Aerco KC1000 Heater Mar 2011 User Manual

Printed in U.S.A. REVISED 02/16/12 GF-111LN OMM-0030_0B KC Series Low NOx Gas-Fired Water Heater USER MANUAL Applicable to Serial Numbe

INSTALLATION 2-2 2.3 INSTALLATION The unit must be installed with the prescribed clearances for service as shown in Figure 2.1. These are the minim

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

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 OXYGENMANDATORY

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

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

APPENDIX F F-5 CONNECT 5/8'' I.D. HOSE TO CONDENSATE DRAINSHELL DRAIN VALVERELIEF VALVESD-A-709WITH STRATIFIED PEAK STORAGE TANKKC1000 1 MIL

APPENDIX G G-1 CLOSURE SWITCHPROOF OFGRNWHT60 Hz120 VAC IN20 ANEUGNDHOTNCCGNHGNDHGN123456123456789123456789101112131415123456789101112CONTROL BOX CONN

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

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

APPENDIX H H-2 P1P2P3P4P5P6SHELL HARNESS CONNECTOR(19 PIN)INTERLOCK HARNESS CONNECTOR(16 PIN)EXT. SENSOR/COMM HARNESS CONNECTOR(24 PIN)GAS TRA

APPENDIX I KC1000 LOW NOx DUAL-FUEL SWITCH-OVER INSTRUCTIONS The KC1000 Low NOx Heater is shipped from the factory configured for either natural g

APPENDIX J J-1 RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix E for the locations of the recommended and opti

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

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

INSTALLATION 2-4 A 1” drain valve assembly is furnished with each unit. The drain valve assembly should be in-stalled as shown in Figure 2.5. and hard

INSTALLATION 2-5 The location of the 1-1/4" inlet gas connection on the right side of the unit is shown in Figure 2.7. All pipe should be de-

INSTALLATION 2-6 2.4.2 MANUAL GAS SHUTOFF VALVE A 1-1/4” manual gas shutoff valve is furnished with each unit and should be positioned as shown in Fi

INSTALLATION 2-7 GAS SHUT-OFF VALVEI/O BOXBLOWER Figure 2.10 Input/Output (I/O) Box Location CAUTION! DO NOT make any connections to the I/O Box term

INSTALLATION 2-8 2.6.9.1 REMOTE INTERLOCK IN The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if desi

INSTALLATION 2-9 2.7 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide, GF-1050, must be consulted before any flue or com

INSTALLATION 2-10 In addition, Cold Air Damper # 99026 must be installed. It should be located along the inlet duct run as close as possible to the KC

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

Printed in U.S.A. REVISED 02/16/12 GF-111LN OMM-0030_0B KC Series Low NOx Gas-Fired Water Heater USER MANUAL Telephone Support Direct

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

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

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 Defa

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 sa

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

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 Low NOx Water Heater is c

CONTENTS i GF-111LN - AERCO KC1000 GAS FIRED LOW NOx WATER HEATER Operating & Maintenance Instructions FOREWORD A Section 1 – SAFETY PRECAUTION

INITIAL START-UP 4-2 SSOV1/8" NPT PLUG(INSTALLMANOMETERHERE) Figure 4.1 1/8” Gas Plug Location 4.2.3 PREPARING THE FLUE VENT PROBE HOLE 1. I

INITIAL START-UP 4-3 On initial start-up, or return to service from a fault condition, the unit will remain at a 29% valve position for two-minutes.

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

INITIAL START-UP 4-5 BLOWEROUTLETBLOWERINLETSCREENSHUTTERSHUTTER LOCKING NUTS Figure 4.4 Air Shutter Locking Nut Location REMINDER: At 30% valve posi

INITIAL START-UP 4-6 5. Set the unit to the Manual Mode by pressing the AUTO/MAN switch. A flashing Manual Valve Position message will be display

INITIAL START-UP 4-7 14. Use a flat-tip screwdriver to adjust the differential pressure regulator. Turn the screwdriver: • counterclockwise to incre

INITIAL START-UP 4-8 22. Wait for the analyzer to settle and then compare the new oxygen reading to Table 6 (or 6A). Repeat the inlet air shutter

INITIAL START-UP 4-9 5. Make small adjustments and allow time between adjustments for the outlet water temperature to stabilize. 6. Maintain water

INITIAL START-UP 4-10 7. Press the CHANGE key. The display will begin to flash. 8. Raise or lower the maximum load adjustment using the ▲ or

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

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 6-3 6.4 Combustion

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 a

MAINTENANCE 6-2 FLAMEDETECTORPROBELOWERBURNERSHELLBURNERHEADBURNERPLATEIGNITER(124570)FLAME DETECTOR(124837)STAGEDIGNITIONORIFICE Figure 6.1 Spark Ign

MAINTENANCE 6-3 6.3 FLAME DETECTOR The flame detector (part no. 124837) is located in the body of the burner (see Fig. 6.1). The flame detector may

MAINTENANCE 6-4 6.7 BTU TRANSMITTER ASSEMBLY The BTU Transmitter is a crucial part of the unit’s temperature control system. It must be inspected and

MAINTENANCE 6-5 COMPRESSIONFITTINGSLOWER TUBING ASSEMBLY Figure 6.4 Compression Fitting Locations 10. Carefully remove the lower tubing assembly tak

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

MAINTENANCE 6-6 COMPRESSIONFITTINGSIMPELLERHOUSINGPUMP OUTLETTUBE Figure 6.6 BTU Transmitter Pump Compression Fitting Locations 12. Remove the c

MAINTENANCE 6-7 HOT WATER TUBECOMPRESSION FITTING Figure 6.8 BTU Transmitter Shell Components IMPELLER HOUSINGCOVER Figure 6.9 Impeller Housing Disa

MAINTENANCE 6-8 The following parts will be necessary for reassembly after inspection: GP-122537 Exhaust Manifold to Combustion Chamber Gasket GP-18

MAINTENANCE 6-9 10. Using a 7/16” socket or open end wrench, remove the four 1/4-20 nuts on the gas inlet pipe flange at the burner. LOW NOxBURNER

MAINTENANCE 6-10 TO FRAMEHARNESSBLOWER PROOF SWITCHAIR/FUEL VALVE Figure 6.13 Blower Proof Switch Wire Location (older style switch shown at l

MAINTENANCE 6-11 AIR/FUELVALVECOMPRESSIONFITTINGSDIFFERENTIAL PRESS.REGULATOR3/8 - 16HEX NUT/BOLT Figure 6.15 Feedback Tube and Air/Fuel Valve to Diff

MAINTENANCE 6-12 28. Replace the gasket between the manifold and the combustion chamber (Part Number GP-122537). The use of Permatex or a similar ga

MAINTENANCE 6-13 5/8-11 HEX NUT5/8-11 X 3" CAP SCREWKC1000 SS HEATER5/8 EYE NUT5/8-11 X 4-1/2" STUDUPPER HEAD (P.N. 18842)UPPER HEAD LINERR

MAINTENANCE 6-14 Figure 6.18 – 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

SAFETY PRECAUTIONS 1-2 CAUTION! Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be rinsed thoroughly with clean wa

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 and

MAINTENANCE 6-18 6.13 FLAME STRENGTH MEASURMENT The flame sensor is a very important safety device. Its function is to sense the absence of a flame (

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 flame

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

TROUBLESHOOTING 7-3 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1

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

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

SAFETY PRECAUTIONS 1-3 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipm

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

TROUBLESHOOTING 7-7 not closed. operational. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTI

TROUBLESHOOTING 7-8 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 4. Defective

TROUBLESHOOTING 7-9 KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV FAULT DURING RUN 1.

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

RS232 COMMUNICATION 8-2 Diagnostic Menus should only be used by Factory-Trained service personnel). (c) Menu changes will be stored in non-volatile

RS232 COMMUNICATION 8-3 Table 8-1. Sample Fault Log Display No. Fault Message Cycle Date Time 0 Direct Drive Signal Fa

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

SAFETY PRECAUTIONS 1-4 not provide the parts for venting the flue gases, but identifies "special venting systems", the following requiremen

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

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

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

APPENDIX B B-3 TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outd

APPENDIX C [Type text] C-1 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

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

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-209341123581G

APPENDIX E E-5 363534715181716103329323130402413427 284943SEE DETAIL "A"EXPLODEDDETAIL "A"13121142958SEE DRAWING PL-B-13452AERCO

APPENDIX E E-6 TABLE 1BEFORE G-07-0883G-07-0883 AND AFTERSERIAL NUMBERITEM 15 PART NUMBERGP-122512530131/4"NPT x 3/8"OD TUBE 90° COMP. FTG.P

APPENDIX E E-7 JDWN.BYAPPD.SCALEPL-A-134CZ041304DATEDATEDAERCOINTERNATIONAL, INC.NORTHVALE, NJ 07647(SH. 2 OF 2)(COMPLETE ASS'Y GM-20872)BTU T

APPENDIX E E-8 DWN.BYSCALEAPPD.KC1000 LOW NOx WATER HEATERIRI GAS TRAINSD-A-661022305GSDATEDATENTSREV.DNORTHVALE, NJ 07647INTERNATIONAL, INC.AERCO3/

APPENDIX E E-9 126115917108241413DO NOT CUT WIRESITEM NO. QTY. PART NO. DESCRIPTION1 1 124866 SOLENOID VALVE, 1/4" NPT2 1 122712 1/2" NPT,