Document Outline

• FOREWORD
• CHAPTER 1. SAFETY PRECAUTIONS
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2. INSTALLATION
  • 2.1 INTRODUCTION
  • 2.2 RECEIVING THE UNIT
  • 2.3 UNPACKING
  • 2.4 SITE PREPARATION
    • 2.4.1 Installation Clearances
    • 2.4.2 Setting the Unit
  • 2.5 SUPPLY AND RETURN PIPING
  • 2.6 PRESSURE RELIEF VALVE INSTALLATION
  • 2.7 CONDENSATE DRAIN & PIPING
  • 2.8 GAS SUPPLY PIPING
    • 2.8.1 Gas Supply Specifications
    • 2.8.2 Manual Gas Shutoff Valve
    • 2.8.3 External Gas Supply Regulator
      • 2.8.3.1 Massachusetts Installations Only
      • 2.8.3.2 All Installations (Except Massachusetts)
  • 2.9 AC ELECTRICAL POWER WIRING
    • 2.9.1 Electrical Power Requirements
  • 2.10 FIELD CONTROL WIRING
    • 2.10.1 OUTDOOR AIR IN Terminals
    • 2.10.2 COMBUSTION AIR Terminal
    • 2.10.3 O2 SENSOR Terminals
    • 2.10.4 SPARK SIGNAL Terminals
    • 2.10.5 ANALOG IN Terminals
    • 2.10.6 B.M.S. (PWM) IN Terminals
    • 2.10.7 SHIELD Terminals
    • 2.10.8 ANALOG OUT Terminals
    • 2.10.9 RS-485 Comm Terminals
    • 2.10.10 RS-232 Comm Terminals
    • 2.10.11 VFD/Blower (0-10 & AGND)
    • 2.10.12 Interlocks
      • 2.10.12.1 REMOTE INTL’K Terminals
      • 2.10.12.2 DELAYED INTL’K Terminals (OUT & IN)
        • 2.10.12.2.1 Remote Interlock In (OUT & IN)
        • 2.10.12.2.2 Delayed Interlock In (OUT & IN)
    • 2.10.13 FAULT RELAY (NC, COM, & NO) Terminals
    • 2.10.14 AUX RELAY CONTACTS (NC, COM, & NO) Terminals
  • 2.11 FLUE GAS VENT INSTALLATION
  • 2.12 COMBUSTION AIR
    • 2.12.1 Combustion From Outside the Building
    • 2.12.2 Combustion Air from Inside the Building
  • 2.13 DUCTED COMBUSTION AIR
  • 2.14 BENCHMARK PUMP RELAY OPTION
  • 2.15 SEQUENCING ISOLATION VALVE INSTALLATION
• CHAPTER 3. OPERATION
  • 3.1 INTRODUCTION
  • 3.2 CONTROL PANEL DESCRIPTION
  • 3.3 CONTROL PANEL MENUS
    • 3.3.1 Menu Processing Procedure
  • 3.4 OPERATING MENU
  • 3.5 SETUP MENU
  • 3.6 CONFIGURATION MENU
  • 3.7 TUNING MENU
  • 3.8 COMBUSTION CAL MENU
  • 3.9 BST (Boiler Sequencing Technology ) Menu
  • 3.10 START SEQUENCE
  • 3.11 START/STOP LEVELS
• CHAPTER 4. INITIAL START-UP
  • 4.1 INITIAL START-UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
    • 4.2.1 Required Tools & Instrumentation
    • 4.2.2 Installing Gas Supply Manometer
    • 4.2.3 Accessing the Analyzer Probe Port
  • 4.3 NATURAL GAS COMBUSTION CALIBRATION
  • 4.4 PROPANE COMBUSTION CALIBRATION
  • 4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION
  • 4.6 OVER-TEMPERATURE LIMIT SWITCHES
    • 4.6.1 Digital Alarm Switch Checks and Adjustments
• CHAPTER 5. MODE OF OPERATION
  • 5.1 INTRODUCTION
  • 5.2 INDOOR/OUTDOOR RESET MODE
    • 5.2.1 Reset Ratio
    • 5.2.2 Building Reference Temperature
    • 5.2.3 Outdoor Air Temperature Sensor Installation
    • 5.2.4 Indoor/Outdoor Startup
  • 5.3 CONSTANT SETPOINT MODE
    • 5.3.1 Setting the Setpoint
  • 5.4 REMOTE SETPOINT MODES
    • 5.4.1 Remote Setpoint Field Wiring
    • 5.4.2 Remote Setpoint Startup
  • 5.5 DIRECT DRIVE MODES
    • 5.5.1 Direct Drive Field Wiring
    • 5.5.2 Direct Drive Startup
  • 5.6 AERCO CONTROL SYSTEM (ACS)
    • 5.6.1 ACS External Field Wiring
    • 5.6.2 ACS Setup and Startup
  • 5.7 COMBINATION CONTROL SYSTEM (CCS)
    • 5.7.1 Combination Control System Field Wiring
    • 5.7.2 Combination Control System Setup and Startup
• CHAPTER 6. SAFETY DEVICE TESTING
  • 6.1 TESTING OF SAFETY DEVICES
  • 6.2 LOW GAS PRESSURE FAULT TEST
  • 6.3 HIGH GAS PRESSURE TEST
  • 6.4 LOW WATER LEVEL FAULT TEST
  • 6.5 WATER TEMPERATURE FAULT TEST
  • 6.6 INTERLOCK TESTS
    • 6.6.1 Remote Interlock Test
    • 6.6.2 Delayed Interlock Test
  • 6.7 FLAME FAULT TESTs
  • 6.8 AIR FLOW FAULT TESTS
    • 6.8.1 Blower Proof Switch Test
    • 6.8.2 Blocked Inlet Switch Test
  • 6.9 SSOV PROOF OF CLOSURE SWITCH
  • 6.10 PURGE SWITCH OPEN DURING PURGE
  • 6.11 IGNITION SWITCH OPEN DURING IGNITION
  • 6.12 SAFETY PRESSURE RELIEF VALVE TEST
• CHAPTER 7. MAINTENANCE
  • 7.1 MAINTENANCE SCHEDULE
  • 7.2 IGNITER-INJECTOR REPLACEMENT
  • 7.3 FLAME DETECTOR REPLACEMENT
  • 7.4 O2 SENSOR REPLACEMENT
  • 7.5 COMBUSTION CALIBRATION
  • 7.6 SAFETY DEVICE TESTING
  • 7.7 BURNER ASSEMBLY INSPECTION
  • 7.8 CONDENSATE DRAIN TRAP MAINTENANCE
  • 7.9 AIR FILTER CLEANING & REPLACEMENT
  • 7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
  • 7.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
• CHAPTER 8. TROUBLESHOOTING GUIDE
  • 8.1 INTRODUCTION
  • 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
• CHAPTER 9. RS-232 COMMUNICATION
  • 9.1 INTRODUCTION
    • 9.1.1 Aquiring the PuTTY Application
    • 9.1.2 Logging on to a Remote Machine Using PuTTY
    • 9.1.3 Running a Command on a Remote Machine Using PuTTY
  • 9.2 RS-232 COMMUNICATION SETUP
  • 9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION
  • 9.4 DATA LOGGING
    • 9.4.1 Fault Log
    • 9.4.2 Operation Time Log
    • 9.4.3 Sensor Log
• CHAPTER 10. Boiler Sequencing Technology
  • 10.1 INTRODUCTION
  • 10.2 AERCO BST Quick Start Chart
  • 10.3 BST Implementation Instruction
    • 10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor
    • 10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor
    • 10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor
    • 10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor
    • 10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive
    • 10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive
    • 10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive
    • 10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive
  • APPENDIX A: BOILER MENU ITEM DESCRIPTIONS
  • APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES
  • APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART
  • APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS
  • APPENDIX E – BOILER DEFAULT SETTINGS
  • APPENDIX F – DIMENSIONAL DRAWINGS
  • APPENDIX G – PART LIST DRAWINGS
  • APPENDIX H – PIPING DRAWINGS
  • APPENDIX I – C-MORE WIRING DIAGRAMS
  • APPENDIX J – RECOMMENDED PERIODIC TESTING
  • APPENDIX K – C-MORE CONTROL PANEL VIEWS
  • APPENDIX L: RECOMMENDED SPARES
  • APPENDIX M – ULTRA-LOW NOx CALIBRATION
  • LIMITED WARRANTY
  • LIMITED WARRANTY:
  • BENCHMARK 750 - 6000 GAS-FIRED BOILERS