AERCO BMK 2.0 LN Natural Gas 2008 User Manual

Installation, operation & maintenance instructions, Gf-123

Printed in U.S.A.

REVISED

9/21/09

Instruction

No.

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

GF-123

Installation, Operation

& Maintenance Instructions

Benchmark
2.0 Low NOx
Natural Gas Fired
Boiler System

Condensing, Modulating

Forced Draft, Hot Water Boiler

2,000,000 BTU/H Input

Table of contents

Document Outline

Foreword
TABLE OF CONTENTS
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
- 2.5 SUPPLY AND RETURN PIPING
- 2.6 CONDENSATE DRAIN AND PIPING
- 2.7 GAS SUPPLY PIPING
- 2.8 AC ELECTRICAL POWER WIRING
- 2.9 MODES OF OPERATION
- 2.10 I/O BOX CONNECTIONS
- 2.11 AUXILIARY RELAY CONTACTS
- 2.12 FLUE GAS VENT INSTALLATION
- 2.13 COMBUSTION AIR
CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES
- 3.1 INTRODUCTION
- 3.2 CONTROL PANEL DESCRIPTION
- 3.3 CONTROL PANEL MENUS
- 3.4 OPERATING MENU
- 3.5 SETUP MENU
- 3.6 CONFIGURATION MENU
- 3.7 TUNING MENU
- 3.8 START SEQUENCE
- 3.9 START/STOP LEVELS
CHAPTER 4 INITIAL START-UP
- 4.1 INITIAL START-UP REQUIREMENTS
- 4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION
- 4.3 NATURAL GAS COMBUSTION CALIBRATION
- 4.4 UNIT REASSEMBLY
- 4.5 OVER-TEMPERATURE LIMIT SWITCHES
CHAPTER 5 MODE OF OPERATION
- 5.1 INTRODUCTION
- 5.2 INDOOR/OUTDOOR RESET MODE
- 5.3 CONSTANT SETPOINT MODE
- 5.4 REMOTE SETPOINT MODES
- 5.5 DIRECT DRIVE MODES
- 5.6 BOILER MANAGEMENT SYSTEM (BMS)
- 5.7 COMBINATION CONTROL SYSTEM (CCS)
CHAPTER 6 SAFETY DEVICE TESTING
- 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 HIGH WATER TEMPERATURE FAULT TEST
- 6.6 INTERLOCK TESTS
- 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
CHAPTER 7 MAINTENANCE
- 7.1 MAINTENANCE SCHEDULE
- 7.2 SPARK IGNITER
- 7.3 FLAME DETECTOR
- 7.4 COMBUSTION CALIBRATION
- 7.5 SAFETY DEVICE TESTING
- 7.6 BURNER ASSEMBLY
- 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
APPENDIX A- BOILER MENU ITEM DESCRIPTIONS
APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES
APPENDIX C - TEMPERATURE SENSOR RESISTANCE CHART (BALCO)
APPENDIX D - INDOOR/OUTDOOR RESET RATIO CHARTS
APPENDIX E - BOILER DEFAULT SETTINGS
APPENDIX F - DIMENSIONAL AND PART DRAWINGS
APPENDIX G - PIPING DRAWINGS
APENDIX H - WIRING SCHEMATICS
APPENDIX I - RECOMMENDED PERIODIC TESTING CHECK LIST
APPENDIX J - BENCHMARK CONTROL PANEL VIEWS
WARRANTY