Instruction No. GF-112 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA C-MORE CONTROL PANEL OPERATION For Benchmark Series & KC Series Systems Printed in U.S.A.
C-MORE CONTROL PANEL OPERATION TABLE OF CONTENTS PARA. PAGE SECTION 1 – GENERAL INFORMATION 1 1.1 INTRODUCTION 1 1.2 SAFETY PRECAUTIONS AND WARNINGS 1 1.3 FEATURES AND BENEFITS 1 1.4 CONTROL PANEL DESCRIPTION 2 SECTION 2 – CONTROL PANEL MENU STRUCTURE 6 2.1 CONTROL PANEL MENUS 6 2.2 MENU PROCESSING PROCEDURES 6 2.3 OPERATING MENU 7 2.4 SETUP MENU 7 2.5 CONFIGURATION MENU 8 2.6 TUNING MENU 10 2.7 CALIBRATION MENU 11 2.
C-MORE CONTROL PANEL OPERATION TABLE OF CONTENTS - Continued SECTION 6 – CALIBRATION AND DIAGNOSTIC MENUS 6.1 INTRODUCTION 33 6.2 CALIBRATION PROCEDURES 33 6.3 DIAGNOSTICS PROCEDURES 35 SECTION 7 – RS232 COMMUNICATION ii 33 38 7.1 INTRODUCTION 38 7.2 RS232 COMMUNICATION SETUP 38 7.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION 38 7.
C-MORE CONTROL PANEL OPERATION SECTION 1 - GENERAL INFORMATION 1.1 INTRODUCTION The information in this Section provides a guide to the operation of KC and Benchmark Series units using the C-More Control Panel. In addition, it provides information describing the numerous types of external sensors and control devices which can be interfaced to the unit using terminals provided in the Input/Output (I/O) Box utilized with the Control Panel.
C-MORE CONTROL PANEL OPERATION Temp Hi Limit The Temp Hi Limit is a temperature limit feature that will shut down the unit and generate an alarm if the if the outlet temperature exceeds its setting. It is preset at 210°F, however it is adjustable from 40°F to 240°F. 1.3.5 Max Fire Rate This feature allows the user to limit the unit’s firing rate. This feature can be useful if site or equipment limitations require that less BTU’s be input into the system.
C-MORE CONTROL PANEL OPERATION Figure 1-1A. C-More Control Panel For KC Series Units 3 1 2 4 12 8 11 9 10 5 6 7 Figure 1-1B.
C-MORE CONTROL PANEL OPERATION Table 1-1. Operating Controls, Indicators and Displays ITEM NO. 1 CONTROL, INDICATOR OR DISPLAY LED Status Indicators COMM MANUAL REMOTE DEMAND Four Status LEDs indicate the current operating status as follows: Lights when RS232 communication is occurring Lights when the unit is being controlled using the front panel keypad. Lights when the unit is being controlled by an external signal from an Energy Management System Lights when there is a demand for heat.
C-MORE CONTROL PANEL OPERATION Table 1-1. Operating Controls, Indicators and Displays - Continued ITEM NO. 10 (Cont.) CONTROL, INDICATOR OR DISPLAY ▲ (Up) Arrow When in one of the main menu categories (Figure 1-2), pressing this key will select the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, pressing the ▲ arrow key will increment the selected setting.
C-MORE CONTROL PANEL OPERATION SECTION 2 - CONTROL PANEL MENU STRUCTURE 2.1 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of six major menu categories as shown in Figure 2-1. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by two different password levels to prevent unauthorized use.
C-MORE CONTROL PANEL OPERATION 5. Continue pressing the ▲or ▼ arrow key until the desired menu option is displayed. Pressing the ▲ arrow key will display the available menu options in the Top-Down sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence. The menu options will wraparound after the first or last available option. menu is “Read-Only”, it can be viewed at any time without entering a password.
C-MORE CONTROL PANEL OPERATION Table 2-2. Setup Menu Menu Item Display Passsword Level 1 = 159 Level 2 = 6817 Language Time Date Unit of Temp Comm Address Baud Rate Software Available Choices or Limits Minimum Maximum 0 9999 English 12:00 am 11:59 pm 01/01/00 12/31/99 Fahrenheit Celsius 0 127 2400 4800 9600 19.2K Ver 0.0 2.
C-MORE CONTROL PANEL OPERATION Table 2-3.
C-MORE CONTROL PANEL OPERATION 2.6 TUNING MENU The Tuning Menu items in Table 2-4 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel. NOTE The Breakpoint Menu items shown in the following Table with an asterisk are displayed only if Unit Type = Water Heater and the Heatr Bkpt Dsp option in the Calibration Menu (Table 2-5) is Enabled. These Breakpoint values correspond to a 130°F default setpoint Table 2-4.
C-MORE CONTROL PANEL OPERATION 2.7 CALIBRATION MENU The Calibration Menu is used by Factory Trained Service personnel to adjust or reset the parameters listed in Table 2-5. Table 2-5.
C-MORE CONTROL PANEL OPERATION Table 2-6.
C-MORE CONTROL PANEL OPERATION SECTION 3 - CONTROL PANEL MENU DESCRIPTIONS 3.1 MENU ITEM DESCRIPTIONS 3.2 FACTORY DEFAULTS Descriptions of the menu items and options contained in each of the six major menu categories are listed and described in Table 3-1. Factory Default values for each of these items are summarized in Table 3-2. The factory default values for each menu item are summarized in Table 3-2. Table 3-1.
C-MORE CONTROL PANEL OPERATION Table 3-1. Menu Item Descriptions - Continued MENU LEVEL & OPTION SETUP MENU Password Allows Level 1 or 2 password to be entered. Level 1 Entering the Level 1 Password (159) allows options in the Setup, Configuration and Tuning Menus to be modified. Level 2 Entering the Level 2 Password (6817) allows options in the Calibration and Diagnostics Menus to be changed/activated, in addition to all Level 1 Menu options.
C-MORE CONTROL PANEL OPERATION Table 3-1.
C-MORE CONTROL PANEL OPERATION `Table 3-1.
C-MORE CONTROL PANEL OPERATION Table 3-1.
C-MORE CONTROL PANEL OPERATION Table 3-1. Menu Item Descriptions – Continued MENU LEVEL & OPTION DIAGNOSTICS MENU Display Test* Keypad Test* Relay Test* Switch Test* Stepper Test* Sensor Log Int DESCRIPTION Allows testing of the front panel LED indicators, 3character, 7-segment LED display and 20-segment LED Bargraph. Allows testing of the operational status of each front panel key. The VFD will display the name of each key as it is pressed. Allows user to force relay outputs ON or OFF.
C-MORE CONTROL PANEL OPERATION Table 3-2.
C-MORE CONTROL PANEL OPERATION Table 3-2.
C-MORE CONTROL PANEL OPERATION SECTION 4 - CONTROL PANEL DISPLAY MESSAGES 4.1 STARTUP & STATUS MESSAGES. Startup and status messages are displayed on the VFD display on the front panel of the C-More Control Panel. This display is comprised of two lines with 16 characters per line. The startup and status messages which may appear in the display are listed in Tables 4-1. FAULT MESSAGES. Fault messages which may appear in the VFD display are listed in Table 4-2. 4.2 Table 4-1.
C-MORE CONTROL PANEL OPERATION Table 4-2.
C-MORE CONTROL PANEL OPERATION Table 4-2. Fault Messages - Continued FAULT MESSAGE RESIDUAL FLAME HEAT DEMAND FAILURE IGN BOARD COMM FAULT DIRECT DRIVE SIGNAL FAULT REMOTE SETPT SIGNAL FAULT OUTDOOR TEMP SENSOR FAULT OUTLET TEMP SENSOR FAULT FFWD TEMP SENSOR FAULT HIGH WATER TEMPERATURE LINE VOLTAGE OUT OF PHASE STEPPER MOTOR FAILURE MODBUS COMM FAULT FAULT DESCRIPTION The Flame signal was seen for more than 30 seconds during standby.
C-MORE CONTROL PANEL OPERATION SECTION 5 - INPUT/OUTPUT INTERFACES & OPERATING MODES 5.1 INTRODUCTION This Section provides descriptions of the Input/Output (I/O) wiring connections which can be made at the Input/Output (I/O) Box included with the C-More Control Panel. For KC Series units, the I/O Box is located on the left side of the unit. For Benchmark Series units, the I/O Box is located on the front of the unit behind the door.
C-MORE CONTROL PANEL OPERATION only at the source end and must be left floating (not connected) at the unit’s I/O Box. Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F setpoint or a 0% to 100% firing rate. No scaling for these signals is provided. 5.2.4 B.M.S. (PWM) IN NOTE Only BMS Model 168 can utilize pulse width modulation, not the BMS II Model 5R5-384. These terminals are used to connect the AERCO Boiler Management System (BMS Model 168) to the unit.
C-MORE CONTROL PANEL OPERATION Figure 5-1. I/O Box Terminal Strip Connections 5.3 MODES OF OPERATION KC Series Water Heaters are capable of being operated in either the Constant Setpoint Mode or Remote Setpoint Mode. In addition to the Constant and Remote Setpoint Modes, KC and Benchmark Series Boilers can also be operated in the Direct Drive Mode, Boiler Management System (BMS) Mode, Indoor/Outdoor Reset Mode or Combination Mode.
C-MORE CONTROL PANEL OPERATION The current/ voltage signal can be at either of the following levels: and their factory defaults, refer to Tables 3-1 and 3-2. 4 - 20 mA/1 - 5 Vdc 0 - 20 mA/0 - 5 Vdc 5.3.2.1 Remote Setpoint Field Wiring The only wiring necessary for the Remote Setpoint modes is the external control wiring from the source, to the ANALOG IN terminals on the terminal strip inside the I/O Box.
C-MORE CONTROL PANEL OPERATION 5.3.3.1 Reset Ratio Reset ratio is an adjustable number from 0.1 to 9.9. Once adjusted, the supply header temperature will increase by that number for each degree that the outside air temperature decreases. For instance, if a reset ratio of 1.6 is used, for each degree that outside air temperature decreases, the supply header temperature will increase by 1.6 degrees. 5.3.3.2 Building Reference Temperature This is a temperature from 40°F to 230°F.
C-MORE CONTROL PANEL OPERATION When in a Direct Drive mode, the boiler is a slave to the energy management system and does not have a role in temperature control. Direct Drive can be used to drive single as well as multiple boilers. NOTE: To change back to the Direct Drive mode, simply press the AUTO switch. The REMOTE LED will again light and the MANUAL LED will go off. 5.3.
C-MORE CONTROL PANEL OPERATION Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the polarity shown for the B.M.S. (PWM) IN connections. The shield is connected at the BMS to any minus (-) boiler terminal and the boiler end of the shield must be left floating. Each unit’s wiring must conform to the above. 5.3.5.2 Boiler Management System Setup and Startup This mode of operation is factory preset and the AERCO BMS Model 168 controls the firing rate.
C-MORE CONTROL PANEL OPERATION 5.4 START SEQUENCE When the unit is in the Standby mode and all pre-purge safety switches are closed, the READY light above the ON/OFF switch will be lit. When there is a demand for heat, the following events will occur: switch. The dial on the Air/Fuel Valve (Figure 5-3) will read 100 to indicate that the valve is full-open (100%). (c) The FIRE RATE bargraph will show 100%.
C-MORE CONTROL PANEL OPERATION 7. With the unit firing properly, it will be controlled by the temperature controller circuitry. The FIRE RATE will be continuously displayed on the front panel bargraph. 8. Once the demand for heat has been satisfied, the Control Box will turn off the gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will be displayed. STEPPER MOTOR Figure 5-4. Blower Proof Switch 5.
C-MORE CONTROL PANEL OPERATION SECTION 6 - CALIBRATION AND DIAGNOSTIC MENUS 6.1 INTRODUCTION The Level 2 Password (6817) must be entered to access the Calibration and Diagnostic procedures describe in this Section. 6.2 CALIBRATION PROCEDURES The items contained in the Calibration Menu shown in Table 2-5 permit the user to set or adjust a number of functions in the KC and Benchmark Series units.
C-MORE CONTROL PANEL OPERATION 1. Press the ▲ or ▼ arrow key until Analog In Adj is displayed along with the current adjustment percentage 2. If the desired percentage is not displayed, press the CHANGE key. Analog In Adj will begin to flash. 3. Press the ▲ or ▼ arrow key to increment or decrement the display until the desired adjustment percentage is displayed. 4. Press ENTER to store the selection. 5. Pres BACK to exit the adjustment procedure. 6.2.4 Flow In Adjustment.
C-MORE CONTROL PANEL OPERATION 4. Press BACK to exit the Water Temp Reset function. 6.2.11 Gas Press Reset The Gas Pressure Reset function can be set to Automatic or Manual to indicate whether the unit can be restarted or must wait for manual acknowledgement following a high or low gas pressure fault and fault correction. The default setting for this function is Manual. Regardless which setting is used, the High or Low Gas Pressure fault message will be latched. The default for this function is Manual.
C-MORE CONTROL PANEL OPERATION Keypad Test The Keypad Test checks the status of the eight keypad keys on the front panel. The test is initiated as follows: 1. Press the ▲ or ▼ arrow key until Keypad Test Off is displayed. 2. Press the CHANGE key. Keypad Test will begin to flash. 3. Press each of the keys in the following sequence and verify that the name of each key appears in the panel display: (a) AUTO/MAN (Manual is displayed).
C-MORE CONTROL PANEL OPERATION Stepper Test The Stepper Test allows the Air/Fuel Valve Stepper Motor to be rotated between virtually any position between 0% (fully closed) and 100% (fully open). 1. Press the ▲ or ▼ arrow key until Stepper Test 0% is displayed. 2. Press the CHANGE key. Stepper Test will begin to flash. 3. Press and hold the ▲ arrow key to increment the Stepper Motor position.
C-MORE CONTROL PANEL OPERATION SECTION 7 - RS232 COMMUNICATION 7.1 INTRODUCTION The RS232 port on the front panel can be interfaced to a laptop computer or other suitable terminal using a RS232 adapter cable. RS232 communication can be accomplished using any “Dumb Terminal” emulation, such as “Hyper Terminal” which is included with Microsoft Windows.
C-MORE CONTROL PANEL OPERATION 9. To redisplay the menu and view the option which was just changed in step 5, enter D and press . 10. To display the Fault (F) Log, Sensor (S) Log or Time (T) Line Log, press F, S or T followed by . Refer to paragraph 7.4 for descriptions and samples of these data logs. 11. To log off and terminate the RS232 communication link, press L followed by . 7.
C-MORE CONTROL PANEL OPERATION Table 7-1. Sample Fault Log Display No. 0 1 2 Fault Message Direct Drive Signal Fault Low Gas Pressure Loss of Power Cycle 609 366 0 Date 1/10/02 7/04/01 1/01/01 Time 8:42am 5:29pm 11:50am Table 7-2.
APPENDIX A APPENDIX A C-MORE CONTROL PANEL VIEWS A-1
APPENDIX A CONTROL PANEL EXPLODED VIEW – KC SERIES SYSTEMS A-2
APPENDIX A CONTROL PANEL REAR VIEW – KC SERIES SYSTEMS A-3
APPENDIX A CONTROL PANEL EXPLODED VIEW – BENCHMARK SERIES SYSTEMS A-4
P1 P2 P3 P4 P5 P6 APPENDIX A CONTROL PANEL REAR VIEW – BENCHMARK SERIES SYSTEMS + A-5
APPENDIX B APPENDIX B TROUBLESHOOTING GUIDE B-1
APPENDIX B APPENDIX B- TROUBLESHOOTING GUIDE 7.5 B-1. INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark Series Boiler, KC1000 Boiler or KC1000 Water Heater. The troubleshooting procedures contained herein are presented in tabular form in Table B-1 and B-2. Table B-1 pertains to Benchmark and KC1000 Boilers and Table B-2 pertains to KC1000 Water Heaters.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blower stopped running due to thermal or current overload 2. Blocked Blower inlet or inlet ductwork 1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. 2.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1. Delayed Interlock Jumper not installed or removed. 2. Device proving switch hooked to interlocks is not closed 1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box. 2. If there are 2 external wires on these terminals, check to see if an end switch for a device such as a pump, louver, etc.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 7. Carbon or other debris on Burner 7. Remove the burner and inspect for any carbon or debris. Clean and reinstall FLAME LOSS DURING RUN 1. Worn Flame Detector or cracked ceramic. 1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary. 2. Defective Differential Regulator. 2.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION HIGH WATER TEMP SWITCH OPEN PROBABLE CAUSES 1. Faulty Water temperature switch. 2. Incorrect PID settings. 3. Faulty shell temperature sensor. 4. Unit in Manual mode 5. Unit setpoint is greater than Over Temperature Switch setpoint. 6. Boiler Management System PID or other settings not correctly setup. 7. No interlock to boiler or BMS to disable boiler(s) in event that system pumps have failed. 8.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION (continued) PROBABLE CAUSES 2. Defective or shorted switch 3. Switch wired incorrectly 4. Defective Power Supply Board or fuse 5. Defective IGST Board IGN SWTCH OPEN DURING IGNITION 1. Air/Fuel Valve not rotating to ignition position. 2. Defective ignition switch 3. Defective Power Supply Board or fuse 4. Defective IGST Board INTERLOCK OPEN LINE VOLTAGE OUT OF PHASE B-7 1.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION LOW GAS PRESSURE PROBABLE CAUSES 1. Incorrect supply gas pressure. 2. Defective or incorrectly sized Gas Supply Regulator. 3. Defective Low Pressure Gas Switch LOW WATER LEVEL 1. Insufficient water level in system 2. Defective water level circuitry. 3. Defective water level probe. MODBUS COMM FAULT PRG SWTCH CLOSED DURING IGNITION 1.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION PRG SWTCH OPEN DURING PURGE PROBABLE CAUSES 1. Defective purge switch. 2. No voltage present at switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board OUTDOOR TEMP SENSOR FAULT 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. REMOTE SETPT SIGNAL FAULT RESIDUAL FLAME CORRECTIVE ACTION 1.
APPENDIX B TABLE B-1. BENCHMARK & KC1000 BOILER TROUBLESHOOTING TABLE – Continued FAULT INDICATION (continued) SSOV FAULT DURING PURGE PROBABLE CAUSES 2. Defective Flame Detector CORRECTIVE ACTION 2. Replace Flame Detector. See SSOV SWITCH OPEN SSOV FAULT DURING RUN 1. SSOV switch closed for 15 seconds during run. 1. Replace or adjust microswitch in SSOV actuator. If fault persists, replace actuator. SSOV RELAY FAILURE 1. SSOV relay failed on board. 1. Press CLEAR button and restart unit.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blower stopped running due to thermal or current overload 2. Blocked Blower inlet or inlet ductwork 1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. 2. Inspect the inlet to the combustion blower including any duct work leading up to the combustion blower for signs of blockage. 3.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION DELAYED INTERLOCK OPEN DIRECT DRIVE SIGNAL FAULT FLAME LOSS DURING IGN PROBABLE CAUSES 1. Delayed Interlock Jumper not installed or removed. 2. Device proving switch hooked to interlocks is not closed 1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box. 2.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION FFWD TEMP SENSOR FAULT PROBABLE CAUSES 1. Loose or broken wiring. 2. Defective Sensor. 3. Incorrect Sensor. FLAME LOSS DURING RUN 1. Worn Flame Detector or cracked ceramic. 2. Defective Differential Regulator. 3. Poor combustion calibration. 4. Debris on burner. 5. Blocked condensate drain. HEAT DEMAND FAILURE HIGH EXHAUST TEMPERATURE 1. Press CLEAR button and restart the unit.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION (continued) HIGH WATER TEMP SWITCH OPEN PROBABLE CAUSES CORRECTIVE ACTION 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. Replace the switch if it does not show continuity. 1. Scaled BTU Transmitter. 2. Faulty Water Temperature Switch. 1.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION IGN SWTCH CLOSED DURING PURGE PROBABLE CAUSES 1. Air/Fuel Valve not rotating 2. Defective or shorted switch 3. Switch wired incorrectly 4. Defective Power Supply Board or fuse 5. Defective IGST Board IGN SWTCH OPEN DURING IGNITION 1. Air/Fuel Valve not rotating to ignition position. 2. Defective ignition switch 3. Defective Power Supply Board or fuse 4. Defective IGST Board INTERLOCK OPEN 1.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE PROBABLE CAUSES 1. Line and Neutral switched in AC Power Box. 2. Incorrect power supply transformer wiring. 1. Check hot and neutral in AC Power Box to ensure they are not reversed 2. Check transformer wiring, in AC Power Box, against the power box transformer wiring diagram to ensure it is wired correctly 1. Incorrect supply gas pressure. 1.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION (continued) PRG SWTCH OPEN DURING PURGE PROBABLE CAUSES 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board 3. If the switch is wired correctly, replace the switch. 4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board. 5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.
APPENDIX B TABLE B-2. KC1000 WATER HEATER TROUBLESHOOTING TABLE – Continued FAULT INDICATION SSOV FAULT DURING PURGE PROBABLE CAUSES CORRECTIVE ACTION 1. See SSOV SWITCH OPEN SSOV FAULT DURING RUN 1. SSOV switch closed for 15 seconds during run. 1. Replace or adjust microswitch in SSOV actuator. If fault persists, replace actuator. SSOV RELAY FAILURE 1. SSOV relay failed on board. 1. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board. 1.
APPENDIX C APPENDIX C INDOOR/OUTDOOR RESET RATIO CHARTS C-1
APPENDIX C INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX C Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX C Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX C Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX D APPENDIX D TEMPERATURE SENSOR RESISTANCE CHART D-1
APPENDIX D TEMPERATURE SENSOR RESISTANCE CHART (BALCO) TEMPERATURE SENSOR AERCO PART NO. 123449 R = RESISTANCE (OHMS) T = TEMPERATURE (°F) R=.00161T^2+1.961T+854.841 TEMP (°F) RES. (OHMS) -40 779.0 -30 797.5 -20 816.3 -10 835.4 0 854.8 10 874.6 20 894.7 30 915.1 40 935.9 50 956.9 60 978.3 70 1000.0 80 1022.0 90 1044.4 100 1067.0 110 1090.0 120 1113.3 130 1137.0 140 1160.9 150 1185.2 160 1209.5 170 1234.7 180 1260.0 190 1285.6 200 1311.4 210 1337.7 220 1364.2 230 1391.0 240 1418.2 250 1445.
APPENDIX E APPENDIX E WIRING DIAGRAMS E-1
APPENDIX E E-2
ECO 2 3 4 6 5 REVISIONS SEE SHEET ONE 237 7 236 8 238 240 241 242 243 244 245 9 10 11 12 13 14 15 239 THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL, INC. THEY ARE ISSUED IN STRICT CONFIDENCE AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER. REV J1 1 235 8 234 13 233 DATE 247 16 1 246 2 BY 4 251 5 252 6 253 8 7 254 CK'D J3 B ORIGINAL DWG.
APPENDIX E E-4
J1 1 231 1 2 232 2 3 233 3 4 5 6 237 7 7 236 6 235 5 234 4 8 238 8 240 241 242 243 244 245 246 1 247 3 4 251 5 252 6 253 7 254 8 INPUT/OUTPUT BOX 2 250 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 239 9 10 11 12 24-PIN CONNECTOR J3 226 LS3 LS4 J2 1 2 4 220 LS2 3 221 LS1 5 219 6 8 7 216 7 6 8 215 5 9 213 3 212 2 211 1 E-5 SHEET 68014 2 OF 2 DWG. NO.: A REV INTERNATIONAL INC. 159 PARIS AVE, NORTHVALE, N.J.
APPENDIX E E-6
APPENDIX E E-7
E-8 154 155 136 154 138 AUTO RESET 192 209 135 170 169 168 DATE REVISIONS THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL, INC. THEY ARE ISSUED IN STRICT CONFIDENCE AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER.
APPENDIX E E-9
APPENDIX E E-10
APPENDIX E E-11
E-12 BLOWER PROOF SW. 142 FLAME ROD WATER LEVEL PROBE 351 321 IGNITOR IGNITION POSITION SWITCH PURGE POSITION SWITCH GND 352 WHT YEL BLK BLU GRN 142 RED LOW GAS PRESS. SW. 205 HIGH GAS PRESS. SW. 360 FROM 6 PIN CONNECTOR 359 358 FROM I/O BOX } SSOV PROOF OF CLOSURE SW.
E-13 OUTDOOR AIR SENSOR IN SENSOR COMMON IN AUX SENSOR IN CO SENSOR IN FLOW SENSOR IN + + - + OXYGEN SENSOR IN SENSOR EXCIT. (12 VDC) + ANALOG IN + BMS (PWM) IN - SHIELD 358 TO VFD GND - AUX RELAY A B A B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 3 1 2 3 4 7 6 N.O. C N.C. N.O. 15 16 + ANALOG OUT 359 TO VFD + RS-485 IN IN LONWORKS OUT NOT USED C N.C.
E-14 136 154 193 194 195 204 202 203 206 209 208 210 6 PIN CONNECTOR201 190 191 192 190 195 2 1 SOLENOID 206 L1 L3 3O 60 HZ 460VAC L2 GND 209 321 320 350 208 207 260 261 316 263 317 262 260 FUSE 201 142 53 5K 3 A C B 10K 1 200 203 315 314 152 153 153 330 MCR T1 T1 POWER BOX 366 319 261 L1 A1 RELAY WITH 205 OVERLOAD 120 VAC A2 95/NC 263 L3 T3 T3 262 L2 T2 T2 204 205 202 200 210 24 VAC XFMR FUSE GND BLOCK AIR/FUEL VALVE STEPPING MOTOR 2 172 170 168 166 164
E-15 OUTDOOR AIR SENSOR IN SENSOR COMMON IN AUX SENSOR IN CO SENSOR IN FLOW SENSOR IN + + - + OXYGEN SENSOR IN SENSOR EXCIT. (12 VDC) ANALOG IN + + BMS (PWM) IN - SHIELD 358 TO VFD GND - OUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 + ANALOG OUT 359 TO VFD + RS-485 IN IN LONWORKS NOT USED A B A B 1 2 1 2 3 1 2 3 4 7 6 N.O. AUX RELAY 5 4 C N.C. 3 2 N.O. FAULT RELAY C N.C.
APPENDIX F APPENDIX F C-MORE CONTROL PANEL DIP SWITCH SETTINGS F-1
APPENDIX F APPENDIX F - C-MORE CONTROL PANEL DIP SWITCHES F-1. INTRODUCTION The PMC (Primary Micro-Controller) Board in the C-More Control Panel Assembly contains two 4-position DIP switches (S1, S2) as shown in Figure F-1. The functions of these DIP switches are as follows: • 4-Position DIP switch S1 (Detail “A”) is used to select either current or voltage as the Remote Signal Source when operating in the Remote Setpoint or Direct Drive Mode. The factory default for this switch is current (CURR).
APPENDIX F RIBBON CABLE CONNECTOR (J1) SEE DETAIL “B” SEE DETAIL “A” CBS1 R49 R55 C40 R50 C38 RX TX BIAS2 TERM BIAS1 RS485 R52 U7 C39 S2 U8 R1 R46 C36 R81 C37 R53 U6 C9 R9 J3 U2 R44 R45 C7 R4 R62 U3 R51 C13 R10 C12 R47 R48 R3 R6 B1 Y2 HB U21 C5 R75 C6 JP2 C1 C2 R76 R77 C43 R65 C16 C19 C29 C31 C28 C55 R70 C23 C22 R24 R25 R26 R28 C18 C26 R27 U4 C34 R18 C20 R15 C17 C44 R16 U18 C45 C33 R42 R43 R41 R40 R39 C35 C32 C27 R14 R32 R17 C63 R61 R59 C42 R60 U5 R
APPENDIX F Figure F-2.
APPENDIX F RIBBON CABLE RS485 DIP SW. CURR/VOLT DIP SW.
