Document Outline

• CHAPTER 1: SAFETY PRECAUTIONS
  • 1.1 WARNINGS & CAUTIONS
  • 1.2 EMERGENCY SHUTDOWN
  • 1.3 PROLONGED SHUTDOWN
• CHAPTER 2: INSTALLATION
• CHAPTER 2
  • 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
    • 2.6.1 Exhaust Manifold Condensate Drain
  • 2.7 GAS SUPPLY PIPING
    • 2.7.1 Gas Supply Specifications.
    • 2.7.2 Manual Gas Shutoff Valve
    • 2.7.3 External Gas Supply Regulator
    • 2.7.4 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 (1)
    • 2.10.2 AIR TEMP. SENSOR (2)
    • 2.10.3 ANALOG IN (3)
    • 2.10.4 B.M.S. (PWM) IN (4)
    • 2.10.5 SHIELD (5)
    • 2.10.6 mA OUT (6)
    • 2.10.7 RS-485 COMM (7)
    • 2.10.8 TxD, RxD (8)
    • 2.10.9 VFD/BLOWER (9)
    • 2.10.10 EXHAUST SWITCH IN (11)
    • 2.10.11 INTERLOCKS (10, 12)
      • 2.10.11.1 REMOTE INTERLOCK IN (10)
      • 2.10.11.2 DELAYED INTERLOCK IN (12)
    • 2.10.12 FAULT RELAY (13)
  • 2.11 AUXILIARY RELAY CONTACTS (14)
  • 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
  • 2.14 BENCHMARK PUMP RELAY OPTION
• CHAPTER 3: CONTROL PANEL OPERATION
• CHAPTER 3
  • 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
  • CHAPTER 1
  • CHAPTER 2
  • 2.1
  • 2.2
  • 2.3
  • 2.4
  • 2.5
  • 2.6
  • 2.7
  • 2.8
  • 2.9 START SEQUENCE
  • 3.9
  • 3.10 START/STOP LEVELS
• CHAPTER 4: INITIAL START-UP
• CHAPTER 4
  • 4.1 INITIAL START-UP REQUIREMENTS
  • 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
    • CHAPTER 4
    • 4.1
    • 4.2
    • 4.2.1 Required Tools & Instrumentation
    • 4.2.2 Installing Gas Supply Manometer
    • 4.2.3 Accessing the Vent Probe Port
  • 4.3 RSI REGULATOR SAFE TEST
  • 4.4 NATURAL GAS COMBUSTION CALIBRATION
  • 4.5 UNIT REASSEMBLY
  • 4.6 OVER-TEMPERATURE LIMIT SWITCHES
• CHAPTER 5: MODE OF OPERATION
• CHAPTER 5
  • 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
• CHAPTER 6
  • 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
    • 6.6.2 DELAYED INTERLOCK
  • 6.7 FLAME FAULT TESTS
  • 6.8 AIR FLOW FAULT TESTS
  • 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
• CHAPTER 7
  • 7.1 MAINTENANCE SCHEDULE
  • 7.2 IGNITER-INJECTOR
  • 7.3 FLAME DETECTOR
  • 7.4 COMBUSTION CALIBRATION & RSI REGULATOR ADJUSTMENT
    • 7.4.1 RSI Regulator Pressure
      • 7.4.1.1 RSI Regulator Pressure Test
      • 7.4.1.2 RSI Regulator Calibration
  • 7.5 SAFETY DEVICE TESTING
  • 7.6 BURNER ASSEMBLY INSPECTION
  • 7.7 CONDENSATE DRAIN 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 GUIDE
  • 8.1 INTRODUCTION
  • 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
    • Figure 8-1: High Gas Pressure Switch & Snubber Locations
    • Figure 8-2: Staged Ignition Solenoid Location
    • Figure 8-3: Damping Orifice Location
• CHAPTER 9: RS232 COMMUNICATION
  • CHAPTER 8
  • CHAPTER 9
  • 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
• APPENDIX A: MENU ITEM DESCRIPTIONS
• APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES
• APPENDIX C: SENSOR TEMPERATURE RESISTANCE
• APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS
• APPENDIX E: BOILER DEFAULT SETTINGS
• APPENDIX F: PART AND DIMENSIONAL DRAWINGS
• APPENDIX G: PIPING DRAWINGS
• APPENDIX H: WIRING SCHEMATICS
• APPENDIX I: RECOMMENDED PERIODIC TESTING CHECK LIST
• APPENDIX J: BENCHMARK CONTROL PANEL FEATURES
• APPENDIX K: RECOMMENDED SPARE PARTS LISTS
• STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler