Aerco KC Series Equipped with C-More version 3.04 User Manual

Printed in U.S.A. REVISED 12/10 AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-

SAFETY PRECAUTIONS 1-4 2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall

APPENDIX F F-1 PIPING DRAWINGS CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVE *RELIEF VALVE *HOUSE RECIRCULATION(NOTE 6)6&apo

APPENDIX F F-2 COLD WATER INCONNECT 5/8" I.D. HOSE SHELL DRAIN VALVE *RELIEF VALVE *HOUSE RECIRCULATION(NOTE 6)6(NOTE 6)6TAP FOR OXYGENMANDATOR

APPENDIX F F-3 CONNECT 5/8" I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVE *RELIEF VALVE *HOUSE RECIRCULATION(NOTE 6)6TAP FOR OXYGENMANDATORY G

APPENDIX F F-4 COLD WATER INCONNECT 5/8" I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVE *RELIEF VALVE *HOUSE RECIRCULATIONHOT WATER OUTINLET BAF

APPENDIX F F-5 CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVERELIEF VALVESD-A-607WITH STRATIFIED PEAK STORAGE TANKKC SERIES G

APPENDIX G G-1 SCHEMATICS CLOSURE SWITCHPROOF OFGRNWHT60 Hz120 VAC IN20 ANEUGNDHOTNCCGNHGNDHGN123456123456789123456789101112131415123456789101112CONTR

APPENDIX G G-2 CONTROL BOX CONNECTORSGAS FIRED BOILER SYSTEMWIRING SCHEMATIC1616131210 11 13 14 1615 17 18 19 2120 22 23 2424-PIN CONNECTOR241240 2422

APPENDIX H I-1 CONNECTOR BOARDP/N 124366POWER SUPPLY BOARDP/N 124362LOW WATER CUTOFF BOARD P/N 124363PMC BOARDP/N 124364IGNITION/STEPPER BOARD

APPENDIX H I-2 P1P2P3P4P5P6SHELL HARNESSCONNECTOR(19 PIN)INTERLOCK HARNESSCONNECTOR(16 PIN)EXT. SENSOR/COMMHARNESS CONNECTOR(24 PIN)GAS TRAIN

STANDARD WARRANTY: Gas-Fired Water Heater International, Inc. Rev. 04/16/09 D102.0 PRESSURE VESSEL: 10 YEARS NON-PRORATED The 304L stainl

INSTALLATION 2-1 SECTION 2 - INSTALLATION 2.1 RECEIVING THE UNIT Each KC1000 Heater is shipped as a single crated unit. The shipping weight is appr

STANDARD WARRANTY: Gas-Fired Water Heater International, Inc. Rev. 04/16/09 D102.1 CONDITIONS OF WARRANTY Should an AERCO gas-fired (nat

INSTALLATION 2-2 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Fig 2.1 These are the minimum c

INSTALLATION 2-3 Shut-off valves and union conections must be installed in the inlet and outlet lines for main-tenance. The use of dielectric unions

INSTALLATION 2-4 2.3.5 SYSTEM RECIRCULATION The system recirculating line ties into the unit at the recirculating tee fitting provided in the drain v

INSTALLATION 2-5 Figure 2.6 Gas Supply Regulator and Manual Shut -Off Valve Location All pipe should be de-burred and internally cleared of any sc

INSTALLATION 2-6 2.5 ELECTRICAL SUPPLY The AERCO Gas Fired Equipment Electrical Power Wiring Guide, (GF-1060), must be consulted in addition to the

INSTALLATION 2-7 2.6.1 OUTDOOR AIR SENSOR IN Not applicable to Water Heaters. 2.6.2 AUX SENSOR IN The AUX SENSOR IN terminals can be used to ad

INSTALLATION 2-8 requires time to close (make), a time delay (Aux Start On Dly) that holds the start sequence of the unit long enough for a proving s

INSTALLATION 2-9 For Massachusetts installations, the Heatfab Division of the Selkirk Corporation provides vent systems which conform to all applica

Printed in U.S.A. REVISED 12/10 AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-

CONTROL PANEL OPERATING PROCEDURES 3-1 SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION The information in this Section provides a

CONTROL PANEL OPERATING PROCEDURES 3-2 Table 3-1. Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 Fo

CONTROL PANEL OPERATING PROCEDURES 3-3 Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM NO. CONTROL, INDICATOR OR DISPLAY F

CONTROL PANEL OPERATING PROCEDURES 3-4 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the selected menu wil

CONTROL PANEL OPERATING PROCEDURES 3-5 NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outd

CONTROL PANEL OPERATING PROCEDURES 3-6 Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Intern

CONTROL PANEL OPERATING PROCEDURES 3-7 Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Def

CONTROL PANEL OPERATING PROCEDURES 3-8 3.8. START SEQUENCE When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge s

CONTROL PANEL OPERATING PROCEDURES 3-9 154155AIR/FUEL VALVEBLOWER PROOFSWITCHTO FRAMEHARNESS Figure 3-5. Blower Proof Switch 5. Upon completion of

CONTENTS i GF-111 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER Operating & Maintenance Instructions FOREWARD A Section 1 – SAFETY PRECAUTI

CONTROL PANEL OPERATING PROCEDURES 3-10 Table 3-6. Relationship Between Air/Fuel Valve Position and Energy Input of a Unit Running on Natural Gas A

INITIAL START-UP 4-1 SECTION 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the KC-1000 Water Heater is comprised

INITIAL START-UP 4-2 *For propane fired units, an additional 8" W.C. manometer and 1/2" NPT to barbed fitting is needed. 4.2.2 INSTALLING

INITIAL START-UP 4-3 IMPORTANT The unit is shipped from the factory set up for either natural gas or propane, as specified by the Style No. on the Sal

INITIAL START-UP 4-4 NOTE: Always go to a percentage of valve position from the same direction, (i.e., 100% to 30% or 30% to 20%). Whenever going to

INITIAL START-UP 4-5 15. Replace the regulator cap and cap gasket and wait for the analyzer reading to settle. 16. When the analyzer reading settle

INITIAL START-UP 4-6 50°F 5.4 % <150 ppm 60°F 5.2 % <150 ppm 70°F 5.0 % <150 ppm 80°F 4.8 % <150 ppm 90°F 4.6 % <150 ppm 100°F 4.4 % &

INITIAL START-UP 4-7 NOTE: The combustion calibration data in Tables 1, 2 and 3 apply to both natural gas and propane units. Therefore, refer to the

INITIAL START-UP 4-8 7. Remove the combustion analyzer probe from the vent hole. Seal the probe hole and replace the vent connection cover. 8. R

INITIAL START-UP 4-9 3. Once stabilized, the OUTLET TEMPERATURE display should read no more than 2 to 3 degrees above the unit’s setpoint. 4. If th

CONTENTS ii Section 6 – MAINTENANCE 6-1 Para. Subject Page 6.1 Maintenance Schedule 6-1 6.2 Spark Ignitor 6-1 6.3 Flame Detector 6-2 6.4 Combustion

INITIAL START-UP 4-10 4.7 OVER-TEMPERATURE LIMIT SWITCH ADJUSTMENTS There are two over-temperature limit switches that turn off the unit when the o

INITIAL START-UP 4-11

SAFETY DEVICE TESTING 5-1 SECTION 5 - SAFETY DEVICE TESTING PROCEDURES 5.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety de

SAFETY DEVICE TESTING 5-2 HIGH GASPRESSURE SWITCH Figure 5.2 High Gas Pressure Switch 5.4 LOW WATER LEVEL FAULT TEST 1. Set the ON/OFF switch in t

SAFETY DEVICE TESTING 5-3 5.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Inter-lock. Te

SAFETY DEVICE TESTING 5-4 Figure 5.4 Manual Leak Detection Valve 5.8 AIR FLOW FAULT TEST 1. Start the unit in manual mode and set the valve posit

SAFETY DEVICE TESTING 5-5 SSOVACTUATORCOVERSSOVCOVERSCREW Figure 5.6 SSOV Actuator Cover Screw Location 5.10 PURGE SWITCH OPEN DURING PURGE 1. Set

SAFETY DEVICE TESTING 5-6 IGNITIONPOSITIONSWITCHPURGEPOSITIONSWITCH169170172171STEPPERMOTORDIALBLOWERBURNER Figure 5.8 Air/Fuel Valve Purge and Igniti

MAINTENANCE 6-1 SECTION 6 – MAINTENANCE 6.1 MAINTENANCE SCHEDULE The KC1000 Heater requires regular routine maintenance to maintain efficiency

MAINTENANCE 6-2 SPARK IGNITORASSEMBLYBURNERSHELLFLAMEDETECTORSILICONEPLUG Figure 6.1 Spark Ignitor and Flame Detector Location Table 6-1. Maintenan

FOREWORD A Foreword The AERCO KC Water Heating System is a true industry advance that meets the needs of today's energy and environment

MAINTENANCE 6-3 2. Remove the left side panel from the unit. 3. Disconnect the flame detector lead wire and unscrew the flame detector and remove

MAINTENANCE 6-4 3. Shut the water inlet, outlet and recirculation valves to the unit. 4. Open the drain valve on the unit. 5. Slowly open the pre

MAINTENANCE 6-5 10. Carefully remove the lower tubing assembly taking care not to lose either the cold water or hot water mixing orifice, (See Fig.

MAINTENANCE 6-6 12. Remove the compression fitting at the top of the impeller housing and remove the impeller housing, (See Fig. 6.6). HOT WATER TUB

MAINTENANCE 6-7 IMPELLER HOUSINGCOVER Figure 6.9 Impeller Housing Disassembly 19. Once the BTU transmitter has been inspected and cleaned, reassemb

MAINTENANCE 6-8 5. Disconnect the flame detector and ignition cable wires from the flame detector and ignitor contactor. Remove the flame detector an

MAINTENANCE 6-9 Figure 6.12 Exhaust Sensor Connector Location 13. Disconnect the air/fuel valve wiring harness connector from the control panel.

MAINTENANCE 6-10 Figure 6.14 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube betwe

MAINTENANCE 6-11 21. Loosen the three 1-1/16” nuts that hold the manifold. Remove the two side nuts. DO NOT REMOVE THE FRONT NUT, (See Fig. 6.16). 2

MAINTENANCE 6-12 Figure 6.17 Propane Air Regulator Measuring Taps 6.9 HEAT EXCHANGER INSPECTION AND CLEANING Inspecting the Heat Exchanger The wate

MAINTENANCE 6-13 10. Reassemble the cap screws and nuts through the upper head and shell ring. Cross tighten the nuts to approximately 75 ft./lb. tor

MAINTENANCE 6-14 Figure 6.19 – HydroSkrub Pumping System Set-Up Diagram for KC-1000 Pumping System Set-Up Directions 1. Turn off the water heater a

MAINTENANCE 6-15 strength is depleted (two pounds of deposits removed per gallon used) or the equipment is free from calcium and other water formed mi

MAINTENANCE 6-16 6.11 LOW WATER CUTOFF PROBE INSPECTION AND CLEANING KC Heaters feature a Low Water Cutoff sensor probe (P/N 122843 as part of probe/

MAINTENANCE 6-17 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-MORE CONTROL BOX) The Hydraulic Zero Needle Valve is factory set in new equipment an

6.13 FLAME STRENGTH MEASURMENT The flame sensor is a very important safety device. Its function is to sense the absence of a flame (over a certai

MAINTENANCE 6-19 Check for the following during the reading: • Measure the voltage in µA between the flame rod and the flame connector. If the flam

Figure 6.22 – Manifold Gasket Part Numbers and Locations

TROUBLESHOOTING 7-1 SECTION 7- TROUBLESHOOTING GUIDE7.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in is

TROUBLESHOOTING 7-2 KC1000 WATER HEATER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. B

SAFETY PRECAUTIONS 1-1 SECTION 1 -- SAFETY PRECAUTIONS1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe al

TROUBLESHOOTING 7-3 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OP

TROUBLESHOOTING 7-4 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FFWD TEMP SENSOR FAU

TROUBLESHOOTING 7-5 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS PRESSURE

TROUBLESHOOTING 7-6 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED DUR

TROUBLESHOOTING 7-7 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE OUT OF PH

TROUBLESHOOTING 7-8 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION PRG SWTCH CLOSED DUR

TROUBLESHOOTING 7-9 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV FAULT DURING PU

RS232 COMMUNICATION 1 SECTION 8 - RS232 COMMUNICATION INTRODUCTION The RS232 port on the front panel of the C-More Control Box (Figure 3-1) can be i

RS232 COMMUNICATION 2 (c) Menu changes will be stored in non-volatile memory. To redisplay the menu and view the option which was just changed in st

RS232 COMMUNICATION 3

SAFETY PRECAUTIONS 1-2 CAUTIONS! Must be observed to prevent equipment damage or loss of operating effectiveness. CAUTION! Many soaps used for gas p

RS232 COMMUNICATION 4 Table 8-1. Sample Fault Log Display No. Fault Message Cycle Date Time 0 Direct Drive Signal Faul

APPENDIX A A-1 APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the

APPENDIX A A-2 APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpo

APPENDIX A A-3 APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS - CONTINUED MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI

APPENDIX A A-4 APPENDIX A - WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates

APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DEMAND DELAY XX sec Dis

APPENDIX B TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge, or a

APPENDIX B TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoo

APPENDIX C TEMPERATURE SENSOR RESISTANCE CHART (Balco)

APPENDIX D D-1 WATER HEATER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit C

SAFETY PRECAUTIONS 1-3 1. INSTALLATION OF CARBON MONOXIDE DETECTORSa. In the event that the side wall horizontally vented gas fueled equipment is in

APPENDIX D D-2 WATER HEATER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Tuning Menu Prop Band 8°F Integral Gain 1.60 Derivati

APPENDIX E E-1

APPENDIX E E-2 18(45.7)49(124.5)57(144.8)16-3/422-5/871-7/871-7/819(48)15-1/2(39.4)6(15.2) I.D.FLUE CONN.3/4(1.9) DIA.(ENCLOSURE)PRESS./TEMP.RELIEF2

APPENDIX E E-3 18(45.7)49(124.5)57(144.8)16-3/422-5/871-7/871-7/819(48)15-1/2(39.4)6(15.2) I.D.FLUE CONN.3/4(1.9) DIA.(ENCLOSURE)PRESS./TEMP.RELIEF2&

APPENDIX E E-4 1/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.3/8" NPT x 3/8" O.D. TUBE AL. COMP. FTG.32GP-1226141293531GM-209341123581

APPENDIX E E-5 1436351634715181716103329323130402413427 284943SEE DETAIL "A"EXPLODEDDETAIL "A"13121142958SEE DRAWING PL-B-134 FOR

APPENDIX E E-6 1 1/2" SAFETY SHUT-OFF VALVEDIFFERENTIAL PRESSURE REGULATOR W/ BROWN SPRINGBURNER/GAS VA. ADAPTOR23451GM-161095GAS COCKGP-122415G

APPENDIX E E-7 5413718166231/4"NPT x 3/8"OD TUBE 90° COMP. FTG.PUMP OUTLET TUBE1/4"NPT STREET ELBOW1/4"NPT CLOSE NIPPLE1/4"N

APPENDIX E E-8 1714J15159845111041312DWN.BYAPPD.SCALEPL-A-134CZ 041304DATEDATEDAERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647(SH. 2 OF 2)(COMPLETE AS

APPENDIX E E-9 DWN.BYSCALEAPPD.KC1000 WATER HEATERIRI GAS TRAINSD-A-606030801PDRDATEDATENTSREV.FNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCO3/4&quo