Document Outline

• GF-127-BMK2.0LN-DF-TOC.pdf
  • FOREWORD A
  • Chapter 1 – SAFETY PRECAUTIONS 1-1
  • Chapter 2 – INSTALLATION 2-1
  • Chapter 3 – CONTROL PANEL OPERATING PROCEDURES 3-1
  • Chapter 4 – INITIAL START-UP 4-1
  • Chapter 5 – MODE OF OPERATION 5-1
  • Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1
  • Chapter 7 – MAINTENANCE REQUIREMENTS 7-1
  • Chapter 8 – TROUBLESHOOTING GUIDE 8-1
  • Chapter 9 - RS232 COMMUNICATION 9-1
  • APPENDICES
  • WARRANTY W-1
• 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 CONDENSATE DRAIN AND PIPING
  • 2.7 GAS SUPPLY PIPING
    • 2.7.1 Gas Supply Specifications.
    • 2.7.2 Manual Gas Shutoff Valve
    • 2.7.3 IRI Gas Train Kit
  • 2.8 AC ELECTRICAL POWER WIRING
    • 2.8.1 Electrical Power Requirements
  • 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING
    • 2.9.1 Constant Setpoint Mode
    • 2.9.2 Indoor/Outdoor Reset Mode
    • 2.9.3 Boiler Management System Mode
    • 2.9.4 Remote Setpoint and Direct Drive Modes
    • 2.9.5 Combination Mode
  • 2.10 I/O BOX CONNECTIONS
    • 2.10.1 OUTDOOR SENSOR IN
    • 2.10.2 AIR SENSOR IN
    • 2.10.3 ANALOG IN
    • 2.10.4 B.M.S. (PWM) IN
    • 2.10.5 SHIELD
    • 2.10.6 mA OUT
    • 2.10.7 0 – 10V OUT
    • 2.10.8 RS-485 COMM
    • 2.10.9 EXHAUST SWITCH IN
    • 2.10.10 INTERLOCKS
      • 2.10.10.1 REMOTE INTERLOCK IN
      • 2.10.10.2 DELAYED INTERLOCK IN
    • 2.10.11 FAULT RELAY
  • 2.11 AUXILIARY RELAY CONTACTS
  • 2.12 FLUE GAS VENT INSTALLATION
  • 2.13 COMBUSTION AIR
    • 2.13.1 Combustion Air From Outside the Building
    • 2.13.2 Combustion Air From Inside the Building
    • 2.13.3 Sealed Combustion
    • 2.13.4 Temporary Combustion Air Filtering During Construction
• CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES
  • 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 START SEQUENCE
  • 3.10 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 UNIT REASSEMBLY
  • 4.6 OVER-TEMPERATURE LIMIT SWITCHES
• 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 BOILER MANAGEMENT SYSTEM (BMS)
    • 5.6.1 BMS External Field Wiring
    • 5.6.2 BMS 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 NATURAL GAS LOW GAS PRESSURE FAULT TEST
  • 6.3 PROPANE LOW GAS PRESSURE FAULT TEST
  • 6.4 NATURAL GAS HIGH GAS PRESSURE FAULT TEST
  • 6.5 PROPANE HIGH GAS PRESSURE FAULT TEST
  • 6.6 LOW WATER LEVEL FAULT TEST
  • 6.7 WATER TEMPERATURE FAULT TEST
  • 6.8 INTERLOCK TESTS
    • 6.8.1 REMOTE INTERLOCK
    • 6.8.2 DELAYED INTERLOCK
  • 6.9 FLAME FAULT TESTS
  • 6.10 AIR FLOW FAULT TESTS
  • 6.11 SSOV PROOF OF CLOSURE SWITCH
  • 6.12 PURGE SWITCH OPEN DURING PURGE
  • 6.13 IGNITION SWITCH OPEN DURING IGNITION
  • 6.14 SAFETY PRESSURE RELIEF VALVE TEST
• CHAPTER 7 MAINTENANCE
  • 7.1 MAINTENANCE SCHEDULE
  • 7.2 IGNITOR-INJECTOR
  • 7.3 FLAME DETECTOR
  • 7.4 COMBUSTION CALIBRATION
  • 7.5 SAFETY DEVICE TESTING
  • 7.6 BURNER ASSEMBLY INSPECTION
  • 7.7 CONDENSATE TRAP
  • 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
  • 7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN
• CHAPTER 8 - TROUBLESHOOTING
  • 8.1 INTRODUCTION
  • 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
  • CHAPTER 9 RS232 COMMUNICATION
    • 9.1 INTRODUCTION
    • 9.2 RS232 COMMUNICATION SETUP
    • 9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
    • 9.4 DATA LOGGING
      • 9.4.1 Fault Log
      • 9.4.2 Operation Time Log
      • 9.4.3 Sensor Log
• CHAPTER 9 - RS232 COMMUNICATION
  • 9.1 INTRODUCTION
  • 9.2 RS232 COMMUNICATION SETUP
  • 9.3 MENU PROCESSING UTILIZING RS232 COMMUNICATION
  • 9.4 DATA LOGGING
• APPENDIX A - VOILER MENU ITEM DESCRIPTIONS
• APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES
• APPENDIX C - TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART
• APPENDIX D - INDOOR/OUTDOOR RESET RATIO CHARTS
• APPENDIX E - BOILER DEFAULT SETTINGS
• APPENDIX F - DIMENSIONALS AND PARTS LISTS
• APPENDIX G - PIPING DIAGRAMS
• APENDIX H - WIRING SCHEMATICS
• APPENDIX I - RECOMMENDED PERIODIC TESTING CHECK LIST
• APPENDIX J - BENCHMARK CONTROL PANEL VIEWS
• APPENDIX K - BENCHMARK 2.0LN DUAL-FUEL SWITCHOVER INSTRUCTIONS
• APPENDIX L - RECOMMENDED SPARE PARTS LIST
• WARRANTY