AERCO BMK 1.5 LN Dual Fuel Feb 2013 User Manual

User manual, Benchmark 1.5ln dual-fuel, Low nox boiler

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PR2: 05/09/12 Page

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Benchmark 1.5LN Dual-Fuel Low NOx Boiler

Operation and Maintenance Manual

OMM-0043_0C

GF-121

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288

USER MANUAL

Modulating, Condensing,

Forced Draft, Hot Water Boiler

1,500,000 BTU/H Input

Revised: 05/09/2012

Benchmark 1.5LN Dual-Fuel Low NOx Boiler

Installation, Operation, and Maintenance

Benchmark

1.5LN Dual-Fuel

Low NOx Boiler

Table of contents

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
- 2.8 AC ELECTRICAL POWER WIRING
  - 2.8.1 Electrical Power Requirements
- 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING
- 2.10 I/O BOX CONNECTIONS
- 2.11 FLUE GAS VENT INSTALLATION
- 2.12 COMBUSTION AIR
- 2.13 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
- 4.3 RSI REGULATOR SAFE TEST
- 4.4 NATURAL GAS COMBUSTION CALIBRATION
- 4.5 PROPANE COMBUSTION CALIBRATION
- 4.6 UNIT REASSEMBLY
- 4.7 OVER-TEMPERATURE LIMIT SWITCHES
CHAPTER 5: MODE OF OPERATION
CHAPTER 5
- 5.1 INTRODUCTION
- 5.2 INDOOR/OUTDOOR RESET MODE
- 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, BMS II, or ACS)
  - 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 NATURAL GAS LOW GAS PRESSURE FAULT TEST
- 6.3 PROPANE GAS 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
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
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
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: BMK 1.5 DUAL-FUEL SWITCHOVER INSTRUCTIONS
- K.1 Switchover From Natural Gas to Propane
- K.2 Switchover From Propane to Natural Gas
APPENDIX L: RECOMMENDED SPARE PARTS LISTS
STANDARD WARRANTY: Benchmark Gas-Fired Hydronic Boiler