beautypg.com
Benchmark 6000 DF
Installation, Operation & Maintenance Manual
OMM-0096_0B
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Page 5 of 219
GF-141
Ph.: 800-526-0288
03/21/2014
6.7 FLAME FAULT TESTs ............................................................................................................................................ 87
6.8 AIR FLOW FAULT TESTS ....................................................................................................................................... 88
6.8.1 Blower Proof Switch Test ............................................................................................................................. 89
6.8.2 Blocked Inlet Switch Test .............................................................................................................................. 90
6.9 SSOV PROOF OF CLOSURE SWITCH ..................................................................................................................... 92
6.10 PURGE SWITCH OPEN DURING PURGE .............................................................................................................. 93
6.11 IGNITION SWITCH OPEN DURING IGNITION ...................................................................................................... 94
6.12 SAFETY PRESSURE RELIEF VALVE TEST............................................................................................................... 95
CHAPTER 7.
MAINTENANCE ............................................................................................................... 97
7.1 MAINTENANCE SCHEDULE .................................................................................................................................. 97
7.2 PILOT BURNER ..................................................................................................................................................... 98
7.3 MAIN FLAME DETECTOR ...................................................................................................................................... 99
7.4 O
2
SENSOR ......................................................................................................................................................... 100
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT .................................................................... 101
7.5.1 Pilot Regulator Pressure Testing................................................................................................................. 101
7.5.2 Pilot Regulator Pressure Calibration ........................................................................................................... 103
7.6 SAFETY DEVICE TESTING .................................................................................................................................... 104
7.7 BURNER ASSEMBLY INSPECTION ....................................................................................................................... 105
7.8 REFRACTORY REMOVAL & REPLACEMENT ........................................................................................................ 108
7.8.1 Rear Refractory Removal & Replacement .................................................................................................. 109
7.8.2 Front Refractory Removal & Replacement ................................................................................................. 112
7.9 CONDENSATE DRAIN TRAP ................................................................................................................................ 114
7.10 AIR FILTER CLEANING & REPLACEMENT .......................................................................................................... 114
7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................................. 116
7.12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................................. 116
CHAPTER 8.
TROUBLESHOOTING GUIDE ...................................................................................... 117
8.1 INTRODUCTION ................................................................................................................................................. 117
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................................................ 130
CHAPTER 9.
RS-232 COMMUNICATION ........................................................................................... 135
9.1 INTRODUCTION ................................................................................................................................................. 135
9.1.1 Aquiring the PuTTY Application .................................................................................................................. 135
9.1.2 Logging on to a Remote Machine Using PuTTY .......................................................................................... 135
9.1.3 Running a Command on a Remote Machine Using PuTTY ......................................................................... 136
9.2 RS-232 COMMUNICATION SETUP ..................................................................................................................... 137
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................................... 137
9.4 DATA LOGGING .................................................................................................................................................. 138
9.4.1 Fault Log ..................................................................................................................................................... 138
9.4.2 Operation Time Log .................................................................................................................................... 139
9.4.3 Sensor Log .................................................................................................................................................. 140
CHAPTER 10.
BOILER SEQUENCING TECHNOLOGY ...................................................................... 141
10.1 INTRODUCTION ............................................................................................................................................... 141
10.2 AERCO BST Quick Start Chart .......................................................................................................................... 142
10.3 BST Implementation Instruction ...................................................................................................................... 143
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor ............................................................ 143
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor......................................................... 144
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ..... 145
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ...................... 147
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ............... 149
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive............. 150
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive ........................ 151
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ..................... 153
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS ................................................................................................. 155
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES ........................................................................................ 161
