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Aerco KC Series User Manual

Aerco KC Series
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REVISED JULY 8, 2011
GF-111LN
OMM-0029_0B
KC Series Low NOx Gas-Fired Water Heater
USER MANUAL
Applicable to Serial Numbers G-11-0694 and Above
KC Series
Low NOx
Gas Fired
Water Heating
System
Natural Gas or Propane Fired,
Condensing and Forced Draft Hot Water Heater
1,000,000 BTU/HR Input
Patent No. 4,852,524

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Aerco KC Series Specifications

General IconGeneral
ModelKC Series
Turn Down RatioUp to 20:1
Fuel TypeNatural Gas or Propane
TypeCondensing
EfficiencyUp to 96%
FootprintCompact
Flow RateVaries by model
Power Supply120V, 60Hz

Summary

Safety Precautions

Warnings & Cautions

General safety warnings and cautions that must be observed.

Emergency Shutdown

Procedure for shutting down the unit in case of emergency.

Prolonged Shutdown

Recommendations for units that have been shut down for extended periods.

Massachusetts Installations

Specific installation requirements for Massachusetts, including codes and licensing.

Installation Procedures

Receiving and Unpacking the Unit

Procedures for inspecting and unpacking the unit upon receipt.

Installation Guidelines

General installation guidelines, including clearances, setting, and piping.

Gas Supply Piping

Guidelines for designing and installing the gas supply piping.

Electrical Supply and Control Wiring

Requirements for electrical connections and field control wiring.

Flue Gas Vent and Combustion Air

Guidelines for flue gas venting and providing combustion air.

Control Panel Operating Procedures

Control Panel Description

Description of controls, indicators, and displays on the control panel.

Control Panel Menus

Overview of the menu structure for unit setup and configuration.

Menu Processing and Navigation

Procedures for navigating and processing menu options.

Operating, Setup, and Configuration Menus

Details of operating, setup, and configuration menu parameters.

Start Sequence and Levels

Step-by-step start sequence and start/stop level settings.

Initial Start-Up

Start-Up Requirements and Tools

Essential requirements and tools needed for initial start-up.

Natural Gas and Propane Combustion Calibration

Procedures for calibrating combustion for both fuel types.

Temperature Control Calibration

Procedures for calibrating the unit's temperature control settings.

Safety Device Testing Procedures

Overview of Safety Device Testing

Importance of periodic testing for controls and safety devices.

Gas Pressure and Water Level Tests

Procedures for testing gas pressure and water level safety shutdowns.

Interlock, Flame, and Airflow Tests

Testing interlock, flame, and airflow safety shutdown functions.

SSOV and Ignition Switch Tests

Testing SSOV, purge, and ignition switch safety operations.

Maintenance

Maintenance Schedule

Routine maintenance procedures and recommended time intervals.

Ignitor and Flame Detector Maintenance

Procedures for inspecting and replacing the spark ignitor and flame detector.

Heat Exchanger and Condensate Drain Maintenance

Steps for inspecting and cleaning the heat exchanger and condensate drain.

Hydraulic Zero Needle Valve and Flame Strength

Adjustment of hydraulic zero valve and measurement of flame strength.

Troubleshooting

Troubleshooting Introduction

Guide for isolating and correcting faults in the water heater.

Airflow Faults

Troubleshooting common airflow faults during ignition, purge, and run.

Gas Pressure Faults

Troubleshooting high and low gas pressure fault indications.

Water Level and Temperature Faults

Troubleshooting low water level, high water temp, and related switch faults.

Ignition and Valve Faults

Troubleshooting ignition switch, SSOV, and stepper motor faults.

RS232 Communication

RS232 Setup and Menu Processing

Setting up RS232 communication and processing menus via terminal.

Data Logging

Explanation of fault, operation time, and sensor logs accessible via RS232.

Water Heater Menu Item Descriptions

Operating, Setup, and Configuration Menus

Descriptions of parameters in Operating, Setup, and Configuration menus.

Tuning Menu Descriptions

Descriptions of tuning parameters for performance adjustment.

Startup, Status, and Fault Messages

Startup and Status Messages

Table detailing various startup and status messages displayed by the unit.

Fault Messages

Table listing fault messages and their descriptions for troubleshooting.

KC1000 Low NOx Dual-Fuel Switch-Over Instructions

Regulator Spring Replacement

Step-by-step instructions for switching between natural gas and propane.

Recommended Spare Parts Lists

Spare Parts Lists

Lists of spare parts recommended for emergency, maintenance, and optional use.

Standard Warranty

Warranty Coverage Details

Warranty periods and conditions for vessel, heat exchanger, and other components.

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