AER KC Series Guide

Printed in U.S.A. REVISED 12/30/04

Instruction

No.

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

Installation, Operation

& Maintenance Instructions

KC Series

Gas Fired

Water Heating

System

Natural Gas or Propane Fired,

Condensing and Forced Draft Hot Water Heater

1,000,000 BTU/HR Input

Applicable to Serial Numbers G-01-026 and above

Patent No. 4,852,524

GF-105

Telephone Support

Direct to AERCO Technical Support

(8 to 5 pm EST, Monday through

Friday)

(800) 526-0288

AERCO International, Inc.

159 Paris Avenue

Northvale, NJ 07647-0128

The information contained in this operation

and maintenance manual is subject to

change without notice from AERCO

International, Inc.

AERCO makes no warranty of any kind with

respect to this material, including but not

limited to implied warranties of

merchantability and fitness for a particular

application. AERCO International is not

liable for errors appearing in this manual.

Nor for incidental or consequential damages

occurring in connection with the furnishing,

performance, or use of this material.

CONTENTS

GF-105 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER

Operating & Maintenance Instructions

FOREWORD

Section 1 SAFETY PRECAUTIONS--------------------------------1

Section 2 INSTALLATION PROCEDURES-----------------------2

2.1 Receiving the Unit

2.2 Unpacking

2.3 Installation

2.4 Gas Supply Piping

2.5 Electrical Supply

2.6 Field Control Wiring

2.7 Flue Gas Vent Installation

2.8 Combustion Air

2.9 Unit Initial Fill

Section 3 CONTROL PANEL COMPONENTS

and OPERATING PROCEDURES------------9

3.1 The Control Panel

3.2 The Temperature Controller

3.3 The Primary Menu

3.4 The Secondary Menu

3.5 The Annunciator Circuit

3.6 The Combustion Safeguard

Controller

3.7 Water Level Test and Reset Switches

3.8 On\Off Switch

3.9 Starting Sequence

3.10 After Flame

3.11 Flame Test Jacks

3.12 Start\Stop Levels

3.13 Auto Restarts

Section 4 INITIAL START-UP--------------------------------------17

4.1 Initial Start-Up requirements

4.2 Tools and Instrumentation for

Combustion Calibration

4.3 Combustion Calibration

4.4 Propane Combustion Calibration

4.5 Unit Reassembly

4.6 Temperature Control Calibration

4.7 Over Temperature Limit Switch

Adjustments

Section 5 SAFETY DEVICE TESTING

PROCEDURES-----------------------------------25

5.1 Testing of Safety Devices

5.2 Gas Pressure Fault Test

5.3 Low Water Level Fault Test

5.4 Water Temperature Fault Test

5.5 Flame Fault Test

5.6 Air Pressure Fault Test

5.7 Purge Interlocks Fault Test

5.8 Safety Pressure Relief Valve Test

CONTENTS

2/27/99

Section 6 MAINTENANCE REQUIREMENTS-------------------29

6.1 Maintenance Schedule

6.2 Spark Ignitor

6.3 Flame Detector

6.4 Combustion Calibration

6.5 Safety Device Testing

6.6 BTU Transmitter Pump

Lubrication

6.7 BTU Transmitter Assembly

6.8 Manifold and Exhaust Tubes

6.9 Heat Exchanger Inspection

Section 7 TROUBLESHOOTING-----------------------------------39

7.1 Gas Pressure Fault

7.2 Exhaust Temperature Fault

7.3 Water Level Fault

7.4 Water Temperature Fault

7.5 Flame Fault

7.6 Air Pressure Fault

7.7 System Fault

APPENDICES

A. Temperature Controller Menus

B. Temperature Controller Quick

Programming Guide

C. Shell Sensor Resistance Chart

D. Mode of Operation Default

Settings

E. Dimensional & Parts Drawings

F. Piping Drawings

G. Wiring Schematics

H. Control Panel Isometric Drawing

WARRANTIES

FOREWORD

iii

Foreword

The AERCO KC Hot Water Heating System is a true industry advance that meets the needs of

today’s energy and environmental concerns. Designed for use in any potable water heating

system, it provides constant temperature water regardless of flow rate. It’s small space

requirements and venting capabilities allows installations without normal restrictions yet with

maximum flexibility. The KC Heater’s load tracking controls modulate over a 14:1 turndown ratio

to match the system demand and yield thermal efficiencies in excess of 93%.

Because of its compact design with direct or chimney venting, the KC Water Heating System is

applicable to any installation with excellent results. Efficiency, reliability and longevity make the

KC Water Heating System a true step forward in Water Heating System design.

After prolonged shutdown, it is recommended that the startup procedures in Section 4 and test

procedures in Section 5 of this manual be performed, to verify system operating parameters. If

there is an emergency, turn off the electrical power supply to the AERCO Heater or close the

Manual Gas Valve located before the AERCO heater. The Installer is to identify the emergency

shut-off device. FOR SERVICE OR PARTS, contact your local Sales Representative listed below

or AERCO INTERNATIONAL.

NAME:

ORGANIZATION:

ADDRESS:

TELEPHONE:

INSTALLATION DATE: _____________________________________________

SAFETY PRECAUTIONS

SECTION 1 -- SAFETY PRECAUTIONS

Installing or operating personnel MUST, at

all times, observe all safety regulations.

The following warnings are general and

must be given the same attention as

specific precautions included in these

instructions. In addition to the

requirements included in this instruction

manual, the installation of units MUST

conform with local building codes, or, in

the absence of local codes, ANZI Z223.1

(National Fuel Gas Code, Publication No.

NFPA-54) for gas-fired heaters and

ANSI/NFPASB for LP gas-fired heaters.

Where applicable, the equipment shall be

installed in accordance with CGA B149.

WARNINGS!

MUST BE OBSERVED TO PREVENT

SERIOUS INJURY TO PERSONNEL.

WARNING!

BEFORE PERFORMING ANY

MAINTENANCE ON THE UNIT,

SHUT OFF THE GAS SUPPLY AND THE

ELECTRICAL POWER SUPPLY TO THE

UNIT.

WARNING!

FLUIDS UNDER PRESSURE MAY

CAUSE INJURY TO PERSONNEL OR

DAMAGE TO EQUIPMENT WHEN

RELEASED.. BE SURE TO SHUT OFF

ALL INCOMING AND OUTGOING

WATER SHUTOFF VALVES AND

CAREFULLY DECREASE ALL TRAPPED

PRESSURES TO ZERO BEFORE

PERFORMING ANY MAINTENANCE.

WARNING!

DO NOT USE MATCHES, CANDLES,

FLAMES, OR OTHER SOURCES OF

IGNITION TO CHECK FOR GAS LEAKS.

WARNING!

THE EXHAUST VENT PIPE OPERATES

UNDER POSITIVE PRESSURE AND

MUST BE COMPLETELY SEALED TO

PREVENT LEAKAGE OF COMBUSTION

PRODUCTS INTO LIVING SPACES.

CAUTIONS!

Must be observed to prevent equipment

damage or loss of operating

effectiveness.

CAUTION!

Many soaps used for gas pipe leak testing

are corrosive to metals. The piping must

be rinsed thoroughly with clean water after

leak checks have been completed.

CAUTION!

Do not use this unit if any part has been

under water. Call a qualified service

technician to inspect and replace any

part that has been under water.

NOTES:

Must be observed for effective operating

procedures & conditions

INSTALLATION PROCEDURES

SECTION 2 - INSTALLATION PROCEDURES

2.1 RECEIVING THE UNIT

Each KC unit is shipped as a single crated unit.

The shipping weight is approximately 1500 lb.

and must be moved with the proper rigging

equipment for safety and to avoid damages.

The unit should be completely inspected at the

time of receipt from the carrier before the bill of

lading is signed. Each unit has Tip-N-Tell

indicator on the outside of the crate. This

indicates if the unit has been turned on its side.

If the Tip-N-Tell indicator is tripped, do not sign

for the shipment. Note the information on the

carrier’s paperwork and request a freight claim

and inspection by a claims adjuster before

proceeding. Any other visual damage to the

packaging materials should also be made clear

to the delivering carrier.

2.2 UNPACKING

Carefully unpack the unit by removing the

packaging material. Take care not to damage

the unit jacket when cutting away packaging

materials. A close inspection of the unit should

be made to determine if there has been any

damage during shipment that was not indicated

by the Tip-N-Tell.

The freight carrier should be notified immediately

if any damage is detected. The following

accessories come standard with each unit and

are packed separately within the unit’s packing

container

•Spare Spark Ignitor

•Spare Flame Detector

•Manual 1-1/4" Gas Shutoff Valve

•Drain Valve Assembly

•ASME Pressure/Temperature

Relief Valve

•Ignitor Removal Tool (One per Site)

•Regulator Adjustment Tool (One

•per Site)

•2 Lifting Lugs

•Stainless Steel Condensate Cup

•Flue Clamps (2 Pieces)

Optional accessories are also separately packed

within the unit’s packing container. Standard and

optional accessories shipped with the unit

should be identified and put in a safe place until

installation/use.

Figure 2.1

Heater Clearances

INSTALLATION PROCEDURES

2.3 INSTALLATION

The unit must be installed with the prescribed

clearances for service as shown in Fig 2.1

These are the minimum clearance dimensions

required by AERCO. Local building codes may

require more clearance and take precedence.

WARNING !

KEEP UNIT AREA CLEAR AND FREE

FROM COMBUSTIBLE MATERIALS AND

FLAMMABLE VAPORS AND LIQUIDS.

2.3.1 SETTING THE UNIT

Locate the lifting lugs, shipped with the unit, and

attach them to the 5/8” x 11 studs at the top of

the unit. Remove the unit from the wooden skid

and place in position using a block and tackle or

hoist attached to the lifting lugs. (see Fig. 2.2).

USE THE LIFTING LUGS TO MOVE THE

UNIT.

Figure 2.2

Lifting Lug Location

The KC-1000 is U/L approved for installation on

combustible flooring. A 4” to 6" high

housekeeping concrete pad is recommended

and allows for sufficient drainage of the

condensate.

The unit must be secured using only the holes

provided in the frame base. Do not use piping to

secure the unit in place. See drawing AP-A-576

in Appendix E for the base frame dimensions.

In multiple unit installations it is important to

plan the position of each unit. Sufficient space

for piping connections and maintenance

requirements must be given. All piping must

include ample provision for expansion.

2.3.2 WATER INLET AND OUTLET

PIPING

The locations of the 2" NPT cold water inlet and

hot water outlet piping connections are shown in

Figure 2.4. Flow rates through the unit are

limited to 30 gpm continuous and 40 gpm

intermittent.

Shut-off valves and union conections must be

installed in the inlet and outlet lines for

maintenance. The use of dielectric unions is

recommended. Install the piping and

accessories as per the following drawings,

located in Appendix F of this manual.

•SD-B-424 for single units

•SD-B-425 for multiple units

•SD-B-432 for single units with a stratified

tank

•SD-B-434 for multiple units with a stratified

storage tank

NOTE:

All piping must be arranged so that it does

not interfere with removal of any cover,

inhibit service or maintenance, or prevent

access between the unit and walls, or

another unit.

Figure 2.3

Inlet and Outlet Location

2.3.3 TEST HOSE BIB

A Test Hose Bib connection, upstream of the

shut off valve on the hot water outlet, is required

INSTALLATION PROCEDURES

for startup and testing. It should be a minimum

of 3/4". It cannot be omitted (See Fig. 2.4a)

Figure 2.4a

Hose Bibb Location

2.3.4 PRESSURE/TEMPERATURE

RELIEF AND DRAIN VALVE

INSTALLATION

An ASME rated Pressure/Temperature Relief

Valve is supplied with each unit. The valve

setpoint is 150 psig/2100F. Install the relief

valve as shown in Fig. 2.4. A suitable pipe

compound should be used on the threaded

connections. Any excess should be wiped off to

avoid getting any into the valve body. The relief

valve should be pipied to within 12 inches of the

floor to prevent injury in the event of a

discharge. The relief piping must be full size, 1-

1/2”, without reduction. No valves, restrictions,

or other blockages are allowed in the discharge

line. In multiple unit installations the discharge

lines must not be manifolded together. Each

must be individually run to a suitable discharge

location.

A 1” drain valve assembly is furnished with each

unit. The assembly should be installed as shown

in Figure 2.4. The drain should be hard piped to

a suitable drain.

2.3.5 SYSTEM RECIRCULATION

The system recirculating line ties into the unit at

the recirculating tee fitting provided in the drain

valve assembly (see Fig. 2.4b). Shut off valves

and union connections are recommended for

maintenance. Recirculation flow rates must be

kept to 8 gpm or less. In a multiple unit

installation, each unit must be tied into the

system recirculation system.

Figure 2.4b

Pressure/Temperature Relief and Drain

Valve Installation Location

2.3.6 CONDENSATE PIPING

The KC Heater is designed to condense and the

installation must have provisions for suitable

drainage. A 1 inch ID silicone hose, supplied

with the unit, directs condensate from the

exhaust manifold to a stainless steel condensate

cup. The condensate cup is shipped loose and

should be installed inside the unit directly under

the manifold’s condensate drainage hole. The

condensate drain fitting is attached to the cup

and should be located at the rear of the unit as

shown in Figure 2.5. A 5/8-inch ID flexible

polypropylene tubing (or suitable equivalent)

should be used to carry the condensate by

gravity to a nearby floor drain. If a floor drain is

not available, a condensate pump can be used

to remove the condensate to a convenient drain.

The maximum condensate flow rate is 5 GPH.

The condensate cup and line must be

removable for routine maintenance. Do not

hard pipe.

INSTALLATION PROCEDURES

Figure 2.5

Condensate Drain Assembly Location

2.4 GAS SUPPLY PIPING

AERCO Gas Fired Equipment Gas Components

and Supply Design Guide (GF-1030) should be

consulted before any gas piping is designed or

started.

WARNING !

DO NOT USE MATCHES, CANDLES,

FLAMES OR OTHER SOURCES OF

IGNITION TO CHECK FOR GAS LEAKS.

CAUTION !

Many soaps used for gas pipe leak testing

are corrosive to metals. The piping must be

rinsed thoroughly with clean water after

leak checks have been completed.

NOTE:

All gas piping must be arranged so that it

does not interfere with removal of any

cover, inhibit service or maintenance, or

prevent access between the unit and walls,

or another unit.

The location of the 1-1/4" inlet gas connection

on the right side of the unit is shown in Figure

2.6.

All pipe should be de-burred and internally

cleared of any scale or iron chips before

installation. No flexible connectors or non-

approved gas fittings should be installed. Piping

should be supported from floor or walls only and

must not be secured to the unit.

A suitable piping compound approved for use

with gas should be used sparingly. Any excess

must be wiped off to prevent clogging of

components.

To avoid damage to the unit when pressure

testing gas piping, isolate the unit from the gas

supply piping. At no time should there be more

than 1 psig maximum to the unit. Bubble test all

external piping thoroughly for leaks using a soap

and water solution or suitable equivalent. The

gas piping must meet all applicable codes.

Figure 2.6

Gas Supply Regulator and Manual Shut -

Off Valve Location

2.4.1 GAS SUPPLY PRESSURE REGULATOR

A mandatory external, in line, supply gas

regulator (supplied by others) should be

positioned as shown in Figure 2.6. Union

connections should be placed in the proper

locations to allow maintenance of the regulator if

required.

NOTE:

An individual gas pressure regulator must

be installed upstream of each unit. The

regulator must regulate gas pressure to

8.5” W.C. for FM gas train and 8.9” W.C. for

IRI gas trains at 1,000,000 BTU/H for

natural gas and propane units.

The maximum static inlet pressure to the unit

must be no more than 14” water column.

Minimum gas pressure is 8.5” W.C. for FM gas

trains and 8.9” W.C. IRI gas trains when the unit

is firing at maximum input. Gas pressure should

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