMP LUBRICATION
    • Figure 6.2
      • BTU Transmitter Pump Oil Port Locations
  • 6.7 BTU TRANSMITTER ASSEMBLY
    • Figure 6.3
      • BTU Transmitter Pump Disassembly
    • Figure 6.4
      • Compression Fitting Locations
    • Figure 6.5
      • BTU Transmitter Disassembly
    • Figure 6.6
      • BTU Transmitter Pump Compression Fitting Locations
    • Figure 6.7
      • BTU Transmitter Hot Water Tube Disassembly
    • Figure 6.8
      • BTU Transmitter Shell Components
    • Figure 6.9
      • Impeller Housing Disassembly
  • 6.8 MANIFOLD AND EXHAUST TUBES
    • Figure 6.10
      • Grounding Terminal Location
    • Figure 6.11
      • Burner Disassembly Diagram
    • Figure 6.12
      • Exhaust Sensor Connector Location
    • Figure 6.13
      • Blower Proof Switch Wire Location
      • (older style switch shown at left, newer style at right)
    • Figure 6.14
      • Air/Fuel Valve Inlet Hose Clamp
    • Figure 6.15
      • Feedback Tube and Air/Fuel Valve to Differential Regulator Bolts
    • Figure 6.16
      • Manifold Nut and Bolt Locations
  • 6.9 HEAT EXCHANGER INSPECTION AND CLEANING
  • 6.10 CONDENSATE DRAIN ASSEMBLY
  • 6.11 LOW WATER CUTOFF PROBE INSPECTION AND CLEANING
  • 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-More Control BOX)
  • 6.13 FLAME STRENGTH MEASURMENT
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_09_Ch7_2-16-12.pdf
  • 7.1 INTRODUCTION
  • 1. Inspect feed forward (BTU transmitter) sensor for loose or broken wiring.
  • 2. Check resistance of sensor to determine if it is within specification.
  • 1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 500 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.
• OMM-0030_0A_GF-111LN_KCH-LN _G-11-0029 to G-11-0693_10_CH8_2-16-12.pdf
  • Section 8 - RS232 COMMUNICATION
    • INTRODUCTION
    • RS232 COMMUNICATION SETUP
    • MENU PROCESSING UTILIZING RS232 COMMUNICATION
    • DATA LOGGING
      • 8.4.1 Fault Log
      • 8.4.2 Operation Time Log
      • 8.4.3 Sensor Log
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