Benchmark 6000 Boiler
Installation, Operation & Maintenance Manual
OMM-0086_0D
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 5 of 210
GF-133
Ph.: 800-526-0288
03/20/14
6.9 SSOV PROOF OF CLOSURE SWITCH ..................................................................................................................... 87
6.10 PURGE SWITCH OPEN DURING PURGE .............................................................................................................. 88
6.11 IGNITION SWITCH OPEN DURING IGNITION ...................................................................................................... 89
6.12 SAFETY PRESSURE RELIEF VALVE TEST............................................................................................................... 90
CHAPTER 7.
MAINTENANCE ............................................................................................................... 91
7.1 MAINTENANCE SCHEDULE .................................................................................................................................. 91
7.2 PILOT BURNER ..................................................................................................................................................... 92
7.3 MAIN FLAME DETECTOR ...................................................................................................................................... 93
7.4 O
2
SENSOR ........................................................................................................................................................... 94
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT ...................................................................... 95
7.5.1 Pilot Regulator Pressure Testing................................................................................................................... 95
7.5.2 Pilot Regulator Pressure Calibration ............................................................................................................. 97
7.6 SAFETY DEVICE TESTING ...................................................................................................................................... 98
7.7 BURNER ASSEMBLY INSPECTION ......................................................................................................................... 99
7.8 REFRACTORY REMOVAL & REPLACEMENT ........................................................................................................ 102
7.8.1 Rear Refractory Removal & Replacement .................................................................................................. 102
7.8.2 Front Refractory Removal & Replacement ................................................................................................. 106
7.9 CONDENSATE DRAIN TRAP ................................................................................................................................ 108
7.10 AIR FILTER CLEANING & REPLACEMENT .......................................................................................................... 109
7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................................. 110
7.12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................................. 110
CHAPTER 8.
TROUBLESHOOTING GUIDE ...................................................................................... 111
8.1 INTRODUCTION ................................................................................................................................................. 111
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................................................ 124
CHAPTER 9.
RS-232 COMMUNICATION ........................................................................................... 129
9.1 INTRODUCTION ................................................................................................................................................. 129
9.1.1 Aquiring the PuTTY Application .................................................................................................................. 129
9.1.2 Logging on to a Remote Machine Using PuTTY .......................................................................................... 129
9.1.3 Running a Command on a Remote Machine Using PuTTY ......................................................................... 130
9.2 RS-232 COMMUNICATION SETUP ..................................................................................................................... 131
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................................... 131
9.4 DATA LOGGING .................................................................................................................................................. 132
9.4.1 Fault Log ..................................................................................................................................................... 133
9.4.2 Operation Time Log .................................................................................................................................... 133
9.4.3 Sensor Log .................................................................................................................................................. 134
CHAPTER 10.
BOILER SEQUENCING TECHNOLOGY ...................................................................... 135
10.1 INTRODUCTION ............................................................................................................................................... 135
10.2 AERCO BST Quick Start Chart .......................................................................................................................... 136
10.3 BST Implementation Instruction ...................................................................................................................... 137
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor ............................................................ 137
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor......................................................... 138
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ..... 139
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ...................... 141
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ............... 143
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive............. 144
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive ........................ 145
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ..................... 147
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS ................................................................................................. 149
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES ........................................................................................ 157
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART ............................................................................................ 161
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ...................................................................................... 163
APPENDIX E – BOILER DEFAULT SETTINGS .............................................................................................................. 167
APPENDIX F – CLEARANCE DRAWINGS .................................................................................................................... 169
