AERCO SmartPlate - Manual (Page 3)

SmartPlate Installation, Operation & Maintenance Manual
OMM-0069_0E AERCO International, Inc.  100 Oritani Dr.  Blauvelt, NY 10913 Page 3 of 138
SP-100 Phone: 800-526-0288 PRI: 11/26/2013
TABLE OF CONTENTS
CHAPTER 1. GENERAL INFORMATION .................................................................................. 5
1.1 INTRODUCTION ................................................................................................................................... 5
1.2 ELECTRONIC CONTROL SYSTEM/SMARTPLATE (ECS/SP) .................................................................... 6
1.2.1 Control Box Assembly ................................................................................................................... 7
1.2.2 Feed‐Forward Temperature Sensors ............................................................................................ 7
1.2.3 Outlet Temperature Sensors ........................................................................................................ 7
1.2.4 Boiler Water Inlet/Outlet Temperature Sensors .......................................................................... 7
1.3 SMARTPLATE PIPING ASSEMBLIES ...................................................................................................... 8
1.4 ELECTRONIC CONTROL VALVE, MXG‐461 ............................................................................................ 8
CHAPTER 2. INSTALLATION .................................................................................................. 11
2.1 INTRODUCTION ................................................................................................................................. 11
2.2 RECEIVING AND UNPACKING SMARTPLATE ...................................................................................... 11
2.3 SITE SELECTION AND PREPARATION ................................................................................................. 11
2.3.1 Installation Clearances ................................................................................................................ 11
2.3.2 Setting the Unit ........................................................................................................................... 12
2.3.3 Repositioning ECS/SP Control Box .............................................................................................. 14
2.4 HEATING FLUID AND DOMESTIC HOT WATER (DHW) PIPING........................................................... 15
2.5 SMARTPLATE ELECTRICAL WIRING CONNECTIONS ........................................................................... 16
CHAPTER 3. FUNCTIONAL DESCRIPTION ........................................................................... 21
3.1 INTRODUCTION ................................................................................................................................. 21
3.2 MECHANICAL OVERVIEW .................................................................................................................. 21
3.3 ELECTRONIC CONTROL OVERVIEW ................................................................................................... 22
3.4 OVER‐TEMPERATURE CONTROL AND SAFETY FEATURES ................................................................. 22
CHAPTER 4. ADJUSTMENT ................................................................................................... 25
4.1 INTRODUCTION ................................................................................................................................. 25
4.2 SMARTPLATE 3‐WAY CONTROL VALVE, MXG‐461 ADJUSTMENT ..................................................... 25
4.2.1 Control Valve Calibration and Status Indications ....................................................................... 25
4.2.2 Manual Control of 3‐Way Valve – Removable Handwheel to Hamper Tampering .................... 28
4.2.3 Setpoint Temperature Adjustment ............................................................................................ 29
4.2.4 Over‐Temperature Alarm Limit Adjustment ............................................................................... 32
CHAPTER 5. OPERATION ....................................................................................................... 35
5.1 INTRODUCTION ................................................................................................................................. 35
5.2 PRE‐OPERATIONAL CHECKS & PROCEDURES .................................................................................... 35
5.3 INITIAL START‐UP .............................................................................................................................. 36
5.4 SHUTTING DOWN THE SYSTEM ......................................................................................................... 37
CHAPTER 6. SCHEDULED MAINTENANCE .......................................................................... 39
6.1 INTRODUCTION ................................................................................................................................. 39
6.2 BOILER WATER DIFFERENTIAL PRESSURE GAUGE CHECK ................................................................. 39
6.3 PLATE PACK LEAKAGE CHECKS (DOUBLE‐WALL MODELS ONLY) ....................................................... 40
6.4 OVER‐TEMP SWITCH CHECK .............................................................................................................. 41
6.5 STRAINER INSPECTION AND CLEANING ............................................................................................ 42
6.6 CONTROL VALVE OPERATIONAL CHECK ............................................................................................ 42
6.7 TEMPERATURE SENSOR CHECKS ....................................................................................................... 42
6.8 RECIRCULATION PUMP CHECK .......................................................................................................... 42
6.9 PERIODIC CLEANING OF HEAT EXCHANGER ...................................................................................... 43