Aerco KC Series Operation And Maintenance Manual
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Aerco KC Series Operation And Maintenance Manual

Gas fired water heating system applicable to serial numbers g-02-530 and above natural gas or propane fired, condensing and forced draft hot water heater 1,000,000 btu/hr input
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KC Series Gas Fired Water Heater
Operation and Maintenance Manual
AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-768-7789
Applicable to Serial Numbers G-02-530 and above
KC Series
Gas Fired
Water Heating
System
Condensing and Forced Draft Hot Water Heater
Patent No. 4,852,524
Printed in U.S.A.
Natural Gas or Propane Fired,
1,000,000 BTU/HR Input
REVISED 12/10
GF-111
OMM-xxxx-xx

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Do you have a question about the KC Series and is the answer not in the manual?

Questions and answers

George
March 21, 2025

The solenoid on the vent line between gas valves remain open during operation. What could cause this

0
1 comments:
Mr. Anderson
March 21, 2025

The solenoid on the vent line of an Aerco KC Series could remain open during operation due to the following reasons:

1. SSOV Powered When It Should Not Be – If the SSOV (Safety Shutoff Valve) never closes, it may be powered continuously. To resolve this, close the gas supply and remove power from the unit, then refer the fault to qualified service personnel.

2. Defective Switch or Actuator – If the switch does not show continuity with the gas valve closed, the switch or actuator may need adjustment or replacement.

3. Incorrectly Wired Switch – Ensure that the SSOV Proof of Closure switch is correctly wired.

These issues could cause the vent solenoid to remain open if the SSOV does not properly close or if there is a wiring or switch failure.

This answer is automatically generated

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Summary of Contents for Aerco KC Series

  • Page 1 KC Series Gas Fired Water Heater GF-111 Operation and Maintenance Manual OMM-xxxx-xx AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-768-7789 Applicable to Serial Numbers G-02-530 and above KC Series Gas Fired...
  • Page 2 KC Series Gas Fired Water Heater GF-111 Operation and Maintenance Manual OMM-xxxx_xx AERCO International, Inc. • 159 Paris Ave. • Northvale, New Jersey 07647 • Phone: 201-768-2400 • FAX: 201-768-7789 Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday) (800) 526-0288 AERCO International, Inc.
  • Page 3 CONTENTS GF-111 THE AERCO KC1000 GAS FIRED DOMESTIC WATER HEATER Operating & Maintenance Instructions FOREWARD Section 1 – SAFETY PRECAUTIONS Para. Subject Page Para. Subject Page Warnings & Cautions Prolonged Shutdown Emergency Shutdown Section 2 – INSTALLATION PROCEDURES Para. Subject Page Para.
  • Page 4 CONTENTS Section 5 – SAFETY DEVICE TESTING PROCEDURES Para. Subject Page Para. Subject Page Testing of Safety Devices SSOV Proof of Closure Switch Low Gas Pressure Fault Test 5.10 Purge Switch Open During High Gas Pressure Test Purge Low Water Level Fault Test 5.11 Ignition Switch Open During Water Temperature Fault Test...
  • Page 5 FOREWORD Foreword The AERCO KC 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 allow maximum installation flexibility.

  • Page 7: Safety Precautions

    OUTGOING WATER SHUTOFF AERCO Instruction Manual, the installation of VALVES. CAREFULLY DECREASE units MUST conform with local building codes, ALL TRAPPED PRESSURES TO or, in the absence of local codes, ANSI Z223.1...
  • Page 8 If there is an emergency, turn off the electrical power supply to the AERCO heater and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.
  • Page 9 INSTALLATION SECTION 2 - INSTALLATION 2.1 RECEIVING THE UNIT The freight carrier should be notified immediately if any damage is detected. The following acces- Each KC1000 Heater is shipped as a single sories come standard with each unit and are crated unit.
  • Page 10 Figure 2.3. Flow rates through the unit are by AERCO. Local building codes may require limited to 30 gpm continuous and 40 gpm more clearance and take precedence.
  • Page 11 INSTALLATION 2.3.3 TEST HOSE BIB and union connections are recommended for maintenance. Recirculation flow rates must be A Test Hose Bib connection, upstream of the kept to 8 gpm or less. In a multiple unit shut off valve on the hot water outlet, is required installation, each unit must be tied into the for startup and testing.
  • Page 12 2.4 GAS SUPPLY PIPING All pipe should be de-burred and internally cleared of any scale or iron chips before AERCO Gas Fired Equipment Gas Components installation. No flexible connectors or non- and Supply Design Guide (GF-1030) should be approved gas fittings should be installed. Piping...
  • Page 13 The maximum static inlet pressure to the unit 2.5 ELECTRICAL SUPPLY must not exceed 14” W.C. Minimum gas The AERCO Gas Fired Equipment Electrical pressure is 8.5” W.C. for FM gas trains and 8.9” Power Wiring Guide, (GF-1060), must be W.C.
  • Page 14 NEUTRAL seen in the operating menu. The sensor must be wired to the AUX SENSOR IN and SENSOR COMMON and must be similar to AERCO USE COPPER CONDUCTORS ONLY FOR FIELD WIRING BALCO wire sensor P/N 12449. A resistance chart for this sensor can be found in Appendix C.
  • Page 15 VDC. The relay energizes when any fault condi- of the boiler. The exhaust sensor should be a tion occurs and remains energized until the fault normally open type switch (such as AERCO P/N is cleared and the CLEAR button is depressed. 123463) that closes (trips) at 500°F.
  • Page 16 NOT USED Figure 2.10 I/O Box Wiring FLUE GAS VENT INSTALLATION 2.8 COMBUSTION AIR AERCO Gas Fired Venting and Combustion Air The AERCO Gas-Fired Heater Venting and Guide, GF-1050, must be consulted before any Combustion Air Guide, GF-1050 MUST be...
  • Page 17 Each unit must have a minimum 6" diameter connection made to the optional Inlet Air Adapter # GM-18917 available from AERCO. This Adapter bolts directly on to the air inlet of the unit blower. See installation instructions with Adapter. All inlet air ducts must...
  • Page 19 CONTROL PANEL OPERATING PROCEDURES SECTION 3 - CONTROL PANEL OPERATING PROCEDURES 3.1. INTRODUCTION WARNING: The information in this Section provides a guide DO NOT ATTEMPT TO DRY FIRE THE to the operation of the KC1000 Water Heater HEATER. STARTING THE UNIT WITHOUT using the Control Panel mounted on the front of A FULL WATER LEVEL CAN SERIOUSLY the unit.
  • Page 20 CONTROL PANEL OPERATING PROCEDURES Table 3-1. Operating Controls, Indicators and Displays ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring MANUAL Lights when the unit is being controlled using the front panel keypad.
  • Page 21 CONTROL PANEL OPERATING PROCEDURES Table 3-1. Operating Controls, Indicators and Displays - Continued ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION ▲ (Up) Arrow When in one of the main menu categories (Figure 3-2), pressing this key will select the displayed menu category. If (Cont.) the CHANGE key was pressed and the menu item is flashing, pressing the ▲...
  • Page 22 CONTROL PANEL OPERATING PROCEDURES 4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the NOTE: selected menu will be displayed. following paragraphs provide brief 5. Continue to press the ▲ or ▼ arrow key until descriptions of the options contained in each the desired menu option is displayed.
  • Page 23 CONTROL PANEL OPERATING PROCEDURES NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4). Table 3-2. Operating Menu Available Choices or Limits Menu Item Display Minimum Maximum...
  • Page 24 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Internal Setpt Lo Temp Limit Hi Temp Limit 130°F Unit Type Boiler Boiler Water Heater Unit Size 0.5 MBTU 1.0 MBTU 1.0 MBTU 1.5 MBTU 2.0 MBTU 2.5 MBTU...
  • Page 25 CONTROL PANEL OPERATING PROCEDURES 3.7. TUNING MENU Do not change these menu entries unless The Tuning Menu items in Table 3-5 are Factory specifically requested to do so by Factory- set for each individual unit. Trained personnel. Table 3-5. Tuning Menu Available Choices or Limits Menu Item Display Minimum...
  • Page 26 CONTROL PANEL OPERATING PROCEDURES (a) Blower relay energizes and turns on blower. AIR/FUEL VALVE (b) Air/Fuel Valve rotates to the full-open purge position and closes purge position BLOWER PROOF switch. The dial on the Air/Fuel Valve SWITCH (Figure 3-4) will read 100 to indicate that the valve is full-open (100%).
  • Page 27 CONTROL PANEL OPERATING PROCEDURES DIAL STEPPER 8. With the unit firing properly, it will be (DETAIL “A”) MOTOR controlled by the temperature controller cir- cuitry. The FIRE R ATE will be continuously displayed on the front panel bargraph. 9. Once the demand for heat has been satisfied, the Control Box will turn off the gas valve.
  • Page 29 Section 5 to complete the initial unit start-up. 5. Small and large flat blade screwdrivers. An AERCO Gas Fired Startup Sheet included 6. 7/16" open end wrench and small adjustable with each KC-1000 must be completed for each wrenches.
  • Page 30 INITIAL START-UP 4.2.4 INSTALLING THE DIFFERENTIAL REGULATOR ADJUSTMENT TOOL 1. Remove the cap from the differential pres- sure regulator (see Fig. 4.3). 1/4" NPT PLUG (INSTALL 2. Place the gasket from the regulator cap onto MANOMETER the regulator adjustment tool. HERE) Prior to Installing the tools on the regulator pull up the tool's screwdriver blade.
  • Page 31 Table 1. Repeat adjustment until oxygen is rate, it will be necessary to stop calibration and within the specified range. contact the local AERCO representative in your area. Running the unit on insufficient gas pressure will void the warranty. 10. Once 8.5” W.C. or 8.9” W.C. is set at the...
  • Page 32 INITIAL START-UP 15. If the measured oxygen level is above the Firmly tighten the inlet air shutter locking oxygen range in Table 1, rotate the differen- nuts when finished. tial regulator adjustment tool clockwise 1/4 Table 3 to 1/2 revolution to increase gas flow. Combustion Oxygen Levels for a 100% 16.
  • Page 33 Tables 1, 2 and 3. After an adjustment is made to the air regulator, the cap must be put back on securely to obtain 27. Record all readings on the AERCO start-up an accurate reading. sheet provided with each unit. Proceed to paragraph 4.5.
  • Page 34 INITIAL START-UP 6. Reinstall the cap and gasket back on the 4.6.1 SETTING THE OUTLET WATER regulator. Tighten the cap using a screw- TEMPERATURE SETPOINT driver or wrench. The setpoint temperature of the unit may be 7. Remove all of the manometers and barbed changed by following the procedure below.
  • Page 35 11. If the outlet temperature does not maintain time for the system to stabilize between setpoint after a reasonable amount of time adjustments and adjustment, contact your local AERCO representative. 10. Repeat steps 5 through 9 as needed until the temperature is stabilized at no more than NOTE: 2 to 3 degrees above the setpoint.
  • Page 36 INITIAL START-UP OVER TEMP. SWITCH (SEE DETAIL) FROM SHELL HARNESS TEMPERATURE SWITCH DETAILS OVER-TEMPERATURE SWITCHES Figure 4.6 Over Temperature Limit Switch Location...
  • Page 37 SAFETY DEVICE TESTING SECTION 5 - SAFETY DEVICE TESTING PROCEDURES 5.1 TESTING OF SAFETY DEVICES 6. Open the gas supply to the unit and press the CLEAR button on the Control Box. Periodic testing of all controls and safety devices is required to insure that they are operating as 7.
  • Page 38 SAFETY DEVICE TESTING 10. After the shell is full, press the LOW WATER L EVEL R ESET button to reset the low water cutoff. Press the CLEAR button to reset the FAULT LED and clear the error message. 11. Set the ON/OFF switch to the ON position. HIGH GAS PRESSURE The unit is now ready for operation.
  • Page 39 SAFETY DEVICE TESTING 5.6 INTERLOCK TESTS 5. Once the interlock connection is recon- nected, depress the CLEAR button. The unit is equipped with two interlock circuits unit should start. called the Remote Interlock and Delayed Inter- lock. Terminal connections for these circuits are 5.7 FLAME FAULT TEST located in the I/O Box and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.
  • Page 40 SAFETY DEVICE TESTING 5.8 AIR FLOW FAULT TEST 5.9 SSOV PROOF OF CLOSURE SWITCH 1. Start the unit in manual mode and set the 1. Set the unit’s ON/OFF switch to the OFF fire rate between 25% and 30%. position. Place the unit in manual mode and 2.
  • Page 41 SAFETY DEVICE TESTING 5.10 PURGE SWITCH OPEN DURING 5.11 IGNITION SWITCH OPEN DURING PURGE IGNITION 1. Set the unit’s ON/OFF switch to the OFF 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and position.
  • Page 42 SAFETY DEVICE TESTING 5.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.
  • Page 43 MAINTENANCE SECTION 6 – MAINTENANCE 6.1 MAINTENANCE SCHEDULE The KC1000 Heater requires regular routine maintenance to maintain efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 6-1. Appendix I contains recommended spare parts lists for maintenance of the KC1000 Heater.
  • Page 44 Hard water deposits must be removed to prevent corrosion and leaking. Checking at more frequent intervals may be required to prevent scale buildup. See page 6-13 for information about removing scale deposits using AERCO HydroSkrub scale remover. 6.3 FLAME DETECTOR The flame detector (part no.
  • Page 45 MAINTENANCE Remove the left side panel from the unit. Disconnect the flame detector lead wire and unscrew the flame detector and remove it from the burner. 4. Inspect the detector thoroughly. If eroded, the detector should be replaced. A white coating is an indication of oxidation, which may be removed with an abrasive cloth (such as Scotch Brite).
  • Page 46 MAINTENANCE 3. Shut the water inlet, outlet and recirculation valves to the unit. 4. Open the drain valve on the unit. 5. Slowly open the pressure relief valve to allow air-flow into the unit. 6. Fully drain the unit. 7. Disconnect electrical power from the unit. 8.
  • Page 47 MAINTENANCE Figure 6.4 Compression Fitting Locations 10. Carefully remove the lower tubing assembly taking care not to lose either the cold water or hot water mixing orifice, (See Fig. 6.5). 11. Loosen the compression fitting holding the hydraulic zero and control orifice tube assembly to the pump’s impeller housing, (See Fig.
  • Page 48 MAINTENANCE Figure 6.6 BTU Transmitter Pump Compression Fitting Locations 12. Remove the compression fitting at the top of the impeller housing and remove the impeller housing, (See Fig. 6.6). HOT WATER TUBE COMPRESSION FITTING BALL VALVE Figure 6.7 BTU Transmitter Hot Water Tube Disassembly 13.
  • Page 49 MAINTENANCE Figure 6.8 BTU Transmitter Shell Components IMPELLER HOUSING COVER Figure 6.9 Impeller Housing Disassembly 19. Once the BTU transmitter has been inspected and cleaned, reassemble in the reverse order. NOTE: Do not attempt to adjust the Hydraulic Zero Needle Valve. This is a factory-preset item. Refer to Figure 6.5.
  • Page 50 MAINTENANCE 4. Remove the condensate cup from under the unit and the condensate drainage tubing from the manifold. 5. Disconnect the flame detector and ignition cable wires from the flame detector and ignitor contactor. Remove the flame detector and ignitor as per paragraphs 6.2, and 6.3. 6.
  • Page 51 MAINTENANCE Figure 6.12 Exhaust Sensor Connector Location 13. Disconnect the air/fuel valve wiring harness connector from the control panel. 14. Disconnect wires #24 and #17 from the blower proof switch (See Fig. 6.13). To Frame Harness AIR/FUEL VALVE TO FRAME HARNESS BLOWER PROOF SWITCH...
  • Page 52 MAINTENANCE Figure 6.14 Air/Fuel Valve Inlet Hose Clamp 16. Using an 11/16” wrench, loosen the compression fittings on the feedback tube between the air/fuel valve and the differential pressure regulator. Remove the feedback tube, (See Fig. 6.15). 17. Using two 9/16” wrenches remove the two 3/8-16 hex nuts and bolts securing the air/fuel valve to the differential pressure regulator, (See Fig.
  • Page 53 27. Beginning with the manifold, reinstall all the components in the reverse order that they were removed. Replace the o-ring seals removed with the air/fuel valve. AERCO recommends that NEW o-ring seals be used when reassembling.
  • Page 54 6. Inspect and, if necessary, clean the heat exchanger tubes of scale and all gasket surfaces thoroughly before reassembling the upper head. Refer to heat exchanger cleaning steps on page 6.13. AERCO recommends that NEW gaskets be used when reassembling.

  • Page 55: Cleaning The Heat Exchanger

    Configuration Cleaning the Heat Exchanger Precautions: Please review MSDS, specifications, and our website www.aerco.com for additional information, or call technical service at (800) 526-0288. OTICE Mix the HydroSkrub with an equal volume of water to obtain a 50% concentration (11.5 gallons of each = 23 gallons total).
  • Page 56 MAINTENANCE Figure 6.19 – HydroSkrub Pumping System Set-Up Diagram for KC-1000 Pumping System Set-Up Directions 1. Turn off the water heater and close all isolation valves. 2. Drain at least half of the Heat Exchanger water-side volume. The KC-1000 heat exchanger holds a total volume of 23 gallons.
  • Page 57 MAINTENANCE strength is depleted (two pounds of deposits removed per gallon used) or the equipment is free from calcium and other water formed mineral deposits. 12. Periodically test the solution for effectiveness to determine if more HydroSkrub is needed—refer to “Testing hydroSkrob Effectiveness”...
  • Page 58 MAINTENANCE 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/capacitor assembly P/N 69126) which should be inspected and, if needed, cleaned every six months or replaced (if damaged) to ensure proper operation.
  • Page 59 MAINTENANCE 6.12 HYDRAULIC ZERO NEEDLE VALVE ADJUSTMENT (C-MORE CONTROL BOX) The Hydraulic Zero Needle Valve is factory set in new equipment and should not be changed unless the BTU Transmitter is being replaced. If adjustment is necessary, the following procedure must be followed to assure optimum temperature control.
  • Page 60 When the flame is extinguished, there is a disruption of this electrical circuit, which the controller senses and so initiates shutdown procedures. This current is referred to by AERCO as the flame strength (also known as flame current or flame signal). CAUTION! There is a very low AC current used to energise the flame sensor when power is applied to the system (should be between 90 and 110 volts), so touching the energized sensor may cause a mild electric shock.
  • Page 61 MAINTENANCE Check for the following during the reading: • Measure the voltage in µA between the flame rod and the flame connector. If the flame senser is operating correctly, the reading will be between 3.4 µA and 12.0 µA. If there is a lower voltage reading or no voltage, check to make sure that the wires from the control module to the flame- sensing rod are correctly connected and ensure the the flame rod or the wire connected to it is grounded properly.
  • Page 62 Figure 6.22 – Manifold Gasket Part Numbers and Locations...

  • Page 63: Troubleshooting

    Heater, proceed as follows to isolate and correct the fault: 6. If the fault cannot be corrected using the information provided in the Troubleshooting 1. Observe the fault messages displayed in the Tables, contact your local AERCO Control Box display. Representative.
  • Page 64 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped running due to 1. Check combustion blower for signs of excessive heat or high DURING IGNITION thermal or current overload current drain that may trip thermal or current overload devices. 2.
  • Page 65 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED 1. Delayed Interlock Jumper not 1. Check for a jumper properly installed across the delayed INTERLOCK OPEN installed or removed. interlock terminals in the I/O box. 2.
  • Page 66 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FFWD TEMP 1. Loose or broken wiring. 1. Inspect feed forward (BTU transmitter) sensor for loose or SENSOR FAULT broken wiring. 2. Defective Sensor. 2. Check resistance of sensor to determine if it is within specification.
  • Page 67 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing.
  • Page 68 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge DURING PURGE (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 69 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION LINE VOLTAGE 1. Line and Neutral switched in AC 1. Check hot and neutral in AC Power Box to ensure they are not OUT OF PHASE Power Box.
  • Page 70 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 3. Switch wired incorrectly. 3. If the switch is wired correctly, replace the switch. 4. Defective Power Supply Board or 4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not fuse steady ON, replace Power Supply Board.
  • Page 71 TROUBLESHOOTING KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV FAULT 1. See SSOV SWITCH OPEN DURING PURGE SSOV FAULT 1. SSOV switch closed for 15 seconds 1. Replace SSOV actuator. DURING RUN during run. SSOV RELAY 1.
  • Page 72 TROUBLESHOOTING fuse steady ON, replace Power Supply Board. 6. Defective IGST Board 6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. 7-10...
  • Page 73 APPENDIX A WATER HEATER MENU ITEM DESCRIPTIONS MENU LEVEL & FUNCTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is operating when operating in the Constant Setpoint or Remote Setpoint Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu.
  • Page 74 APPENDIX A WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered. Once the valid password (159) is entered, options in the Setup, Configuration and Tuning Menus can be modified. Language English Only Time...
  • Page 75 APPENDIX A WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set. Default is 130°F. Unit Type Allows selection of Boiler or Water Heater. Unit Size Sets unit size from 0.5 to 3.0 MBTUs. Default is 1.0 MBTU.
  • Page 76 APPENDIX A WATER HEATER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%.
  • Page 77 APPENDIX B STARTUP, STATUS AND FAULT MESSAGES STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DISABLED Displayed if ON/OFF switch is set to OFF. The display also HH:MM pm MM/DD/YY shows the time and date that the unit was disabled. STANDBY Displayed when ON/OFF switch is in the ON position, but there is no demand for heat.
  • Page 78 APPENDIX B FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION HIGH WATER TEMP The High Water Temperature Limit Switch is open. SWITCH OPEN LOW WATER The Water Level Control board is indicating low water level. LEVEL LOW GAS The Low Gas Pressure Limit Switch is open. PRESSURE HIGH GAS The High Gas Pressure Limit Switch is open.
  • Page 79 APPENDIX B FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION RESIDUAL The Flame signal was seen for more than 60 seconds during FLAME standby. HEAT DEMAND The Heat Demand Relays on the Ignition board failed to FAILURE activate when commanded. IGN BOARD A communication fault has occurred between the CPU board COMM FAULT...
  • Page 81 APPENDIX C Temperature Sensor Resistance Chart (Balco)
  • Page 83 APPENDIX D WATER HEATER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password Language English Unit of Temp Fahrenheit Comm Address Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type Boiler Unit Size 1.0 MBTU Heater Mode Constant Setpoint Remote Signal 4 –...
  • Page 84 APPENDIX D WATER HEATER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Tuning Menu Prop Band 8°F Integral Gain 1.60 Derivative Time 0.10 min Min Load Adj 0°F Max Load Adj 0°F FFWD Temp Outlet Feedback Feedback Gain 0.05 Breakpoint At 100% 77°F Breakpoint At 90%...
  • Page 85 APPENDIX E...
  • Page 86 APPENDIX E...

  • Page 87: Parts List

    LOW WATER CUT-OFF 122843 EXHAUST TEMPERATURE SWITCH 123463 123711 TEMPERATURE SWITCH THERMOWELL SHELL WIRING HARNESS 161569 EXHAUST TEMP. SWITCH HARNESS 124334 AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER PARTS LIST PL-A-137 041304 DWN.BY DATE SCALE (SH. 1 OF 2) APPD.
  • Page 88 APPENDIX E SEE DETAIL "A" DETAIL "A" EXPLODED SEE DRAWING PL-A-134 FOR AVAILABLE PARTS AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER PARTS LIST PL-A-137 DWN.BY DATE 041304 SCALE (SH. 2 OF 2) APPD. DATE...
  • Page 89 APPENDIX E...
  • Page 90 GP-122512 ORIFICE DISC GM-161212 HYD. ZERO & CONT. ORIFICE TUBE ASS'Y GP-122552 2"NPT 90° COLD WATER INLET ELBOW 123449 BTU TRANSMITTER SENSOR AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER BTU TRANSMITTER ASSEMBLY (COMPLETE ASS’Y GM-20872) PL-A-134 DWN.BY DATE...
  • Page 91 APPENDIX E AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 KC1000 WATER HEATER BTU TRANSMITTER ASSEMBLY (COMPLETE ASS’Y GM-20872) PL-A-134 041304 DWN.BY DATE SCALE (SH. 2 OF 2) APPD. DATE...
  • Page 92 APPENDIX E...
  • Page 93 APPENDIX F...
  • Page 94 APPENDIX F...
  • Page 95 APPENDIX F...
  • Page 96 APPENDIX F...
  • Page 97 APPENDIX F...
  • Page 99 APPENDIX G...
  • Page 100 APPENDIX G...
  • Page 101 APPENDIX H LOW WATER CUTOFF BOARD P/N 124363 CONNECTOR BOARD PMC BOARD P/N 124366 P/N 124364 DISPLAY BOARD POWER SUPPLY BOARD P/N 124365 P/N 124362 IGNITION/STEPPER V.F.D. DISPLAY BOARD MODULE P/N 124361 P/N 124527 ENCLOSURE P/N 124951 FISH PAPER INSULATOR P/N 124960 FRONT FACE PLATE, KC1000...
  • Page 102 APPENDIX H TO INPUT/OUTPUT (I/O) BOX EXT. SENSOR/COMM INTERLOCK HARNESS HARNESS CONNECTOR CONNECTOR (24 PIN) (16 PIN) SENSOR A/F VALVE SHELL HARNESS GAS TRAIN HARNESS HARNESS HARNESS CONNECTOR CONNECTOR CONNECTOR CONNECTOR (19 PIN) (9 PIN) (7 PIN) (16 PIN) KC1000 CONTROL PANEL REAR VIEW...
  • Page 103 APPENDIX I LOW WATER CUTOFF BOARD P/N 124363 CONNECTOR BOARD PMC BOARD P/N 124366 P/N 124364 DISPLAY BOARD POWER SUPPLY BOARD P/N 124365 P/N 124362 IGNITION/STEPPER V.F.D. DISPLAY BOARD MODULE P/N 124361 P/N 124527 ENCLOSURE P/N 124951 FISH PAPER INSULATOR P/N 124960 FRONT FACE PLATE, KC1000...
  • Page 104 APPENDIX I TO INPUT/OUTPUT (I/O) BOX EXT. SENSOR/COMM INTERLOCK HARNESS HARNESS CONNECTOR CONNECTOR (24 PIN) (16 PIN) SENSOR A/F VALVE SHELL HARNESS GAS TRAIN HARNESS HARNESS HARNESS CONNECTOR CONNECTOR CONNECTOR CONNECTOR (19 PIN) (9 PIN) (7 PIN) (16 PIN) KC1000 CONTROL PANEL REAR VIEW...
  • Page 105 AERCO will r epair, r ebuild or...
  • Page 106 AERCO shall accept no responsibility if such item has been improperly installed, operated, or maintained or i f t he buy er has permitted any unauthorized modification, adjustment, and/or repairs to the item. The use of replacement parts not manufactured or sold by AERCO will void any warranty, express or limited.

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