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Benchmark 2000
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Benchmark 1500
-
2000
Boilers
APPENDIX I
–
PIPIN
G D
RA
W
INGS
OMM
-
0097_0E
AERCO
Internatio
nal, Inc
.
•
100 Oritani Dr.
•
Bla
uvelt, NY 10913
Page
175
of
182
GF
-
142
Ph.: 800
-526-0288
10/01/201
5
Drawing Num
ber: SD
-A-
991 r
ev A
174
176
Table of Contents
Main Page
Default Chapter
3
Table of Contents
3
Foreword
7
Chapter 1. Safety Precautions
11
Warnings & Cautions
11
Emergency Shutdown
12
Prolonged Shutdown
12
Chapter 2. Installation
15
Introduction
15
Receiving the Unit
15
Unpacking
15
Site Preparation
16
Installation Clearances
16
Setting the Unit
17
Supply and Return Piping
19
Pressure Relief Valve Installation
20
Condensate Drain & Piping
21
Condensate Trap Installation
21
Gas Supply Piping
23
Gas Supply Specifications
23
Manual Gas Shutoff Valve
23
External Gas Supply Regulator
24
Ac Electrical Power Wiring
25
Electrical Power Requirements
26
Field Control Wiring
27
Outdoor Air in (OUT) & Air Sensor Common (COM)
28
AIR TEMP SENSOR Terminals
29
SENSOR Terminals (O2+ & O2-)
29
SPARK SIGNAL Terminals
29
ANALOG in Terminals
29
VALVE FEEDBACK Terminals
29
SHIELD Terminals (SHLD & SHLD)
30
ANALOG out Terminals
30
RS485 Comm (+, GND, & -)
30
RS232 Comm (Txd & Rxd)
30
Vfd/Blower (0-10 & AGND)
30
Interlocks
30
Fault Relay (NC, COM, & NO)
31
Auxiliary Relay Contacts (NC, COM, & NO)
31
Flue Gas Vent Installation
31
Combustion Air
32
Ducted Combustion Air
32
Sequencing Isolation Valve Installation
33
Chapter 3. Operation
35
Introduction
35
Control Panel Description
35
Control Panel Menus
39
Menu Processing Procedure
39
Operating Menu
41
Setup Menu
42
Configuration Menu
42
Tuning Menu
45
Combustion Cal Menu
45
Bst (Boiler Sequencing Technology) Menu
46
Start Sequence
48
Start/Stop Levels
52
Chapter 4. Initial Start-Up
53
Initial Start-Up Requirements
53
Tools and Instrumentation for Combustion Calibration
53
Required Tools & Instrumentation
54
Installing Gas Supply Manometer
54
Accessing the Analyzer Probe Port
55
Natural Gas Combustion Calibration
56
BMK 1500 Natural Gas Combustion Calibration
56
BMK 2000 Natural Gas Combustion Calibration
60
Reassembly
62
Over-Temperature Limit Switches
63
Digital Alarm Switch Checks and Adjustments
63
Chapter 5. Mode of Operation
65
Introduction
65
Indoor/Outdoor Reset Mode
65
Reset Ratio
65
Building Reference Temperature
65
Outdoor Air Temperature Sensor Installation
65
Indoor/Outdoor Startup
66
Constant Setpoint Mode
66
Setting the Setpoint
67
Remote Setpoint Modes
67
Remote Setpoint Field Wiring
68
Remote Setpoint Startup
68
Direct Drive Modes
68
Direct Drive Field Wiring
69
Direct Drive Startup
69
Aerco Control System (Acs)
70
ACS External Field Wiring
70
ACS Setup and Startup
70
Combination Control System (Ccs)
71
Combination Control System Field Wiring
72
Combination Control System Setup and Startup
72
Chapter 6. Safety Device Testing
73
Testing of Safety Devices
73
Low Gas Pressure Test
74
High Gas Pressure Test
75
Low Water Level Fault Test
76
Water Temperature Fault Test
76
Interlock Tests
78
Remote Interlock Test
78
Delayed Interlock Test
78
Flame Fault Tests
79
Air Flow Fault Tests
81
Blower Proof Switch Test
81
Blocked Inlet Switch Test
81
Ssov Proof of Closure Switch
83
Purge Switch Open During Purge
84
Ignition Switch Open During Ignition
85
Safety Pressure Relief Valve Test
86
Chapter 7. Maintenance
87
Maintenance Schedule
87
Igniter-Injector
88
Flame Detector
90
O 2 Sensor
91
Safety Device Testing
91
Burner Assembly Inspection
92
Condensate Drain Trap
95
Air Filter Cleaning & Replacement
96
Water Cutoff (Lwco) Capacitor Integrity Test
97
Low Water Cutoff (LWCO) - Capacitor Electrical Short Test
97
Low Water Cutoff (LWCO) - Standard C-More Test
99
Shutting the Boiler down for an Extended Period of Time
99
Placing the Boiler Back in Service after a Prolonged Shutdown
100
Spark Monitor (Ac Current Transducer)
100
Chapter 8. Troubleshooting Guide
101
Introduction
101
Additional Faults Without Specific Fault Messages
113
Chapter 9. Boiler Sequencing Technology
115
Introduction
115
Installation Notes
116
Aerco Bst Quick Start Chart
117
Bst Implementation Instruction
118
Option 1 - Constant Setpoint with DIRECT Wired Header Sensor
118
Option 2 - Constant Setpoint with MODBUS Wired Header Sensor
119
Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor and DIRECT WIRED Outdoor Sensor
120
Option 4 - Outdoor Reset with MODBUS Header Sensor and MODBUS Outdoor Sensor
122
Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor and 4-20Ma Setpoint Drive
124
Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor and MODBUS Setpoint Drive
126
Option 7 - Remote Setpoint with MODBUS Header Sensor and 4-20Ma Setpoint Drive
127
Option 8 - Remote Setpoint with MODBUS Header Sensor and MODBUS Setpoint Drive
129
Appendix A: Boiler Menu Item Descriptions
131
Table A-2: Setup Menu Item Descriptions
132
Tuning Menu
136
Appendix B: Startup, Status & Display Messages
139
Appendix C: Sensor Resistance/Voltage Chart
143
Appendix D: Recommended Periodic Testing
145
Appendix E: Indoor/Outdoor Reset Ratio Charts
147
Appendix F: Dimensional and Clearance Drawings
151
Appendix G: Part List Drawings
153
Appendix H: Wiring Diagrams
165
Appendix I: Piping Drawings
173
Appendix J: C-More Control Panel Views
179
Appendix K: Recommended Spares
181
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