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Benchmark 6000 Boiler
Installation, Operation & Maintenance Manual
Page 4 of 210
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
OMM-0086_0D
03/20/14
Ph.: 800-526-0288
GF-133
3.2 CONTROL PANEL DESCRIPTION ........................................................................................................................... 37
3.3 CONTROL PANEL MENUS ..................................................................................................................................... 41
3.3.1 Menu Processing Procedure ......................................................................................................................... 41
3.4 OPERATING MENU .............................................................................................................................................. 43
3.5 SETUP MENU ....................................................................................................................................................... 43
3.6 CONFIGURATION MENU ...................................................................................................................................... 44
3.7 TUNING MENU .................................................................................................................................................... 46
3.8 COMBUSTION CAL MENU .................................................................................................................................... 47
3.9 BST (Boiler Sequencing Technology ) Menu ........................................................................................................ 47
3.10 START SEQUENCE .............................................................................................................................................. 50
3.11 START/STOP LEVELS........................................................................................................................................... 55
CHAPTER 4.
INITIAL START-UP.......................................................................................................... 59
4.1 INITIAL START-UP REQUIREMENTS ...................................................................................................................... 59
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ................................................................... 59
4.2.1 Required Tools & Instrumentation ............................................................................................................... 60
4.2.2 Installing Gas Supply Manometer................................................................................................................. 60
4.2.3 Accessing the Analyzer Probe Port ............................................................................................................... 61
4.3 PILOT IGNITION ................................................................................................................................................... 62
4.4 NATURAL GAS COMBUSTION CALIBRATION ....................................................................................................... 62
4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION .............................................................................................. 67
CHAPTER 5.
MODE OF OPERATION .................................................................................................. 69
5.1 INTRODUCTION ................................................................................................................................................... 69
5.2 INDOOR/OUTDOOR RESET MODE ....................................................................................................................... 69
5.2.1 Reset Ratio .................................................................................................................................................... 69
5.2.2 Building Reference Temperature ................................................................................................................. 69
5.2.3 Outdoor Air Temperature Sensor Installation .............................................................................................. 69
5.2.4 Indoor/Outdoor Reset Mode Startup ........................................................................................................... 69
5.3 CONSTANT SETPOINT MODE ............................................................................................................................... 70
5.3.1 Setting the Setpoint ...................................................................................................................................... 70
5.4 REMOTE SETPOINT MODES ................................................................................................................................. 71
5.4.1 Remote Setpoint Field Wiring ...................................................................................................................... 71
5.4.2 Remote Setpoint Startup .............................................................................................................................. 72
5.5 DIRECT DRIVE MODES ......................................................................................................................................... 72
5.5.1 Direct Drive Field Wiring............................................................................................................................... 73
5.5.2 Direct Drive Startup ...................................................................................................................................... 73
5.6 AERCO CONTROL SYSTEM (ACS) .......................................................................................................................... 73
5.6.1 ACS External Field Wiring ............................................................................................................................. 74
5.6.2 ACS Setup and Startup .................................................................................................................................. 74
5.7 COMBINATION CONTROL SYSTEM (CCS) ............................................................................................................. 74
5.7.1 Combination Control System Field Wiring ................................................................................................... 75
5.7.2 Combination Control System Setup and Startup .......................................................................................... 75
CHAPTER 6.
SAFETY DEVICE TESTING ............................................................................................ 77
6.1 TESTING OF SAFETY DEVICES ............................................................................................................................... 77
6.2 LOW GAS PRESSURE FAULT TESTs ....................................................................................................................... 77
6.3 HIGH GAS PRESSURE FAULT TEST ........................................................................................................................ 79
6.4 LOW WATER LEVEL FAULT TEST .......................................................................................................................... 80
6.5 WATER TEMPERATURE FAULT TEST .................................................................................................................... 81
6.6 INTERLOCK TESTS ................................................................................................................................................ 82
6.6.1 Remote Interlock Test .................................................................................................................................. 82
6.6.2 Delayed Interlock Test .................................................................................................................................. 82
6.7 FLAME FAULT TESTs ............................................................................................................................................ 82
6.8 AIR FLOW FAULT TESTS ....................................................................................................................................... 83
6.8.1 Blower Proof Switch Test ............................................................................................................................. 84
6.8.2 Blocked Inlet Switch Test .............................................................................................................................. 85
