Document Outline

• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_01_CVR_10-04-12
  • Telephone Support
  • Direct to AERCO Technical Support
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_02_TOC_4-29-10
  • 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
  • WARRANTIES W-1
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_03_Fwd_5-1-07
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_04_CH1-7-7-11
  • CHAPTER 1 SAFETY PRECAUTIONS
    • 1.1 WARNINGS & CAUTIONS
    • 1.2 EMERGENCY SHUTDOWN
    • 1.3 PROLONGED SHUTDOWN
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_05_CH2_7-14-11-BB
  • 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
      • 2.4.3 Removal of Support Rod
      • 2.4.4 Removal of Strap and Packing Material From Heat Exchanger
    • 2.5 SUPPLY AND RETURN PIPING
    • 2.6 Condensate drains
      • 2.6.1 Exhaust Manifold Condensate Drain
      • 2.6.2 Connecting Manifold Condensate Drain
    • 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
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_06_Ch3_4-18-11-BB
  • 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
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_07_CH4_3-21-11-BB
  • 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 Vent Probe Port
    • 4.3 NATURAL GAS COMBUSTION CALIBRATION
    • 4.4 propane COMBUSTION CALIBRATION
    • 4.5 UNIT REASSEMBLY
    • 4.6 OVER-TEMPERATURE LIMIT SWITCHes
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_08_CH5_6-1-10-BB
  • 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
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_09_CH6_3-22-11-BB
  • CHAPTER 6 safety device testing
    • 6.1 TESTING OF SAFETY DEVICES
    • 6.2 NATURAL GAS LOW GAS PRESSURE SWITCH TEST
    • 6.3 propane LOW GAS PRESSURE SWITCH TEST
    • 6.4 natural gas HIGH GAS PRESSURE switch TEST
    • 6.5 propane HIGH GAS PRESSURE switch 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
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_10_CH7_4-23-10-BB
  • 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 DRAIN TRAPs
      • 7.7.1 Connecting Manifold Condensate Trap
      • 7.7.2 Exhaust Manifold Condensate Trap
    • 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_11_Ch8_6-1-10-BB
  • Chapter 8- TROUBLESHOOTING GUIDE
    • 8.1 INTRODUCTION
  • 1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 475 o F and the exhaust sensor shows continuity replace the sensor.
  • 2. If exhaust temperature is greater than 500 o F, check combustion calibration. Calibrate or repair as necessary.
  • 2. If gas supply pressure downstream of SSOV cannot be lowered, to 1.5” W.C. (see para. 4.3, step 10), the SSOV Supply Regulator may be defective
    • 2. If there are two external wires on these terminals check any Energy Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning).
    • 3. Verify that the proving switch for any device hooked to the interlock circuit is closing and that the device is operational.
  • TABLE 8-1. BOILER TROUBLESHOOTING – Continued
  • TABLE 8-1. BOILER TROUBLESHOOTING – Continued
  • TABLE 8-1. BOILER TROUBLESHOOTING – Continued
  • TABLE 8-1. BOILER TROUBLESHOOTING – Continued
    • 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES
  • TABLE 8-2. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED
    • Figure 8-1
    • High Pressure Gas Switch & Snubber Locations
    • Figure 8-2
    • Staged Ignition Solenoid Location
    • Figure 8-3
    • Damping Orifice Location
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_12_CH9_6-2-10
  • 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
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_13_APP-A_3-21-11
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_14_APP-B_10-1-09-bb
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_15_APP-C_3-19-10
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_16_APP-D_8-14-06
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_17_App-E_3-21-11
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_18_App-F_7-15-11-BB
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_19_APP-G
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_20_APP-H_1-27-11-BB
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_21_App-I_6-7-10
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_22_App-J_10-18-07
  • BENCHMARK CONTROL PANEL EXPLODED VIEW
  • BENCHMARK CONTROL PANEL REAR VIEW
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_23_APP-K_10-04-12
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_24_APP-L_4-27-10
• OMM-0039_0C_GF-117_BMK3.0-DF_G-11-0708 and UP_25_WARR_2-4-08