Aerco BMK 750, BMK 2000, BMK 750P,BMK 1000P,BMK 1500P,BMK 2000P,BMK 2500P,BMK 3000P, BMK 1500DF,BMK 2000DF,BMK 2500DF,BMK 3000DF, BMK 2500 Installation And Startup Manual

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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
GF-200
Natural Gas:
BMK 2000P
APPLIES TO MODELS:
750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers
SEE ALSO:
USER MANUAL (1 of 2)
INSTALLATION and STARTUP GUIDE
Natural Gas, Propane Gas, or Dual Fuel Fired Modulating, Condensing Boilers
AND MAINTENANCE GUIDE (GF-201)
• BMK 750
• BMK 1000
• BMK 1500
• BMK 2000
• BMK 2500
• BMK 3000
Propane:
BMK 750P
BMK 1000P
BMK 1500P
OPERATION, SERVICE,
Dual-Fuel (NG/P):
• BMK 1500DF
• BMK 2000DF
BMK 2500DF
BMK 3000DF
BMK 2500P
BMK 3000P
Latest Update: 03/15/2017
OMM-0115_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 128 GF-200 Ph.: 800-526-0288 03/15/2017
Applies to Seria l Numbers:
G-17-0001 and above.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONTENTS
TABLE OF CONTENTS
FOREWORD ...................................................................................................... 5
SECTION 1: SAFETY PRECAUTIONS ................................................................... 9
1.1 WARNINGS & CAUTIONS ................................................................................................... 9
1.2 EMERGENCY SHUTDOWN ...............................................................................................10
1.3 PROLONGED SHUTDOWN ...............................................................................................10
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ...............................................11
SECTION 2: INSTALLATION ............................................................................. 13
2.1 INTRODUCTION.................................................................................................................13
2.2 RECEIVING THE UNIT .......................................................................................................13
2.3 UNPACKING .......................................................................................................................13
2.4 SITE PREPARATION .........................................................................................................14
2.4.1 Installation Clearances ................................................................................................................... 14
2.4.2 Setting the Unit .............................................................................................................................. 17
2.5 LIFTING PROVISIONS .......................................................................................................19
2.5.1 BMK 750 – 1000 lifting Provisions .................................................................................................. 19
2.5.2 BMK 1500 – 2000 Lifting Provisions ............................................................................................... 20
2.6 SUPPLY AND RETURN PIPING .........................................................................................21
2.6.1 BMK 750 – 1000 Supply and Return Piping .................................................................................... 21
2.6.2 BMK 1500 – 3000 Supply and Return Piping .................................................................................. 21
2.6.3 Dual Inlet Return Piping ................................................................................................................. 22
2.7 PRESSURE RELIEF VALVE INSTALLATION ....................................................................23
2.8 CONDENSATE DRAIN AND PI PING ..................................................................................24
2.9 GAS SUPPLY PIPING ........................................................................................................26
2.9.1 Gas Supply Specifications ............................................................................................................... 27
2.9.2 Manual Gas Shutoff Valve .............................................................................................................. 27
2.9.3 External Gas Supply Regulator ....................................................................................................... 28
2.10 AC ELECTRICAL POWER WIRING ..................................................................................30
2.10.1 Electrical Power Requirements .................................................................................................... 30
2.10.2 Power Box Locations .................................................................................................................... 32
2.10.3 Electrical Power Box Internal Components .................................................................................. 33
2.11 FIELD CONTROL WIRING ...............................................................................................35
2.11.1 Outdoor Air & Air Sensor Common .............................................................................................. 36
2.11.2 AIR TEMP SENSOR ........................................................................................................................ 37
2.11.3 O
2.11.4 SPARK SIGNAL (+ & –) ................................................................................................................... 37
2.11.5 ANALOG IN ................................................................................................................................... 37
2.11.6 VALVE FEEDBACK .......................................................................................................................... 37
2.11.7 SHIELD (SHLD & SHLD) .................................................................................................................. 38
2.11.8 ANALOG OUT ................................................................................................................................ 38
2.11.9 RS485 Comm (+, GND, & -) ........................................................................................................... 38
2.11.10 RS232 Comm (TxD & RxD) .......................................................................................................... 38
2.11.11 VFD/Blower (0-10 & AGND) ....................................................................................................... 38
2.11.12 Interlocks .................................................................................................................................... 39
SENSOR (+ & –) ........................................................................................................................ 37
2
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CONTENTS
2.11.13 Fault Relay (NC, COM, & NO) ..................................................................................................... 39
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) ................................................................................ 39
2.12 FLUE GAS VENT INSTALLATION ....................................................................................40
2.12.1 MASSACHUSETTS INSTALLATIONS ............................................................................................... 40
2.13 COMBUSTION AIR ...........................................................................................................41
2.13.1 DUCTED COMBUSTION AIR .......................................................................................................... 41
2.14 BENCHMARK PUMP RELAY ...........................................................................................42
2.15 SEQUEN CING ISOLATION VALVE INSTALLATION ........................................................43
SECTION 3: START SEQUENCE ........................................................................ 45
3.1 INTRODUCTION.................................................................................................................45
3.2 START SEQUENCE ...........................................................................................................45
3.3 START/STOP LEVELS .......................................................................................................51
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT .....................................................52
3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input ............................................................. 52
3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input ..................................................................... 53
3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input ..................................................................... 54
3.4.4 BMK 2500 (Nat. Gas) Air/Fuel Valve Position and Energy Input .................................................... 55
3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input ..................................................................... 56
SECTION 4: INITIAL START-UP ........................................................................ 57
4.1 INITIAL S TA RT-UP REQUIREMENTS ................................................................................57
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION ........................................57
4.2.1 Required Tools & Instrumentation ................................................................................................. 57
4.2.2 Installing Gas Supply Manometer .................................................................................................. 58
4.2.3 Accessing the Analyzer Probe Port ................................................................................................. 60
4.3 FUEL TYPES AND COMBUSTI ON CALIBRATION ............................................................61
4.4 COMBUSTION CALIBRATION ...........................................................................................62
4.4.1 NATURAL GAS Combustion Calibration .......................................................................................... 63
4.4.2 PROPANE GAS COMBUSTION CALIBRATION .................................................................................. 67
4.5 REASSEMBLY ....................................................................................................................71
4.6 DUAL FUEL SWITCHOVER ...............................................................................................71
4.6.1 Switchover from NATURAL GAS to PROPANE ................................................................................ 72
4.6.2 Switchover from PROPANE to NATURAL GAS ................................................................................ 73
4.7 OVER-TEMPERATURE LIMIT SWITCHES ........................................................................74
4.7.1 Digital Alarm Switch Checks and Adjustments ............................................................................... 75
SECTION 5: SAFETY DEVICE TESTING .............................................................. 77
5.1 TESTING OF SAFETY DEVI CES .......................................................................................77
5.2 LOW GAS PRESSURE TEST .............................................................................................78
5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500 .................................................................................. 78
5.2.2 LOW GAS PRESSURE TEST: BMK 3000 Only.................................................................................... 80
5.3 HIGH GAS PRESSURE TEST ............................................................................................82
5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500 ................................................................................. 82
5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 Only ................................................................................... 84
5.4 LOW WATER LEVEL FAULT TEST ....................................................................................86
5.5 WATER TEMPERATURE FAULT TEST .............................................................................87
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CONTENTS
5.6 INTERLOCK TESTS ...........................................................................................................89
5.6.1 Remote Interlock Test .................................................................................................................... 89
5.6.2 Delayed Interlock Test .................................................................................................................... 89
5.7 FLAME FAULT TEST ..........................................................................................................90
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED INLET SWITCHES ..............91
5.8.1 Blower Proof Switch Test ............................................................................................................... 91
5.8.2 Blocked Inlet Switch Test................................................................................................................ 93
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ................................................................94
5.10 PURGE SWITCH OPEN DURING PURGE .......................................................................94
5.11 IGNITION SWITCH OPEN DURING IGNITION.................................................................97
5.12 SAFETY PRESSURE RELIEF VALVE TEST ....................................................................97
SECTION 6: BOILER SEQUENCING TECHNOLOGY ............................................ 99
6.1 INTRODUCTION.................................................................................................................99
6.1.1 INSTALLATION NOTES ................................................................................................................... 100
6.2 AERCO BST QUICK START CHART ............................................................................... 100
6.3 BST IMPLEMENTATIO N INST RUCTION ......................................................................... 101
6.3.1 OPTION 1 - CONSTANT SETPOINT WITH DIRECT WIRED HEADER SENSOR .................................. 101
6.3.2 OPTION 2 - CONSTANT SETPOINT WITH MODBUS WIRED HEADER SENSOR .............................. 102
6.3.3 OPTION 3 - OUTDOOR RESET WITH DIRECT WIRED HEADER SENSOR AND DIRECT WIRED
OUTDOOR SENSOR ................................................................................................................................ 103
6.3.4 OPTION 4 - OUTDOOR RESET WITH MODBUS HEADER SENSOR AND MODBUS OUTDOOR SENSOR
............................................................................................................................................................... 105
6.3.5 OPTION 5 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND 4-20MA SETPOINT
DRIVE ..................................................................................................................................................... 107
6.3.6 OPTION 6 - REMOTE SETPOINT WITH DIRECT WIRED HEADER SENSOR AND MODBUS SETPOINT
DRIVE ..................................................................................................................................................... 109
6.3.7 OPTION 7 - REMOTE SETPOINT WITH MODBUS HEADER SENSOR AND 4-20MA SETPOINT DRIVE
............................................................................................................................................................... 111
6.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive......... 113
SECTION 7: ONAER SETUP ............................................................................ 115
7.1 INTRODUCTION............................................................................................................... 115
7.1.1 Connecting the Ethernet Cable .................................................................................................... 115
7.1.2 Confirming the Ethernet Connection ........................................................................................... 117
7.1.3 Confirm Ethernet DHCP Configuration ......................................................................................... 117
SECTION 8: TROUBLESHOOTING .................................................................. 119
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ............................. 121
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
BMK 750
50,000 (14.6 kW)
750,000 (220 kW)
47,750 (14.0 kW)
716,250 (210 kW)
BMK 1000
50,000 (14.6 kW)
1,000,000 (293 kW)
48,300 (14.2 kW)
968,000 (284 kW)
BMK 1500
75,000 (22 kW)
1,500,000 (440 kW)
64,500 (18.9 kW)
1,395,000 (409 kW)
BMK 2000
100,000 (29.3 kW)
2,000,000 (586 kW)
86,000 (25.2 kW)
1,860,000 (545 kW)
BMK 2500
167,000 (48.9 kW)
2,500,000 (732 kW)
144,000 (42.2 kW)
2,395,000 (702 kW)
BMK 3000
200,000 (58.6 kW)
3,000,000 (879 kW)
174,000 (51.0 kW)
2,874,000 (842 kW)
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and propane fueled boilers are modulating and condensing units. They represent a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads. These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature, as well as, conventional heating systems.
IMPORTANT!
Unless otherwise specified all descriptions provided in this document apply to the Benchmark Platinum Series of boiler.
The Benchmark models operate within the input and output ranges listed below. All measurements apply to both natural gas and propane models, unless otherwise specified.
BMK PLATINUM BOILER INTAKE and OUTPUT RANGES
BMK
MODEL
The output of the boiler is a function of the unit’s firing rate (valve position) and return water temperature.
When installed and operated in accordance with this Instruction Manual, these boilers comply with the NO
(SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air Quality Management District regulation 9, Rule 7.
Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting flexibility with minimum installation space requirements. These boilers are Ca tegory II and IV, positive pressure appliances. Single and/or multiple breeched units are capable of operation in the following vent configurations:
Room Combustion Air :
Ducted Combustion Air:
emission standards outlined in: South Coast Air Quality Management District
x
o Vertical Discharge o Horizontal Discharge
o Vertical Discharge o Horizontal Discharge
INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)
MINIMUM MAXIMUM MINIMUM MAXIMUM
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. In addition, the BMK 750 & 1000 models are also approved for PVC and CPVC, vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
British Thermal Unit. A unit of energy approximately equal to the
A control system developed by AERCO and currently used in all CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
CNTL
Control
Double Block and Bleed, a gas trains containing 2 Safety Shutoff GF-xxxx
Gas Fired (an AERCO document numbering system)
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
A (Amp) Ampere ACS AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Anal og Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers AUX Auxiliary
BAS
Baud Rate
BMK (Benchmark) AERCO’s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems
BLDG (Bldg) Building BST AERCO on-board Boiler Sequencing Technology
BTU BTU/HR BTUs per Hour (1 BTU/hr = 0.29 W)
CCP Combination Control Panel CCS Combination Control System C-More Controller
(or Control Box) CFH Cubic Feet per Hour (1 CFH = 0.028 m3/hr)
Building Automation System, often used interchangeably with EMS (see below)
Symbol rate, or simply the number of distinct symbol changes (signaling events) transmitted per second. It is not equal to bits per second, unless each symbol is 1 bit long.
heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
Benchmark, Innovation and KC1000 Series product lines.
CPU Central Processing Unit DBB DIP Dual In-Line Package, a type of switch
ECU Electronic Control Unit (O2 sensor) EMS Energy Management System; often used interchangeably with BAS FM Factory Mutual. Used to define boiler gas trains.
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Valves (SSOVs) and a solenoid operated vent valve.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
MBH
1000 BTUs per Hour
duplex data transmission protocol developed by AEG
onAER
P/N
Part Number
POC
Proof of Closure
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
GND Ground HDR Header Hex Hexadecimal Number (0 – 9, A – F) HP Horse Power HX Heat Exchanger Hz Hertz (Cycles Per Second) I.D. Inside Diameter IGN Ignition IGST Board Ignition/Stepper Board, contained in C-More Control Box INTLK (INTL’K) Interlock I/O Input/Output
I/O Box IP Internet Protocol
ISO International Organization for Standardization Lbs. Pounds (1 lb = 0.45 kg) LED Light Emitting Diode LN Low Nitrogen Oxide MA (mA) Milliampere (1 thousandth of an ampere) MAX (Max) Maximum
MIN (Min) Minimum Modbus® NC (N.C.) Normally Closed
NO (N.O.) Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen
Input/Output (I/O) Box currently used on Benchmark, Innovation and KC1000 Series products
A serial, half­Modicon
O.D. Outside Diameter OMM & O&M Operation and Maintenance Manual
AERCO’s on-line remot e monitoring sys tem PCB Printed Circuit Board PMC Board Primary Micro-Contr oller (PMC) board, contained in the C-More
PPM Part s per Million PSI Pounds per Square Inch (1 PSI = 6.89 kPa)
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duplex (FDX) transmission of data based
duplex (FDX) transmission of data based
data in the
VDC
Volts, Direct Current
VFD
Vacuum Fluorescent Display, also Variable Frequency Drive
W
Watt
W.C.
Water Column, a unit of pressure (1 W.C. = 249 Pa)
FORWARD
AERCO Technical Terminology Meanings
TERMINOLOGY MEANING
PTP Point-to-Point (usually over RS232 networks) P&T Pressure and Temperature ProtoNode Hardware interface between BAS and a boiler or water heater PVC Poly Vinyl Chloride, a common synthetic plastic PWM Pulse Width Modulation REF (Ref) Reference RES. Resistive RS232
(or EIA-232) RS422
(or EIA-422) RS485
(or EIA-485) RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield SPDT Single Pole Double Throw, a type of switch SSOV Safety Shut Off Valve TEMP (Temp) Temperature
Terminating Resistor
Tip-N-Tell A device that indicates if a package was tipped during shipping UL A business that tests and validates products VAC Volts, Alternating Current
A standard for serial, full-
on the RS232 Standard
A standard for serial, full-
on the RS422 Standard
A standard for serial, half-duplex (HDX) transmission of data based
on the RS485 Standard
A resistor placed at each end of a daisy-chain or multi-drop network
in order to prevent reflections that may cause invalid
communication
µA Micro amp (1 millionth of an ampere)
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SECTION 1 – SAFETY PRECAUTIONS
SECTION 1: SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be g iven the same attention as specific precautions included in these instructions. In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
See section 1.4 for important information regarding installation of units within the Commonwealth of Massachusetts.
IMPORTANT!
This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.
WARNING!
Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.
Fluids under pressure may cause injury to personnel or damage to equipment when
released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully decrease all trapped pressures to zero before performing maintenance.
Before attempting to perform any maintenance on the unit, shut off all gas and electrical
inputs to the unit.
The exhaust vent pipe of the unit may operate under a positive pressure and therefore must
be completely sealed to prevent leakage of combustion products into living spaces.
Electrical voltages up to 120 VAC (BMK 750 – 2000) and 208 or 460 VAC (BMK 2500/3000)
may be used in this equipment. Therefore the cover on the unit’s power box (located behind the front panel door) must be installed at all times, except during maintenance and servicing.
A single-pole (120 VAC units) or three-pole (220 VAC or higher units) switch must be
installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and safely disconnect electrical service. Do not affix switch to unit sheet metal enclosures.
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VALVE
OPEN
VALVE
CLOSED
SECTION 1 – SAFETY PRECAUTIONS
CAUTION!
Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be
rinsed thoroughly with clean water after leak checks have been completed.
DO NOT use this boiler if any part has been under water. Call a qualified service technician
to inspect and replace any part that has been under water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit.
NOTE:
The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the initial startup procedures in Section 4 and the safety device test procedures in Section 5, to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.
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REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Commonwealth of Massachusetts must conform to the
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling,
monoxide detector with an alarm is installed on each additional level of the dwelling,
be the responsibility of the property owner to secure the services of qualified licensed
the above requirements; provided, however, that during said thirty (30) day period, a
Each carbon monoxide detector as
accordance with the above provisions shall comply with NFPA 720 and be
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)
SECTION 1 – SAFETY PRECAUTIONS
1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
following requirements:
Boiler must be installed by a plumber or a gas fitter who is licensed within the
Commonwealth of Massachusetts.
Prior to unit operation, the complete gas train and all connections must be leak
tested using a non-corrosive soap.
The vent termination must be located a minimum of 4 feet above grade level. If
side-wall venting is used, the installation must conform to the following requirements extracted from 248 CMR 5.08 (2):
building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
building or structure served by the side wall horizontal vented gas fueled equipment. It shall
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with
battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS: required in
ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS
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REQUIREMENTS FOR MASSACHUSETTS INSTALLATIONS
observes carbon monoxide detectors and signage installed in accordance with the
venting system design or venting system components with the equipment, the instructions
When the manufacturer of a Product Approved side wall horizontally vented gas fueled
nd the
SECTION 1 – SAFETY PRECAUTIONS
4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector
provisions of 248 CMR 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a
provided by the manufacturer for installation of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and
2. The "special venting systems" shall be Product Approved by the Board, a instructions for that system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………
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SECTION 2 – INSTALLATION
SECTION 2: INSTALLATION
2.1 INTRODUCTION
This Section provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark Platinum Boilers, models 750, 1000, 1500, 2000, 2500 and 3000.
2.2 RECEIVING THE UNIT
Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for these BMK models is approximately as follows:
BMK 750: 1100 lbs. (499 kg)
BMK 1000: 1200 lbs. (544 kg)
BMK 1500/2000: 1800 lbs. (817 kg).
BMK 2500/3000: 2200 lbs. (1000 kg)
The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage. The unit should be completely inspected for evidence of shipping damage and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed.
CAUTION!
While packaged in the shipping container, the unit must be moved by pallet jack or fork lift f rom the FRONT ONLY.
NOTE:
AERCO is not responsible for lost or dam aged freight. Each unit has a Tip-N-Tell indicator on the outside of the crate. This indicates if the unit has been turned on its side during shipment. If the Tip-N-Tell indicator is tripped, do not sign for the shipment. Note the information on the carrier’s paperwork and request a freight claim and inspection by a claims adjuster before proceeding. Any other visual damage to the packaging materials should also be made clear to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials
After unpacking, make a close inspection of the unit to ensure that there is no evidence of damage not indicated by the Tip-N-Tell indicator. The freight carrier should be notified immediately if any damage is detected.
The following accessories come standard with each unit and are either pac ked separately within the unit’s shipping container or are factory installed on the unit:
Pressure/Temperature Gauge
ASME Pressure Relief Valve
Condensate Drain Trap (P/N 24441)
A 1 “ or 2” Natural Gas Supply Shutoff Valve, and a Propane Shutoff Valve on Propane
and Dual Fuel units
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION When optional accessories are ordered, they may be packed within the unit’s shipping
container, factory installed on the unit, or packed and shipped in a separate container. Any standard or optional accessories shipped loose should be identified and stored in a safe place until ready for installation or use.
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark Platinum Boiler includes:
Access to AC input power specified in Section 2.10.1.
Access to a natural gas or propane gas with minimum pressure specified in Section
2.9.1.
2.4.1 Installation Clearances
All Benchmark models are the same height, but vary in depth according to model pairs; 750/1000, 1500/2000, and 2500/3000. The unit must be installed with the prescribed clearances for service as shown in Figure 2-1a, 2-1b and 2-1c. The minimum clearance dimensions, required by AERCO, are listed below f or all models. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements. The minimum acceptable clearances required are as follows:
Sides: 24 inches (61 cm)
Front: 24 inches (61 cm)
Rear: 24 inches (61 cm)
Top: 18 inches (45.7 cm)
All gas piping, water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels, or inhibit service or maintenance of the unit.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion.
If installing a Combination (CCP) system using an ACS panel, it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location. For information on Combination Mode Boilers refer to Section 3.7 of th e BMK 750-3000 Platinum Boiler Operation and Maintenance Guide, OMM-0116 (GF-201).
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
NOTE:
housekeeping
NOTE:
pad.
4” High Pad
SECTION 2 – INSTALLATION
Ensure that condensate assembly is
not located
over the
housekeeping
Ensure that condensate assembly is
not located
over the
Figure 2-1a: BMK 750/1000 Clearances
Figure 2-1b: BMK 1500/2000 Clearances
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
Housekeeping Pad.
FRONT
REAR
NOTE:
SECTION 2 – INSTALLATION
Ensure that condensate assembly is
not located
over the
Figure 2-1c: BMK 2500/3000 Clearances
WARNING!
Keep the unit area clear and free from all combustible materials and flammable vapors or liquids.
FOR MASSACHUSETTS ONLY:
For Massachusetts installations, the unit must be installed by a plumber or gas-fitter licensed within the Commonwealth of Massachusetts. In addition, the installation must comply with all requirements specified in Section 1.4, above.
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SECTION 2 – INSTALLATION
2.4.2 Setting the Unit
BMK 750/1000 units must be installed on a 4 to 6 inch (10.2 to 15.2 cm) while BMK 1500 – 3000 units must be installed on a 4 to 8 inch (10.2 to 20.3 cm) housekeeping pad to ensure proper condensate drainage. If anchoring the unit, refer to Figure 2-2a, 2-2b and 2-2c for anchor locations.
All holes are flush with the bottom surface of the frame.
All dimensions shown are in inches [millimeters]
Figure 2-2a: BMK 750/1000 Anchor Bolt Locations
Figure 2-2b: BMK 1500/2000 Anchor Bolt Locations
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
FRONT
REAR
SECTION 2 – INSTALLATION
NOTES:
1) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME
2) ALL DIMENSIONS SHOWN ARE IN INCHES [MILLIMETERS]
Figure 2-2c: BMK 2500/3000 Anchor Bolt Locations
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
ATTACHING THE LIFTING BAR: BMK 750/1000 Instructions
, lift the boiler and
LIFTING TAB
VIEW B - LIFTING POSITION
SECTION 2 – INSTALLATION
2.5 LIFTING PROVISIONS
WARNING!
When lifting or moving the boiler, DO NOT attempt to manipulate the boiler using the gas train or blower.
2.5.1 BMK 750 – 1000 lifting Provisions
Unpack and inspect the unit, then remove the four (4) lag screws securing the boiler to the shipping pallet. The boiler can be lifted and moved by inserting forklift tines in the front slots provided in the base of the unit, or it can be lifted by attaching a lifting bar to the unit’s heat exchanger. A lifting bar (P/N 59174), with attaching hardware, is supplied with each unit. W hen shipped, this bar is attached to the rear of the unit as shown in Figure 2-3a (View A). One (1) lifting tab is provided at the top of the unit’s heat exchanger as shown. This tab is used to attach the lifting bar to the unit, as described below.
WARNING!
When using the lifting tab and bar, ensure there is no load placed on the gas train or blower.
1. Remove the lifting bar from its shipping location at the rear of the unit (Figure 2-3a, View
A). Retain the two (2) hex head cap screws, hex nuts and flat washers.
2. Remove the top shroud from the boiler and locat e the lift ing t ab at the t op-rear of the heat
exchanger.
3. Attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1
(Fig. 2-3a, Vie w B). The upper end of the lifting bar containing the oval cutout should be positioned over the top of the heat exchanger as shown.
4. Using proper rigging equipment capable of lifting 1200 lbs. (544 kg)
position it on the housekeeping pad.
5. After the boiler is properly set on the pad, detach the lifting bar and replace the shroud on
the top of the unit, but retain the lifting bar for possible reuse at the installation site.
LIFTING BAR IN LIFTING POSITION
LIFTING
BAR IN SHIPPING POSITION
VIEW A - SHIPPING POSITION
Figure 2-3a: BMK 750/1000 Boiler Lifting Provisions
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SECTION 2 – INSTALLATION
2.5.2 BMK 1500 – 2000 Lifting Provisions
Three lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-3. Remove the front top panel from the unit to provide access to the lifting lugs. Remove the four (4) lag screws securing the unit to the shipping skid. Lift the unit off the shipping skid and position it on the 4 inch to 8 inch ( 10.2 cm to 20.3 cm) housekeeping concrete pad (required) in the desired location.
LIFTING LUGS (3 POSITIONS)
YELLOW ARROWS
2” NATURAL GAS OR 1” PROPANE GAS INLET
Figure 2-3: Boiler Lifting Provisions – BMK 1500/2000 Shown
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
1” (2.54cm) NATURAL GAS INLET
1/4” ANALYZER
NPT PORT
COOLER
3” SECONDARY WATER INLET WARMER WATER RETURN
EXHAUST
MANIFOLD
1” (2.54cm) PROPANE INLET
SECTION 2 – INSTALLATION
2.6 SUPPLY AND RETURN PIPING
2.6.1 BMK 750 – 1000 Supply and Return Piping
Benchmark 750 and 1000 Boiler utilizes 3” (7.62cm) 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-4a. Refer to Appendix A for dimens ional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
3” HOT WATER O UTLET (SUPPLY)
AIR INLET
3” PRIMARY WATER INLET
WATER RETURN
DRAIN VALVE
CONDENSATE DRAIN
Figure 2-4a: BMK 750/1000 Supply and Return Locations – Two Inlet Option Shown
2.6.2 BMK 1500 – 3000 Supply and Return Piping
All Benchmark 1500, 2000, 2500 and 3000 units have one 4” (10.2 cm) 150# flanges for the water INLET (supply) and one 4” (10.2 cm) 150# flanges for the hot water OUTLET (return) piping connections. Some units have an optional second 4” (10.2 cm) 150# flange for the water INLET, as shown in Figure 2-4b. Refer t o Appendix A for dimensional data.
When connecting the hot water outlet and cold water inlet to building piping, first make sure the mating surfaces are thoroughly clean. AERCO recommends using Loctite ® 7649 to prime the mating surfaces and then Loctite 567 as pipe dope. Do NOT use Teflon tape.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECONDARY WATER INLET
PRIMARY
(COOLER WATER
EXHAUST MANIFOLD
BMK 1500/2000
BMK 2500/3000
SECTION 2 – INSTALLATION
2” NATURAL GAS OR
1” PROPANE INLET
HOT WATER OUTLET (SUPPLY)
AIR INLET
(WARMER WATER RETURN)
WATER INLET
CONDENSATE DRAIN
Figure 2-4b: BMK 1500/2000 and BMK 2500/3000 Supply and Return Locations
2.6.3 Dual Inlet Return Piping
The standard dual inlet connections allow these units to be configured with a separate cooler return temperature zone, rather than blending high and low return temperature zones. Utilizing the dual return capability, these boilers can take further advantage of the condensing capabilities. When configured with a lower return temperature zone or AERCO SmartPlate, thermal efficiency can improve by up to 6% (Based on an 80 °F (26.7 °C) minimum return wat er temperature at full fire. Lower return temperatures are possible which would yield even greater efficiency gains. The maximum temperature differential across the boiler heat exchanger is 100 °F (37.8 °C)).
To use the secondary inlet, pipe the warmer return water to the secondary (upper) inlet and the cooler return water to the primary (lower) inlet. If the flow through b oth the pr imar y an d the secondary return is constant, then the combined minimum flows must equal the specified minimum flow of t he boiler. If the flow through either of the inlet returns is intermittent, then the minimum flow through one of the return connections m ust always equal the specified minimum flow of the boiler. Contact your AERCO representative for additional information.
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SECTION 2 – INSTALLATION
2.7 PRESSURE RELIEF VALVE INSTALLATION
An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler. The pressure rating for the relief valve must be specified on the sales order. Available pressure ratings range from 3 0 to 160 ps i (207 to 1103 kPa). The relief valve is installed on the hot water outlet of the boiler as shown in Figure 2-5a and 2-5b. A su itable pipe joint compound should be used on the threaded connections. Any excess should be wiped off to avoid getting any joint compound into the valve body. The relief valve must be piped to within 12 inches (30.5 cm) of t he floor t o prevent injury in the event of a discharge. No valves, restrictions, or other blockages are allowed in the full port discharge line. In multiple unit installations the discharge lines must NOT be manifolded together. Each must be individually run to a suitable discharge location.
PRESSURE
RELIEF VALVE
3” HOT BOILER
WATER OUTLET
PRESSURE
RELIEF VALVE
4” HOT BOILER
WATER OUTLET
Figure 2-5b: BMK 1500/2000/2500/3000 P&T Relief Valve Location
INSTALL TRIDICATOR GAUGE HERE (P/N 123675-TAB)
Figure 2-5a: BMK 750/1000 P&T Relief Valve Location
INSTALL TRIDICATOR GAUGE HERE (P/N 123675-TAB)
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONDENSATE DRAIN INSTALL ATIO N Instructions
d drain connection using the
BMK Model
Maximum Condensate Flow Per Boiler
BMK 750
6 gallons (23 L) per hour
BMK 1000
8 gallons (30 L) per hour
BMK 1500
9 gallons (34 L) per hour
BMK 2000
10 gallons (38 L) per hour
BMK 3000
20 gallons (76 L) per hour
SECTION 2 – INSTALLATION
2.8 CONDENSATE DRAIN and PIPING
The Benchmark Boiler is designed to condense wat er vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection. See the following subsections for information on the condensate drain and piping for the various models.
The condensate drain port located on the exhaust manifold (see Figure 2-4a and 2-4b) must be connected to the condensate trap (P/N 24441), which is packed separately within the unit’s shipping container. The condensate trap inlet and outlet connections contain tapped 3/4” NPT ports.
A sample condensate trap installation is shown in Figure 2-6a and 2-6b. However, the actual installation details for the trap will vary depending on the available clearances, housekeeping pad height/dimensions and other prevailing conditions at the site. The following general guidelines must be observed to ensure proper condensate drainage:
The condensate trap inlet must be level with, or lower than the exhaust manifold drain port.
The base of the condensate trap must be supported to ensure that it is level (horizontal).
The trap must be removable for routine maintenance. AERCO recommends that a union
be utilized between the exhaust manifold condensate drain port and the trap inlet port.
While observing the above guidelines, install the condensate trap as follows:
1. Connect the condensate trap inlet to the exhaust manifol appropriate piping components (nipples, reducers, elbows, etc.).
2. At the condensate trap outlet, install a 3/4” NPT nipple.
3. Connect a length of 1” (2.54 cm) I.D. polypropylene hose to the trap outlet and sec ure with a hose clamp.
4. Route the hose on the trap outlet to a nearby floor drain.
If a floor drain is not available, a condensate pump can be used to remove the condensate to an appropriate drain. The maximum condensate flow rate is:
BMK 2500 17 gallons (64 L) per hour
WARNING!
Use PVC, stainless steel, aluminum or polypropylene for condensate drain piping. Do NOT use carbon or copper components.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
3/4” NPT
NIPPLE
HOSE CLAMP
1” DIAM. HOSE
3/4” NPT
NIPPLES
UNION
EXHAUST
MANIFOLD
DRAIN
4”
THICK
COMBUSTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
HOSE CLAMP
T O DRAIN
(4 each)
1” (2.54 cm) DIAM. HOSE
4”
4-8” (10-20 cm)
THICK
SECTION 2 – INSTALLATION
COMBUSTION
ANALYZER
PROBE PORT
NOTE
HOUSEKEEPING
PAD MUST NOT
EXTEND UNDER
THE CONDENSATE
ASSEMBLY
4-6” (10-15.2 cm)
TRAP INLET
INTEGRAL ADAPTOR AND
THUMBSCREW
TOP COVER THUMB SCREWS (4 each)
CONDENSATE
TRAP
(P/N 24441)
T O FLOOR
Figure 2-6a: BMK 750/1000 Sample Condensate Trap Installation
ANALYZER
NOTE
HOUSEKEEPING
PAD MUST NOT
EXTEND UNDER
THE CONDENSATE
ASSEMBLY
EXHAUST
MANIFOLD
DRAIN PORT
TRAP INLET INTEGRAL ADAPTOR AND THUMBSCREW
TOP COVER THUMB
SCREWS
CONDENSATE
TRAP (P/N 24441)
FLOOR
Figure 2-6b: BMK 1500/2000/2500/3000 Sample Condensate Trap Installation
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 2 – INSTALLATION
2.9 GAS SUPPLY PIPING
AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0047 (GF-2030) must be consulted prior to designing or installing any gas supply piping.
WARNING!
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.
CAUTION!
Many of the soaps used for gas pipe leak testing are corrosive to metals. Therefore, piping must be rinsed thoroughly with clean water after leak checks have been completed.
NOTE:
All gas piping must be arranged so that it does not interfere with removal of any covers, inhibit service/maintenance, or restrict access between the unit and walls, or another unit.
Benchmark 750 and 1000: Features a 1 inch (2.54 cm) NATURAL GAS gas inlet connection on the rear of the unit.
Benchmark 750P and 1000P: Features a 1 inch (2.54 cm) PROPANE gas inlet connection on the rear of the unit.
Benchmark 1500/2000/2500/3000: Features a 2 inch (5.08 cm) NATURAL GAS gas inlet connection on the top of the unit.
Benchmark 1500P, 2000P, 2500P, and 3000P (Propane): Features a 1 inch (2.54 cm) PROPANE gas inlet connection on the top of the unit.
Benchmark 1500DF, 2000DF, 2500DF, and 3000DF (Dual Fuel): Features a 2 inch (5.08 cm) NATURAL GAS and a 1 inch (2.54 cm) PROPANE gas inlet connection on the top of the unit.
Prior to installation, all pipes should be de-burred and internally cleared of any scale, metal chips or other foreign particles. Do NOT install any flexible connectors or unapproved gas fittings. Piping must be supported from the floor, ceiling or walls only and must not be supported by the unit.
A suitable piping compound, approved for use with natural gas, should be used. Any excess must be wiped off to prevent clogging of components.
To avoid unit damage when pressure testing gas piping, the unit must be isolated fr om the g as supply piping. The gas pressure applied to the unit must never exceed 14” W.C. (3.49 kPa). A thorough leak test of all external piping must be performed using a soap and water solution or suitable equivalent. The gas piping used must meet all applicable codes.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
TABLE 2-1: MAXIMUM STATIC GAS PRESSURE
TABLE 2-2: MINIMUM GAS PRESSURE REQUIREMENTS
Minimum
Pressure
Minimum
Pressure
/hr)
SECTION 2 – INSTALLATION
2.9.1 Gas Supply Specifications
The gas supply input specifications to the unit are as follows: The maximum static pressure to the unit must not exceed the following:
MODEL
BMK 750 - BMK 3000
NATUR AL GAS PROPANE
14” W.C. (3.49 kPa) 14” W.C. (3.49 kPa)
Supply piping and pressure to the unit must be sufficient to provide the volume of gas while maintaining gas pressure listed below while operating at maximum capacity:
NATUR AL GAS PROPANE
MODEL
BMK 750 BMK 1000 BMK 1500 BMK 2000 * BMK 2500 BMK 3000
Gas Volume
3
750 CFH (21.2 m
/hr) 4” W.C. (1.0 kPa) 300 CFH (8.5 m3/hr) 7” W.C. (1.74 kPa) 1000 CFH (28.3 m3/hr) 1500 CFH (42.5 m3/hr) 2000 CFH (56.6 m3/hr) 2500 CFH (70.8 m3/hr) 3000 CFH (85.0 m3/hr)
4” W.C. (1.0 kPa) 6” W.C. (1.5 kPa) 6” W.C. (1.5 kPa) 4” W.C. (1.0 kPa) 4” W.C. (1.0 kPa)
Gas Volume
400 CFH (11.3 m 600 CFH (17.0 m 800 CFH (22.6 m 1000 CFH (28.3 m 1200 CFH (34 m
3
3
/hr) 11” W.C. (2.74 kPa)
3
/hr) 4” W.C. (1.0 kPa)
3
/hr) 4” W.C. (1.0 kPa)
3
4” W.C. (1.0 kPa)
/hr) 4” W.C. (1.0 kPa)
* The BMK 2000 may derate by up to 150,000 BTU’s when operated below 5” W.C. (1245 Pa)
at full fire.
2.9.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown in Figure 1-1.
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TABLE 2-3a: NATURAL GAS Regulator Ca pacity
TABLE 2-3b: PROPANE Gas Regul a t or Capacity
SECTION 2 – INSTALLATION
2.9.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions (see, below). Regulators must conform to the specifications shown in the tables below.
The external natural gas regulator must be capable of regulating the following BTU per hour while maintaining the minimum gas pressure listed below:
Model BTU/HR (kW) Minimum Gas Pressure BMK 750/1000 BMK 1500 BMK 2000 BMK 2500/3000
Model BTU/HR (kW) Minimum Gas Pressure BMK 750/1000 BMK 1500/2000 BMK 2500/3000
A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C. (3.49 kPa).
49,000 – 1,020,000 (14.3 – 299) 4.0” W.C. (1.0 kPa) 100,000 – 2,120,000 (29.3 - 621.3) 6.0” W.C. (1.49 kPa) 100,000 – 2,120,000 (29.3 - 621.3) 8.5” W.C. (2.12 kPa) 150,000 – 3,180,000 (44 - 932) 8.0” W.C. (1.99 kPa)
49,000 – 1,020,000 (14.3 – 299) 11.0” W.C. (2.74 kPa) 100,000 – 2,120,000 (29.3 - 621.3) 4.0” W.C. (1.0 kPa) 150,000 – 3,180,000 (44 - 932) 4.0” W.C. (1.0 kPa)
2.9.3.1 Massachusetts Installations Only
For Massachusetts installations, a mandatory external gas supply regulator must be positioned as shown in Figure 2-7a, 2-7b and 2-7c. The gas supply regulator must be properly vented to outdoors. Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator.
2.9.3.2 All Installations (Except Massachusetts)
For installations with 3 or more units (other than Massachusetts) that EXCEED 7” W.C. (1.7 kPa) gas pressure, a separate external gas supply r egulator, as shown in Figure 2-7a, 2-7b and 2-7c, is highly recommended. No regulator is required for gas pressures below 7” W.C. (1.7 kPa) of pressure. Consult the local gas utility for detailed requirements concerning
venting of the supply gas regulator.
NOTE:
It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact your AERCO sales r epresentative for more information.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
DIRT TRAP
SECTION 2 – INSTALLATION
1” MANUAL
SHUTOFF
VALVE
GAS INLET
GAS PRESSURE
REGULATOR
Figure 2-7a: BMK 750/1000 Manual Gas Shut-Off Valve and Gas Regulator
GAS PRESSURE REGULATOR
NATURAL GAS
INLET
MANUAL
SHUT-OFF
VALVE
GAS INLET
Figure 2-7b: BMK 1500-3000 Manual Gas Shut-Off Valve and Gas Regulator
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
NATURAL GAS
SUPPLY
PROPANE
SUPPLY
PROPANE PRESSURE
piping and
components shown in
will not be
present.
SECTION 2 – INSTALLATION
NATURAL GAS MANUAL SHUT-OFF VALVE
NATURAL GAS PRESSURE REGULATOR
NATURAL GAS INLET
PROPANE MANUAL SHUT-
OFF VALVE
REGULATOR
PROPANE INLET
NOTE
In propane-only units, the natural gas
Figure 2-7c
Figure 2-7c: BMK 1500-3000DF Dual Fue l Manual Gas Shut-Off Valve & Gas
Regulator
2.10 AC ELECTRICAL POWER WIRING
AERCO’s Benchmar k Electrical Power Guide, TAG-0048 (GF-2060), must be consulted prior to connecting any AC power wiring to the unit.
2.10.1 Electrical Power Requirements
The BMK models covered by this manual are available in the following voltage configurations:
• BMK 750/1000: 12 0 VAC, Sin gle-Phase, 60 Hz @ 20 Amps
• BMK 1500/2000: 120 VAC, Sin gle-Phase, 60 Hz @ 20 Amps
BMK 2500-3000/208: 208 VAC, Three-Phase, 60 Hz @ 20 Amps
BMK 2500-3000/460: 460 VAC, Three-Phase, 60 Hz @ 15 Amps
A label showing the required AC power connections is provided on the front cover of the Power Box as shown below in Figures 2-8a and 2-8b. The location of the power box is shown in Section 2.10.2, below.
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SECTION 2 – INSTALLATION
Figure 2-8a: Power Box Cover Label – BMK 750 – 2000
BMK 2500/3000 - 208VAC
Figure 2-8b: Power Box Cover Labels – BMK 2500/3000
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A switch must be installed on the electrical supply line in an easily accessible location to q uickly and safely disconnect electrical service. DO NOT attach the switch to sheet metal enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external electrical power source is used, the installed boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction. In the absence of such requirements, the installation shall conform to National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.
For electrical power wiring diagrams, see the Benchmark Electrical Power Guide, TAG-0048 (GF-2060).
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BMK 2500/3000 - 460VAC
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
POWER BOX
FRONT COVER
FRONT UPPER-RIGHT CORNER OF UNIT
SECTION 2 – INSTALLATION
2.10.2 Power Box Locations
External AC power connections are made to the unit inside the Power Box on the front of the unit. Remove the front panel to access the Power Box, which is mounted in the upper part of the unit as shown in Figure 2-9a and 2-9b. The internal connections inside the power box is shown in Section 2.10.3, below.
WITH HINGED
Figure 2-9a: BMK 750/1000 Power Box with Closed Cover
Figure 2-9b: BMK 1500/2000/2500/3000 Power Box with Closed Cover
POWER BOX
FRONT COVER
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12V POWER
12V POWER
SUPPLY
AMPLIFIER
AMPLIFIER
SECTION 2 – INSTALLATION
2.10.3 Electrical Power Box Internal Components
WARNING!
The power breaker shown in Figure 2-10a, 2-10b and 2-10c does NOT remove power from the terminal blocks.
FUSE BLOCKS (2)
TRANSFORMER
115V/24V
POWER
BREAKER
TERMINAL BLOCKS
FLAME ROD SIGNAL
24 V POWER SUPPLY (SEQUENCING VA LV E)
Figure 2-10a: BMK 750/1000 Power Box Internal Components
WIRE CONDUITS
TRANSFORMER
24V POWER
SUPPLY
SUPPLY
FLAME ROD SIGNAL
FUSE BLOCKS (2)
Figure 2-10b: BMK 1500/2000 Power Box Internal Components
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POWER BREAKER
TERMINAL BLOCKS
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SECTION 2 – INSTALLATION
TRANSFORMER
24V POWER
SUPPLY
12V POWER
SUPPLY
Figure 2-10c: BMK 2500/3000 Power Box Internal Components
NOTES:
FUSE BLOCKS (2)
WIRE CONDUITS
POWER BREAKER
TERMINAL BLOCKS
With the exception of the transformer shown in Figure 2-10a 2-10b, and 2-10c, all of the components in the Power Box are mounted on a DIN rail.
All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers, inhibit service/maintenance, or prevent access between the unit and walls or another unit.
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BMK 750/1000
BMK 1500/2000/2500-3000
SECTION 2 – INSTALLATION
2.11 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the C-More Control system used with all Benchmark units does allow for some additional control and monitoring features. Wiring connections for these features are made on the Input/Output (I/O) board located behind the removable front panel assembly of the unit. The location of the I/O board is shown in Figure 2-
11. The I/O board terminal strip connections are shown in Figur e 2-12. All field wiring is ins talle d from the rear of the panel by routing the wires through one of the four bushings provided on the sides of the I/O board.
TERMINAL STRIPS
I/O BOARD
Figure 2-11: Input/Output (I/O) Box Location
NOTE:
Use Figure 2-12 to determine the functions of the I/O board connections. Do not use the silkscreened label on the I/O board itself, as some labels may not match the func tions. There is also a diagram of the connection functions on the cover of the I/O Box.
WARNING!
DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage.
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Relay Contacts:
DANGER!
IN THIS BOX
DIP 1 Modbus Term DIP 2 RS232 Enable
SECTION 2 – INSTALLATION
Outdoor Air
Air Sensor Common
Air Temp Sensor
O2 Sensor –
Not Used Spark Signal + Spark Signal –
O2 Sensor +
Not Used
+12 V Out Analog In + Analog In –
Valve Feedback + Valve Feedback –
Shield Shield
Analog Out + Analog Out –
RS-485 +
RS-485 Ground
RS-485 -
RS-232 - TxD RS-232 - RxD VFD/Blower +
VFD/Blower –
Remote Intl’k OUT Remote Intl’k IN
NOT USED Delayed Intl’k OUT
Delayed Intl’k IN Not Used
Fault Relay N.C. Fault Relay COMM
Fault Relay N.O. Aux Relay N.C. Aux Relay COMM
Aux Relay N.O. Not Used
120 VAC, 30 VDC 5 Amps, Resistive
120 VAC USED
NOTE:
Refer to this image for connections rather than the silkscreen labels shown on the board.
Figure 2-12: I/O Box Terminal Strips
2.11.1 Outdoor Air & Air Sensor Common
An outdoor temperature sensor (P/N 61047) is required for the INDOOR/OUTDOOR RESET mode of operation. It can also be used with another mode if it is desired to use the outdoor sensor enable/disable feature, which allows the boiler to be enabled or disabled based on the outdoor air temperature.
The factory default for the outdoor sensor is DISABLED. To enable the sensor and/or select an enable/disable outdoor temperature. See Section 2.6: CONFIGURATION Menu, item 7, in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201).
The outdoor sensor may be wired up to 200 feet (61m) from the boiler. It is connected to the OUTDOOR AIR and AIR SENSOR COMMON terminals of the I/O board (Figure 2-12). Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG. There is no polarity to observe when terminating these wires. The shield is to be connected only to the terminals labeled SHIELD in the I/O Box PCB. The sensor end of the shield must be left free and ungrounded.
When mounting the sensor, it must be located on the North side of the building where an average outside air temperature is expected. The sensor must be shielded from direct sunlight as well as impingement by the elements. If a shield is used, it must allow f or free air circulation.
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SECTION 2 – INSTALLATION
2.11.2 AIR TEMP SENSOR
The AIR TEMP SENSOR terminal is used to monitor the air inlet temperature sensor (P/N
61024). This input is always enabled and is a “view only” input. It can be seen in the AIR TEMP
setting in the Operating menu (see Section 2.4: OPERATING Menu, it em 4, of the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201). A resistance
chart for this sensor is provided in APPENDIX C of the s ame guide. This sensor is an active part of the combustion control system and must be operational for accurate air/fuel mixing control.
2.11.3 O2 SENSOR (+ & –)
The two O2 SENSOR terminals (+ and –) are used to connect an integrated oxygen sensor to the I/O board. The O up period. See Section 2.4: OPERATING Menu, item 16, of the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201).
concentration is displayed in the Operating menu after a 60 second warm-
2
2.11.4 SPARK SIGNAL (+ & –)
The two SPARK SIGNAL terminals (+ & -) connect to the spark monitor (P/N 61034, also called "AC Current transducer"), which monitors the current going to the ignition transformer (P/N
65085. See Section 5.12 in the Benchmar k 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201) for more information. If the current is insufficient (too high or low)
during the ignition sequence, the controller will abort the ignition cycle. The controller will attempt up to three ignition cycles. If the current is insufficient by the third try, the controller will shut down and display a fault message.
2.11.5 ANALOG IN
The two ANALOG IN terminals (+ and –) are used when an external signal is used to change the setpoint (REMOTE SETPOINT mode) of the boiler.
Either a 4 to 20 mA/1 to 5 VDC or a 0 to 20 mA/0 to 5 VDC signal may be used to vary the set­point or air/fuel valve position. The factory default setting is 4 to 20 m A/ 1 to 5 VDC, however this may be changed to 0 to 20 mA/0 to 5 VDC in the Configuration menu; see Section 2.6:
CONFIGURATION Menu, item 6, in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201).
If voltage rather than current is selected as the drive signal, a DIP switch must be set on the PMC Board located inside the C-More Control Box. Contact the AERCO factory for information on setting DIP switches.
All supplied signals must be floating (ungrounded) signals. Connections between the source and the boiler’s I/O board (Figure 2-12) must be made using twisted shielded pair of 18–22 AWG wire such as Belden 9841. Polarity must be maintained and the shield must be connected only at the source end and must be left floating (not connected) at the Boiler ’s I/O board.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F (4.4 to 116 °C) setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.11.6 VALVE FEEDBACK
The two VALVE FEEDBACK terminals (+ and –) are used when the Sequencing Isolation Valve Feedback option is selected. The Valve Feedback signal is connected to the “Valve Fdbk” terminals and is used to confirm that the valve has properly opened or closed. If the Valve
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SECTION 2 – INSTALLATION Feedback signal does not match the Valve-Open or Valve-Close command for the time defined
in the "Valve Fdbk timer" entry, the controller will proceed as follows: (a) If the valve fails with the Valve Stuck Open fault, the “Valve Stuck Open” message will be
displayed and the unit will remain active.
(b) If the valve fails with the Valve Stuck Closed fault, the “Valve Stuck Closed” message will be
displayed and the unit will shut down.
NOTE:
If the Valve Feedback option is used, Shorting Jumper MUST be inserted on JP2 on the I/O Board (see Figure 2-12).
2.11.7 SHIELD (SHLD & SHLD)
The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit. Shields must only be connected to these terminals.
2.11.8 ANALOG OUT
The two ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor Setpoint, Outlet Temperature, Valve Position 4-20 mA, Valve Position 0-10v or be set to OFF. The default s etting i n the C-More controller is Valve Position 0-10v, and behaves as follows:
0-10VDC must be selected for the voltage output used by the controller to modulate the combustion blower via the I/O Box terminals labeled VFD/BLOWER (Section 2.11.11).
If Boiler Sequencing Technology (BST) is enabled, the Analog Output terminals are used to drive the isolation valve, open and closed. A 0-20 mA signal is used, with 20 mA to close the valve and 0 to open.
NOTE:
When driving an isolation valve, shorting jumper #JP2 MUST be installed on the I/O Board.
2.11.9 RS485 Comm (+, GND, & -)
The three RS-485 communication terminals are used when the boiler plant is being controlled by an Energy Management System (EMS) or an AERCO Control System (ACS) using Modbus (RS485) communication.
2.11.10 RS232 Comm (TxD & RxD)
As of Firmware version 4.0 and above, these terminals are used only by factory-trained personnel to monitor onAER communications via a portable computer.
2.11.11 VFD/Blower (0-10 & AGND)
The two VFD/BLOWER (0-10 & AGND) terminals send an analog signal to control the blower speed.
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SECTION 2 – INSTALLATION
2.11.12 Interlocks
The unit has two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps, louvers or other accessories. These interlocks are called the Remote Interlock and Delayed Interlock (REMOTE INTL’K IN and DELAYED INTL’K IN in Figure 2-12). Both interlocks, described below, are factory wired in the closed position using jumpers.
NOTE:
Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to fire.
2.11.12.1 Remote Interlock In (OUT & IN)
The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped).
2.11.12.2 Delayed Interlock In (OUT & IN)
The Delayed Interlock terminals can be used in one of two ways:
In conjunction with the optional external sequencing valve (see section 2.15: Sequencing Isolation Valve Installation and Section 6: BST), a component of AERCO’s on-board Boiler
Sequencing Technology (BST) solution. A cable of the boiler’s wiring harness is connected to these terminals on all units; if BST is implemented, the other end of that cable is connected to the sequencing valve.
If BST is NOT implemented, t he second use is typically in conjunction with the AUXILIARY RELAY CONTACTS described in section 2.11.14, below. This interlock circuit is locate d in the purge section of the start string. It can be connected to the proving device (end switch, flow switch etc.) of an auxiliary piece of equipment started by the unit’s auxiliary relay. If the delayed interlock is connected to a proving device that requires time to close (make), a time delay (AUX START ON DLY) that holds the start sequence of the unit long enough for a proving switch to make (close) can be programmed.
To use this option, you must disconnect the harness from the Delayed Interlock terminals and connect the proving device in its place.
Should the proving switch not prove within the programmed time frame, the unit will shut down. The AUX START ON DLY can be programmed from 0 to 120 seconds. This option is located in t he Configuration menu (see Section 2.6: CONFIGURATION Menu, it em 16, in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-
201)).
2.11.13 Fault Relay (NC, COM, & NO)
The fault relay is a single pole double t hrow (SPDT) relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC. The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed.
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO)
Each unit is equipped with a single pole double throw (SPDT) relay that is energized when there is a demand for heat and de-energized after the demand for heat is satisfied. The relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be used as a
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
Selkirk Corporation - Heatfab Division
Watertown Supply Glover Sheet Metal, Inc.
www.gloversheetmetal.com
SECTION 2 – INSTALLATION unit status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 a mps. Ref er to
Figure 2-12 to locate the AUXILIARY RELAY terminals for wiring connections.
2.12 FLUE GAS VENT INSTALLATION
AERCO’s Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) must be consulted before any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive pressure, watertight vent materials MUST be used for safety and UL certification. Because the unit is capable of discharging low temperature exhaust gases, the flue must be pitched back towards the unit a minim um of 1/4" per foot (0.64 cm per 0.3 m) to avoid any condensate pooling and to allow for proper drainage.
While there is a positive flue pressure during operation, the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet (42.7m) or 0.8” W.C. (199 Pa). Fittings as well as pipe lengths must be calculated as part of the eq uivalent lengt h. For a natural draft installation the draft must not exceed -0.25” W.C. (-62 Pa). These factors must be planned into the vent installation. If the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate properly or reliably.
2.12.1 MASSACHUSETTS INSTALLATIONS
For Massachusetts installations, the following companies provide vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts. Contact information is as follows:
130 Industrial Blvd. Turners Falls, MA 01376 Phone: 1-800-772-0739
www.heatfab.com
33 Grove St. Watertown, MA 02472 Phone: (617) 924-2840
www.watertownsupply.com/
44 Riverdale Ave. Newton, MA 02485 Phone: (617) 527-8178
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TABLE 2-4: AIR DUCT MINIMUM DIAMETER
SECTION 2 – INSTALLATION
2.13 COMBUSTION AIR
The Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) MUST be consulted before any inlet air venting is designed or installed. Air supply is a direct requirement of ANSI
223.1, NFPA-54, CSA B149.1 and local codes. These codes should be consulted before a permanent design is determined.
The combustion air must be free of chlorine, halogenated hydrocarbons or other chemicals that can become hazardous when used in gas-fired equipment. Common sources of these compounds are swimming pools, degreasing compounds, plastic processing, and refrigerants. Whenever the environment contains these types of chemicals, combustion air MUST be supplied from a clean area outdoors for the protection and longevity of the equipment and warranty validation.
If combustion air is supplied directly to the unit(s) though air duct(s), see section 2.13.1 below. If combustion air is not supplied through air ducts, it must be supplied to the unit(s) through two
permanent openings. These two openings must have a free area of not less than one square
inch (6.5 cm
into account restrictions such as louvers and bird screens. For Canada installations, refer to the requirements specified in CSA B149.1-10, sections 8.4.1 and 8.4.3.
2
) for each 4000 BTUs (1.17 kW) input for each unit. The f ree area m ust take
2.13.1 DUCTED COMBUSTION AIR
For ducted combustion air installations, the air ductwork must be attached directly to the air inlet connection on the sheet metal enclosure. Consult the Benchmark Venting and Combustion Air Guide, TAG-0022 (GF-2050) when designing combustion air ducting.
In a ducted combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run. When using the unit in a ducted combustion air configuration, the minimum diameter connection at the unit is:
Benchmark Model Duct Diameter
BMK 750 BMK 1000 BMK 1500
BMK 2000 BMK 2500 BMK 3000
6 inch (15.2 cm) diameter connection
8 inch (20.3 cm) diameter connection
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PUMP RELAY
POWER BOX
PUMP RELAY
POWER BOX
SECTION 2 – INSTALLATION
2.14 BENCHMARK PUMP RELAY
All Benchmark Platinum models ship with a pump relay (P/N 69102-2 for BMK750/1000, 69102­3 f or BMK1500-3000) as standard equipment. The pump relay allows the user to turn a pump
on/off and open/close a motorized valve as the boiler cycles on and off on demand. The Pump Delay Timer feature allows the user to keep the pump running and keep the motorized valve open for up to 30 minutes after the boiler has shut down and the demand is satisfied.
The pump relay is attached to the outside of the power box, as shown below. Boilers equipped with the pump relay have a label on the power box cover adjacent to the relay.
Figure 2-13a: BMK 750/1000 Pump Relay Location
Figure 2-13b: BMK 1500/2000/2500-3000 Pump Relay Location (BMK 25000/3000 Shown)
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480 VAC Pilot Duty @ 240-277 VAC Pilot Duty
Heating Pump
Pump Relay Terminals
(Orange) – N/O
Contact Relay (Supplied by Others)
N
H
POWER PUMP(S) FROM INDEPENDENT FUSED CIRCUITS
(Orange) – N/O (Yellow)
Heating Pump
Pump Relay Terminals
SECTION 2 – INSTALLATION See Figures 2-14 and 2-15 for wiring details.
The Benchmark pump relay (SPDT) contact is rated for:
10 A Resistive @ 277 VAC/28 VDC
1/3 HP N/O @ 120/240 VAC
1/6 HP N/C @ 120/240 VAC
Figure 2-14: Schematic – System Pump Start using Boiler Pump Relay
If pump/valve load exceeds the above contact ratings, use a separate contact relay, as shown in Figure 2-15.
- COM
Figure 2-15: Schematic – System Pump Start using a Separate Contact Relay
2.15 SEQUENCING ISOLATION VALVE INSTALLATION
All Benchmark units are pre-wired with a connection for an optional motorized external sequencing isolation valve (P/N 92084-TAB). This valve is an integral component of the AERCO’s on-board Boiler Sequencing Technology (BST) solution. BST allows sites with multiple boilers to have one boiler, acting as a “Manager” to manage the other boilers at t he site, designed as “Clients” in such a way that the efficiency of the entire boiler array is maximized.
When operated with the BST system, the Manager controls its own isolation valve and sends signals to the Client units to open or close their isolation valves. After the boiler load is satisfied, the isolation valve opens for a programmed interval (default = 1 minute) before closing. When the system load is satisfied, the BST system will open the isolation valves for all of the boilers.
The implementation of BST, and the installation and use of this valve is optional. However, when BST is implemented , use of this valve is strongly recommended.
Installation consists of installing the sequencing isolation valve in the hot wat er outlet pipe, and then connecting it to the pre-wired connector on the shell harness, as described below.
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SEQUENCING ISOLATION V ALVE INSTALLATION Instructions
wire inserted in it (this jumper wire
HOT WATER
OUTLET
SEQUENCING
ISOLATION
MOLEX CONNECTOR
JUMPER
CAP
SECTION 2 – INSTALLATION
NOTE:
When the Sequencing Isolation Valve is used, the AUX START ON DLY in the Configuration menu must be set to 120 seconds (see Section 2.6: CONFIG URATION Menu, item 16, in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201)). The Sequencing Isolation Valve control is only available when BST is enabled. Refer to section
2.11.12.2 (wiring) and Section 6: Boiler Sequencing Technology in this guide, and Section 2.6:
CONFIGURATION Menu in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201).
1. Install the sequencing isolation valve in the boiler’s hot water outlet pipe (Figure 2-16).
Figure 2-16: Sequencing Isolation Valve Installed
2. Find the unused black cable, coiled inside the unit’s enclosure. One end is connected to the DELAYED INTERLOCK IN terminals in the I/O board, while the other end contains a Molex connector with a cap containing a jumper allows units that do not have a sequencing isolation valve to operate normally).
3. Remove the cap (with jumper wire attached) from the Molex connector and dispose of it.
Figure 2-17: Sequencing Isolation Valve Molex Connector and Jumper Wire
4. Plug the Molex connector into the sequencing isolation valve’s connector.
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SECTION 3 - START SEQUENCE
SECTION 3: START SEQUENCE
3.1 INTRODUCTION
The information in this Section provides a guide to starting the Benchmark Boiler using the C­More control panel mounted on the front of the unit. I t is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipm ent warranty. I n addition, the following WARNINGS and CAUTIONS must be observed at all times.
WARNING!
Electrical voltages in this system include 120 VAC (BMK 750 – 20000) or 208 or 460 VAC (BMK 2500/3000) and 24 volts AC. It must be serviced only by factory certified service technicians.
Do not attempt to dry fire the unit. Starting the unit without a full water level can seriously damage the unit and may result in injury to personnel or property damage. This situation will void any warranty.
CAUTION!
All of the installation procedures in Section 2 mus t be compl eted befor e attempt ing to star t the unit.
3.2 START SEQUENCE
When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge safety switches to ensure they are closed. These switches include:
Safety Shut-Off Valve (SSOV) Proof of Closure (POC) switch
Low Water Level switch
High Water Temperature switch
High Gas Pressure switch
Low Gas Pressure switch
NOTE:
The Blocked Inlet and downstream Blower Proof switches are not c hecked prior to starting the pre-purge.
If all of the above switches are closed, the READY light above the ON/OFF switch will lig ht and the unit will be in the STANDBY mode.
When there is a demand for heat, the following events will occur:
NOTE:
If any of the Pre-Purge safety device switches are open, the appropriate fault message will be displayed. Also, the appropriate messages will be displayed throughout the start sequence, if the required conditions are not observed
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START SEQUENCE:
SSOV
NATURAL GAS INLET
NATURAL GAS INLET
SECTION 3 - START SEQUENCE
1. Set the C-More control box ON/OFF switch is set to the ON position.
2. The DEMAND LED status indicator will lig h t.
3. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-1a through 3-1d for SSOV location.
TO AIR/FUEL VALVE
MANUAL SHUT-OFF VALVE
LOW GAS PRESSURE SWITCH
MANUAL SHUT-OFF VALVE
Figure 3-1a: BMK 750 & 1000 SSOV Location
TO
AIR/FUEL
VALVE
SSOV
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH
Figure 3-1b: BMK 1500 & 2000 SSOV Location
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
START SEQUENCE:
With all required safety device switches closed, a purge cycle will be initiated and the
open purge position and closes purge position
VALVE
NATURAL GAS INLET
LOW GAS SWITCH
NATURAL GAS INLET
SECTION 3 - START SEQUENCE
TO AIR/FUEL
MANUAL SHUT-OFF VALVE
VALVE
SSOV
LOW GAS PRESSURE SWITCH
TO AIR/FUEL
MANUAL
SHUT-OFF VALVE
HIGH GAS PRESSURE
SWITCH
Figure 3-1c: BMK 2500: SSOV Location
SSOV
PRESSURE
Figure 3-1d: BMK 3000: SSOV Location
4. following events will occur:
a. The Blower relay energizes and turns on the blower. b. The Air/Fuel Valve rotates to the full-
switch. The dial on the Air/Fuel Valve (Figure 3-2a and 3-2b) will read 100 to indicate that it is full-open (100%).
c. The VALVE POSITION bargraph will show 100%.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
START SEQUENCE:
TO BLOWER
STEPPER MOTOR
AIR IN
100
SECTION 3 - START SEQUENCE
STEPPER MOT OR
AIR INLET
TO
BLOWER
Figure 3-2a: BMK 750 & 1000 Air/Fuel Valve in Purge Position
PURGE
VALVE POSITION
DIAL AT 100%
Figure 3-2b: BMK 1500 – 3000 Air/Fuel Valve In Purge Position
5. Next, the blower proof switch on the Air/Fuel Valve (Figure 3-3a and 3-3b) closes. The display will show PURGING and indicate the elapsed time of the purge cycle in seconds.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
START SEQUENCE:
completion of the purge cycle, the Control Box initiates an ignition cycle and the
fire (Ignition Position) position and closes the
to indicate that the valve is in the low fire position.
AIR/FUEL VALVE OUTLET TO BLOWER
SECTION 3 - START SEQUENCE
BLOWER PROOF SWITCH
BLOCKED INLET SWITCH
Figure 3-3a: BMK 750 & 1000 Blower Proof Switch
BLOWER
PROOF
SWITCH
BLOCKED
INLET
SWITCH
AIR/FUEL VALVE INLET FROM GAS TRAIN
Figure 3-3b: BMK 1500 – 3000 Blower Proof Switch
6. Upon following events occur:
a) The Air/Fuel Valve rotates to the low-
ignition switch. The Dial on the Air/Fuel Valve (Figure 3-4) will read between 25 and 35
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
START SEQUENCE:
message. When the
will be displayed and the flame
valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed.
TO BLOWER
AIR IN
STEPPER MOTOR
SECTION 3 - START SEQUENCE
b) The “Spark Cycle Time” item in the Factory m en u can b e s et to e i t he r 0 Sec , 2 S ec or 7
Sec to define the duration of the Spark Element Cleaning Cycle. This cycle turns on the spark transformer to produce a spark (with no gas flowing) to clean t he spark element of moisture or carbon buildup.
c) For the duration of this cycle, the C-More will display the CLEANING IGNITER
message.
d) Following the Spark Element Cleaning Cycle, power is applied to the Gas Safety Shut-
off Valve (SSOV) and the C-More displays the PRE IGNITION SSOV indicates the Gas Valve is OPEN (POC), the C-More displays the IGNITION TRIAL message.
e) If no spark is present 3 seconds into the IGNITION TRIAL, the C-More will abort the
Ignition Cycle and shut down the boiler. Refer to Section 6: Troubleshooting Guide in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201) for guidance if this occurs.
IGNITION
VALVE POSITIO N
DIAL AT
25% to 35%
Figure 3-4: Air/Fuel Valve In Ignition Position
7. Up to 4 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected.
8. After 2 seconds of continuous flame, FLAME PROVEN strength will be indicated. After 5 seconds, the current date and time will be displayed in place of the flame strength.
9. With the unit firing properly, it will be controlled by the temperature controller circuitry. The boiler’s VALVE POSITION will be continuously displayed on the front panel bargraph.
10. Once the demand for heat has been satisfied, the Control Box will turn off the SSOV gas STANDBY will be displayed.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
TABLE 3-1a: Start/Stop Levels – NATURAL GAS
TABLE 3-1b: Start/Stop Levels – PROPANE GAS
SECTION 3 - START SEQUENCE
3.3 START/STOP LEVELS
The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows:
BMK 750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 Start Level: Stop Level:
BMK 750 BM K 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 Start Level: Stop Level:
Normally, these settings do not require adjustment. Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position.
22% 22% 24% 24% 24% 20% 18% 18% 16% 18% 16% 14%
22% 22% 24% 24% 26% 22% 18% 18% 18% 18% 18% 14%
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CAPACITY)
BMK 750
BMK 1000
BMK 750
BMK 1000
0% 0 0
0 0 10% 0 0
0
0
18% (Stop Level)
50,000 (14.7 kW)
50,000 (14.7 kW)
6.7%
5%
20%
52,000 (15.2 kW)
54,000 (15.8 kW)
6.9%
5.4%
30%
108,000 (31.7 kW)
140,000 (41.0 kW)
14%
14%
40%
246,000 (72.1 kW)
297,000 (87.0 kW)
33%
30%
50%
369,000 (108.1 kW)
443,000 (126.9 kW)
49%
44%
60%
465,000 (136.3 kW)
564,000 (165.3 kW)
62%
56%
70%
554,000 (162.4 kW)
660,000 (193.4 kW)
74%
66%
80%
637,000 (186.7 kW)
789,000 (231.2 kW)
85%
79%
90%
733,000 (214.8 kW)
933,000 (273.4 kW)
98%
93%
100%
750,000 (219.8 kW)
1,000,000 (293.1 kW)
100%
100%
BMK 750
BMK 1000
BMK 750
BMK 1000
0% 0 0
0 0 10% 0 0
0
0
18% (Stop Level)
50,000 (14.7 kW
50,000 (14.7 kW
6.7%
5.0%
20%
71,000 (20.8 kW)
71,000 (20.8 kW)
9.5%
7.1%
30%
128,000 (37.5 kW)
181,000 (53.0 kW)
17%
18%
40%
373,000 (109.3 kW)
400,000 (117.2 kW)
50%
40%
50%
508,000 (148.9 kW)
562,000 (164.7 kW)
68%
56%
60%
565,000 (165.6 kW)
703,000 (206.0 kW)
75%
70%
70%
621,000 (182.0 kW)
791,000 (231.8 kW)
83%
79%
80%
660,000 (193.4 kW)
865,000 (253.5 kW)
88%
87%
90%
723,000 (211.9 kW)
963,000 (282.2 kW)
96%
96%
100%
750,000 (219.8 kW)
1,000,000 (293.1 kW)
100%
100%
SECTION 3 - START SEQUENCE
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT
The Tables below show the relationship between the energy input and Air/Fuel Valve position for the BMK models covered in this document.
3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input
TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position – NATURAL GAS
AIR/FUEL VALVE
POSITION (%
OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY
INPUT (% OF FULL
TABLE 3-2b: BMK 750/1000 Air/Fuel Valve Position – PROPANE GAS
Air/Fuel Valve
Position (%
Open)
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Energy Input
(BTU/Hr)
Boiler Energy Input (% of Full Capacity)
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT (% OF FULL CAPACITY)
16% (Stop Level)
76,000 (22.3 kW)
5.0%
20%
127,000 (37.2 kW)
8.5%
30%
366,000 (107.2 kW)
24.4%
40%
629,000 (184.3 kW)
41.9%
50%
822,000 (240.9 kW)
54.7%
60%
977,000 (286.2 kW)
65.0%
70%
1,119,000 (327.9 kW)
74.5%
80%
1,255,000 (367.7 kW)
83.5%
90%
1,396,000 (409.0 kW)
92.9%
100%
1,502,000 (440.1 kW)
100%
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT (% OF FULL CAPACITY)
18% (Stop Level)
75,000
5.0%
20%
93,700
6.2%
30%
254,000
16.9%
40%
505,000
33.7%
50%
680,000
45.3%
60%
807,000
53.8%
70%
947,000
63.1%
80%
1,157,000
77.1%
90%
1,379,000
91.9%
100%
1,503,000
100%
SECTION 3 - START SEQUENCE
3.4.2 BMK 1500 Air/Fuel Valve Position and Energy Input
TABLE 3-3a: BMK 1500 Air/Fuel Valve Posi t ion – NATURAL GAS
TABLE 3-3b: BMK 1500 Air/Fue l Valve Position – PROPANE GAS
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT
(% OF FULL CAPACITY)
18% (Stop Level)
100,000 (29.3 kW)
6.7%
20%
143,000 (41.9 kW)
11%
30%
388,000 (113.7 kW)
23%
40%
759,000 (222.4 kW)
37%
50%
1,069,000 (313.2 kW)
51%
60%
1,283,000 (375.9 kW)
61%
70%
1,476,000 (432.5 kW)
74%
80%
1,675,000 (490.1 kW)
83%
90%
1,833,000 (537.1 kW)
93%
100%
2,000,000 (586.0 kW)
100%
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT (% OF FULL CAPACITY)
18% (Stop Level)
100,000
5.0%
20%
126,600
6.3%
30%
363,000
18.2%
40%
677,000
33.9%
50%
898,000
44.9%
60%
1,070,000
53.5%
70%
1,242,000
62.1%
80%
1,523,000
76.2%
90%
1,845,000
92.3%
100%
2,000,000
100%
SECTION 3 - START SEQUENCE
3.4.3 BMK 2000 Air/Fuel Valve Position and Energy Input
TABLE 3-4a: BMK 2000 Air/Fuel Valve Posi t ion – NATURAL GAS
TABLE 3-4b: BMK 2000 Air/Fue l Valve Position – PROPANE GAS
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT
(% OF FULL CAPACITY)
16% (Stop Level)
167,000 (48.9 kW)
6.7%
30%
430,000 (126.0 kW)
17%
40%
770,000 (225.7 kW)
31%
50%
1,440,000 (422.0 kW)
43%
60%
1,820,000 (533.4 kW)
58%
70%
1,815,000 (531.9 kW)
73%
80%
2,030,000 (594.9 kW)
81%
90%
2,300,000 (674.1 kW)
92%
100%
2,500,000 (732.7 kW)
100%
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT (% OF FULL CAPACITY)
18% (Stop Level)
155,000
6.2%
30%
400,000
16%
40%
808,000
32%
50%
1,055,000
42%
60%
1,330,000
53%
70%
1,671,000
67%
80%
1,998,000
80%
90%
2,280,000
91%
100%
2,500,000
100%
SECTION 3 - START SEQUENCE
3.4.4 BMK 2500 (Nat. Gas) Air/Fuel Valve Position and Energy Input
TABLE 3-5a: BMK 2500 Air/Fuel Valve Posi t ion – NATURAL GAS
TABLE 3-5b: BMK 2500 Air/Fue l Valve Position – PROPANE GAS
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR.)
BOILER ENERGY INPUT
(% OF FULL CAPACITY)
14% (Stop Level)
200,000 (58.6 kW)
6.7%
30%
520,000 (152 kW)
17%
40%
880,000 (258 kW)
29%
50%
1,270,000 (372 kW)
42%
60%
1,680,000 (492 kW)
56%
70%
2,100,000 (615 kW)
70%
80%
2,390,000 (700 kW)
80%
90%
2,650,000 (777 kW)
88%
100%
3,000,000 (879 kW)
100%
AIR/FUEL VALVE POSITION
(% OPEN)
ENERGY INPUT
(BTU/HR)
BOILER ENERGY INPUT (% OF FULL CAPACITY)
18% (Stop Level)
200,000
6.7%
30%
520,000
17%
40%
920,000
31%
50%
1,270,000
42%
60%
1,570,000
52%
70%
1,960,000
65%
80%
2,330,000
78%
90%
2,700,000
90%
100%
3,000,000
100%
SECTION 3 - START SEQUENCE
3.4.5 BMK 3000 Air/Fuel Valve Position and Energy Input
TABLE 3-6a: BMK 3000 Air/Fuel Valve Posi t ion – NATURAL GAS
TABLE 3-6b: BMK 3000 Air/Fue l Valve Position – PROPANE GAS
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 4 – INITIAL START-UP
SECTION 4: INITIAL START-UP
4.1 INITIAL START-UP REQUIREMENTS
The requirements for the initial st a rt-up of the Benchmark boiler consists of the following:
Complete the installation (Section 2: Installation)
Set proper controls and limits (Section 2: Operation of t he of t he Benchmark 750 – 3000
Platinum Operation and Maintenance Guide)
Perform combustion calibration (Section 4: Initial Start-Up)
Test safety devices (Section 5: Safety Device Testing)
All applicable installation procedures in Section 2: Installation must be fully completed prior to performing the initial start-up of the unit. The initial start-up must be successfully completed prior to putting the unit into service. Starting a unit without the proper piping, venting, or electrical systems can be dangerous and may void the product warranty. The following start-up instructions should be followed precisely in order to operate the unit safely and at a high thermal efficiency, with low flue gas emissions.
Initial unit start-up must be performed ONLY by AERCO factory trained start-up and service personnel. After performing the start-up procedures below, it will be necessary to perform the procedures in Section 5: Safety Device Testing, below, to complete all initial unit start-up requirements.
An AERCO Gas Fired Startup Sheet, included with each Benchmark unit, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO via e-mail at: STARTUP@AERCO.COM.
WARNING!
DO NOT ATTEMPT TO DRY FIRE THE UNIT. St arting the unit without a full water level can seriously damage the unit and may result in injury to personnel or property damage. This situation will void any warranty.
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION
To properly perform combustion calibration, the proper instruments and tools must be used and correctly attached to the unit. The following sections outline the necessary tools and instrumentation as well as their installation.
4.2.1 Required Tools & Instrumentation
The following tools and instrumentation are necessary to perform combustion calibration:
Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NO
0 t o 16 inch W.C. (0 to 4.0 kPa) m anomet er or equivalent gauge and plastic tubing.
1/4 inch NPT-to-barbed fittings for use with gas supply manometer or gauge.
Small and large flat blade screwdrivers.
Tube of silicone adhesive
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x
) resolution to 1PPM.
Page 58
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
GAS SUPPLY MANOMETER INSTALLATION Instructions
SSOV
SECTION 4 – INITIAL START-UP
4.2.2 Installing Gas Supply Manometer
The gas supply manometer (or gauge) is used to monitor the gas pressure on the downstream side of the SSOV during the Combustion Calibration procedures described in Section 5.4: Natural Gas Combustion Calibration or Section 5.5: Propane Combustion Calibration
The gas supply manometer is installed at the upstream and/or downstream location shown in Figure 4-1a through 4-1d.
To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration (in Section 4.4, below), install the 16” W.C. (4.0 kP a) manometer(s) as described in the following steps:
1. Turn off the main gas supply upstream of the unit.
2. Remove the top panel and front panel from the boiler to access the gas train components.
3. Remove the 1/4” NPT plug from the leak detection ball valve on the downstream side of the SSOV as shown in Figure 4-1a – 4-1d.
4. Install a NPT-to-barbed fitting into the tapped plug port.
5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16” W.C.
(4.0 kPa) manometer.
SHUT-OFF
NATURAL GAS INLET
MANUAL
VALVE
LEAK DETECTION BALL VALVE
TO AIR/FUEL VALVE
1/4” NTP PLUG (Install manometer here for combustion calibration)
Figure 4-1a: BMK 750 & 1000 1/4 Inch Gas Plug Location
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 4 – INITIAL START-UP
MANUAL
SHUT-OFF
VALVE
TO
AIR/FUEL
VALVE
SSOV
NATURAL GAS INLET
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH
Figure 4-1b: BMK 1500 & 2000 1/4 Inch Gas Plug Location
1/4” NPT PLUG
(Install manometer
here for Combustion
Calibration)
LEAK
DETECTION
BALL VALVE
MANUAL
SHUT-OFF
VALVE
LEAK DETECTION BALL VALVE
HIGH GAS PRESSURE SWITCH
TO AIR/FUEL VALVE
1/4” NPT PLUG (Install manometer here for Combustion Calibration)
NATURAL GAS INLET
SSOV
LOW GAS PRESSURE SWITCH
Figure 4-1c: BMK 2500 1/4 Inch Gas Plug Location
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
ANALYZER PROBE PORT AC CESS Instructions
NATURAL GAS INLET
TO
SECTION 4 – INITIAL START-UP
AIR/FUEL VALVE
SSOV
LOW GAS PRESSURE SWITCH
MANUAL
SHUT-OFF
VALVE
HIGH GAS
PRESSURE
SWITCH
LEAK DETECTION
BALL VALVE
1/4” NPT PLUG (Install manometer here for Combustion Calibration)
Figure 4-1d: BMK 3000 1/4 Inch Gas Plug Location
4.2.3 Accessing the Analyzer Probe Port
The unit contains a 1/4” NPT port on the side of the exhaust manifold as shown in Figure 3-2a and 3-2b. Prepare the port for the co
1. Refer to Figure 4-2a or 4-2b and remove the 1/4” NPT plug from the exhaust manifold.
2. If necessary, adjust the stop on the combustion analyzer probe so it will extend mid-way into the flue gas flow. DO NOT install the probe at this time.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
ANALYZER PROBE PORT AC CESS Instructions
PRIMARY HOT
EXHAUST MANIFOLD
ANALYZER PROB E
CONDENSATE DRAIN
DRAIN VALVE
CONDENSATE DRAIN
EXHAUST MANIFOLD
ANALYZER PROB E
PORT
PRIMARY HOT
SECTION 4 – INITIAL START-UP
WATER INLET
Figure 4-2a: BMK 750 & 1000 Analyzer Probe Port Location
WATER INLET
PORT
Figure 4-2b: BMK 1500 – 3000 Analyzer Probe Port Location
4.3 FUEL TYPES and COMBUSTION CALIBRATION
All BMK Platinum models may be preconfigured at the factory to use either natural gas or propane gas, and BMK models between 1500 and 3000 are available in dual fuel versions, allowing the installer/operator to switch between natural gas and propane gas onsite as needed.
Both fuel types require different combustion calibration values, and so c are should be taken to ensure the appropriate instructions are used for the fuel being used. Instructions for natural gas are presented first, then for propane after.
Instructions for switching between fuel types in dual fuel models is presented in sections after all combustion calibration instructions.
CAUTION!
Ensure the appropriate com bustion calibration instructions are used for the fuel being used in the boiler.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
BRASS HEX HEAD
SECTION 4 – INITIAL START-UP
4.4 COMBUSTION CALIBRATION
The Benchmark boiler is combustion calibrated with either standard combustion or Ultra-Low NO
(on the BMK 750/1000 only) at the factory, whichever was ordered, prior to shipping. This
x
gas pressure must be within the ranges shown in Table 4-1 for each model of boiler at full fire. Recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU
content, gas supply piping and supply regulators. Combustion Calibration Test Data sheet s are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.
IT IS IMPORTANT TO PERFORM THE COMBUSTION CALIBRATION PROCEDURE BELOW TO PROVIDE OPTIMUM PERFORMANCE AND KEEP READJUSTMENTS TO A MINIMUM.
For units running on NATURAL GAS, standard & Ultra-Low NO
For units running on PROPANE gas complete Section 4.4.2
(Remove to access Gas Pressure Adjustment Screw).
Figure 4-3: Gas Pressure Adjustment Screw Location
, complete Section 4.4.1
x
Figure 4-4: TAC Valve Adjust (Idle Screw)
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TAC VALVE
IDLE SCREW
Page 63
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
and then press
and the
brass hex nut on the SSOV actuator to access the gas pressure adjustment screw
TABLE 4-1: Nominal Gas Pressure – NATURAL GAS
BMK Model
Nominal Gas Pressure
BMK 750
2.0 W.C. ± 0.4” W.C. (498 ± 100 Pa)
BMK 1000
2.4 W.C. ± 0.4” W.C. (598 ± 100 Pa)
BMK 1500
BMK 2000
3.4” W.C. ± 0.2” W.C. (847 ± 50 Pa)
BMK 2500
2.1” W.C. ± 0.2” W.C. (523 Pa ± 50 Pa)
BMK 3000
2.1” W.C. ± 0.2” W.C. (523 Pa ± 50 Pa)
SECTION 4 – INITIAL START-UP
4.4.1 NATURAL GAS Combustion Calibration
NAT URAL GAS Combustion Cal ibration Instructions
These instructions apply only to units running on NATURAL GAS. Instructions for doing combustion calibration on a unit running PROPANE appear in the next section, 4.4.2.
1. Open the water supply and return valves to the unit and ensure that the system pumps
are running.
2. Open the NATURAL GAS supply valve to the unit.
3. Set the control panel ON/OFF switch to the OFF position
4. Turn on external AC power to the unit. The display will show a description of the unit and
then the time and date.
5. Press the MENU key on the front panel of the C-MORE and access the Setup menu,
enter the password 6817 and then press the ENTER key.
6. Set the unit to the MANUAL m ode by pressing the AUTO/MAN k ey. A flashing Manual
Valve Position message will be displayed with the present position in % and the MANUAL LED will light.
7. Adjust the air/fuel valve position to 0% by pressing the arrow key
ENTER.
8. Ensure that the leak detection ball valve downstream of the SSOV is open
manometer is attached and functioning properly.
9. Set the ON/OFF switch to the ON position.
10. Press the MENU key on the front panel of the C-MORE until COMBUSTION CAL MENU
appears on the display.
11. Press the Up ▲ arrow key until SET Stdby V Out (Standby Voltage) setting appears.
Verify that it is set t o 2.0 V (the default). AERCO recommends it be kept at 2.0 volts to prevent flue gas recirculation. Individually vented units in positive pressure boiler rooms may set SET Stdby V Out to 0 volts.
12. Press the Down ▼ arrow key until SET Valve Position appears, then press CHANGE.
13. Use the Up ▲ arrow key to change the valve position to 30%. The unit should begin its
start sequence and fire.
14. Next, verify that the gas pressure downstream of the SSOV is set to the value in Table 4-
1 for the model you are calibrating. If gas pressure adjustment is required, remove the (Figur e 4-3). Make gas pressure adjustments using a flat-tip screwdriver to obtain a gas
pressure approximately shown in Table 4-1.
3.6” W.C. ± 0.2” W.C. (897 ± 50 Pa)
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
, then
and your combustion
. Also,
TABLE 4-2: Calibration Readings at 100% – NATURAL GAS
Oxygen (O2)
%
Nitrogen
Oxide (NOx)
Oxygen (O2)
%
Nitrogen
Oxide (NOx)
turn increments) Clockwise to
the combustion analyzer to
SECTION 4 – INITIAL START-UP
NAT URAL GAS Combustion Cal ibration Instructions
15. Press the Down▼ arrow key until SET Valve Position appears on the display
press CHANGE.
16. Press the Up ▲ arrow key until the SET Valve Position reads 100%, then press
ENTER.
17. With the valve position at 100%, insert the combustion analyzer probe into the exhaust
manifold probe opening (see Figure 4-2a or 4-2b in Section 4.2.3) and allow enough time for the combustion analyzer reading to stabilize.
18. On Benchmark 3000 units only, write down the gas pressure at 100% fire rate. This
value will be used later when performing the High and Low Gas Pressure Tests in Section 5.2.2 and 5.3.2.
19. Compare the combustion analyzer’s oxygen readings to the O2 Sensor value displayed
in the Operating menu on the C-More Control Panel. The offset value in the Calibration menu can be adjusted by ±3% to make the o n-board O
sensor match the value from the
2
combustion analyzer. If the values differ by more than ±3% analyzer is correctly calibrated, the on-board O2 sensor may be defective and need to be replaced.
20. Compare the measured oxygen level to the oxygen range shown in Table 4-2
ensure that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the values shown in Table 4-2. If your target NO in the Ultra-Low NO NO
measurement in your analyzer, set the oxygen (O2) at 5.5% ± 0.5%.
x
Valve
columns. If you are not in a “NOx-limited” area and/or do not have a
x
Standard NOx Ultra-Low NOx
Position
value is 9 ppm or less, use the values
x
Carbon
Monoxide (CO)
100% 5.5% ± 0.5% ≤20 ppm 6.0% ± 1.0% 9 ppm <100 ppm
21. Next, press the Down ▼ arrow key until CAL Voltage 100% is displayed.
22. Press the CHANGE key and observe that CAL Voltage 100% is flashing.
23. The oxygen level at t he 100% valve position should match the value in Table 4-2. Also,
ensure that the NO
and CO readings do not exceed the values in Table 4-2.
x
24. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼
arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the Up ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level.
25. Once the oxygen level is wit hin the specified range at 100%, press the ENTER key to
store the selected blower output voltage for the 100% valve position. Record all readings on the Combustion Calibration Sheets provided.
26. With the valve position at 100%, if the oxygen level is not within the required tolerance
after adjusting the blower voltage, then the gas pressure on t he downst ream side of t he SSOV must be adjusted using the gas pr essure adjustment screw on the SSOV (Figure 4-3). Slowly rotate the gas pressure adjustment in 1/4­reduce O2 level or counterclockwise to increase it. Allow stabilize following each adjustment.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
TABLE 4-3a: BMK 750/1000 Final Valve Positions – NATURAL GAS
Carbon
Oxygen (O2)
%
Nitrogen
Oxide (NOx)
Oxygen (O2)
%
Nitrogen
Oxide (NOx)
45%
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤09 ppm
<100 ppm
30%
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤09 ppm
<100 ppm
18% *
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤09 ppm
<100 ppm
TABLE 4-3b: BMK 1500-3000 Final Valve Positions – NATUR AL G AS
Valve
Position
Nitrogen Oxide
(NOx)
Carbon Monoxide
(CO)
1500 – 3000
1500 – 3000
1500 – 3000
1500 – 3000
2000
18% *
6.0% ± 0.5
<20 ppm
<100 ppm
1500, 2500
16%
6.0% ± 0.5
<20 ppm
<100 ppm
3000
14%
6.0% ± 0.5
<20 ppm
<100 ppm
SECTION 4 – INITIAL START-UP
NAT URAL GAS Combustion Cal ibration Instructions
27. Once the oxygen level is wit hin the specified range at 100%, record the O2, NOx and CO
readings on the Combustion Calibration Data Sheets provided with the unit.
28. Press the Up ▲ arrow key until SET Valve Position appears and then press CHANGE.
29. Use the Down ▼arrow key to lower the valve position to one of the following:
BMK 750 & 1000: 80%
BMK 1500 – 3000: 70%
NOTE:
Remaining combustion calibration steps are performed using the Combustion Cal menu in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve position percentages described in the steps below. These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). If NOx readings exceed the target values in Table 4-2, above, increase the O2 level up to 1% higher than the listed calibration range. Record the increased O2 value on the Combustion Calibration sheet.
30. Repeat steps 21 thro ugh 25 for valve positions shown in Table 4-3a (BMK 750 & 1000)
and Table 4-3b (BMK 1500-3000). T he O shown Table 4-3a and Table 4-3b.
, NOx and CO should stay within the ranges
2
BMK
Model
Position
750 &
1000
BMK Model
Valve
Standard NOx Ultra-Low NOx
80% 5.5% ± 0.5% <20 ppm 60% 5.5% ± 0.5% <20 ppm
Oxygen (O2) %
70% 5.9% ± 0.5% ≤20 ppm
50% 6.0% ± 0.5 40% 6.3% ± 0.5 <20 ppm <100 ppm 30% 6.3% ± 0.5 <20 ppm <100 ppm
Monoxide
(CO)
6.0% ± 1.0% ≤09 ppm <100 ppm
6.0% ± 1.0% ≤09 ppm <100 ppm
<100 ppm
<20 ppm
<100 ppm
* NOTE:
Set the Valve Position at 18% but make adjustments to the Combustion Calibration value designated as 16%.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 4 – INITIAL START-UP
NAT URAL GAS Combustion Cal ibration Instructions
NOTE:
If NOx r eadings exceed the target values in Table 4-3a or 4-3b, increase the O2 level up to 1% higher than the listed calibration range shown in the table. Record the increased O2 value on the Combustion Calibration sheet.
31. If the oxygen level at the lowest valve position (14%, 16% or 18%) is too high and the
Blower voltage is at the minimum value, you can adjust the idle screw (TAC valve) which is recessed in the top of the Air/Fuel Valve (see Figure 4-4). Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce the O be performed again from 60% down to the lowest valve posit ion after mak ing a change to the idle screw (TAC valve).
32. This completes the NATURAL GAS combustion calibration procedure.
to the specified level. Recalibration MUST
2
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
arrow key and then press
brass hex nut on the SSOV actuator to access the gas pressure adjustment screw
BMK Model
Nominal Gas Pressure
BMK 750P
3.9” ± 0.2” W.C. (0.97 kPa ± 50 Pa)
BMK 1000P
7.4” ± 0.2” W.C. (1.84 kPa ± 50 Pa)
1500DF & 1500P
1.4 ± 0.2” W.C. (349 Pa ± 50 Pa)
2000DF & 2000P
2.5 ± 0.2” W.C. (623 Pa ± 50 Pa)
2500DF & 2500P
2.0 ± 0.2” W.C. (498 Pa ± 50 Pa)
appears on the display, then
SECTION 4 – INITIAL START-UP
4.4.2 PROPANE GAS COMBUSTION CALIBRATION
PROPANE Combustion Calibration Instr uc t ions
These instructions apply only to units running PROPANE gas. Instructions for doing combustion calibration on a unit running Natural Gas appear in the previous section, 4.4.1.
1. Open the water supply and return valves to the unit and ensure that the system pumps
are running.
2. Open the PROPANE supply valve to the unit.
3. Set the control panel ON/OFF switch to the OFF position
4. Turn on external AC power to the unit. The display will show a description of the unit and
then the time and date.
5. Press the MENU key on the front panel of the C-MORE and access the Setup menu,
enter the password 6817 and then press the ENTER key.
6. Set the unit to the MANUAL mode by pressing the AUTO/MAN key. A flashing Manual
Valve Position message will be displayed with the present position in % and the MANUAL LED will light.
7. Adjust the air/fuel valve position to 0% by pressing the
ENTER.
8. Ensure that the leak detection ball valve downstream of the SSOV is open and the
manometer is attached and functioning properly.
9. Set the ON/OFF switch to the ON position.
10. Press the MENU key on the front panel of the C-MORE until COMBUSTION CAL MENU
appears on the display.
11. Press the Up ▲ arrow key until SET Stdby V Out (Standby Voltage) setting appears.
Verify that it is set t o 2.0 V (the default). AERCO recommends it be kept at 2.0 volts to prevent flue gas recirculation. Individually vented units in positive pressure boiler rooms may set SET Stdby V Out to 0 volts.
12. Press the Down ▼ arrow key until SET Valve Position appears, then press CHANGE.
13. Use the Up ▲ arrow key to change the valve position to 30%. The unit should begin its
start sequence and fire.
14. Next, verify that the gas pressure downstream of the SSOV is set to the value in Table 4-
4 for the model you are calibrating. If gas pressure adjustment is required, remove the (Figur e 4-3). Make gas pressure adjustments using a flat-tip screwdriver to obtain a gas
pressure approximately shown in Table 4-4.
TABLE 4-4: Nominal Gas Pressure – PROPANE Gas
3000DF & 3000P 1. 6 ± 0.2” W.C. (399 Pa ± 50 Pa)
15. Press the Down▼ arrow key until SET Valve Position
press CHANGE.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
, then press
on 5.2.2 and
and your combustion
5. Also,
TABLE 4-5: Calibration Rea dings – PROPANE
Model
Oxygen (O2) %
Nitrogen Oxide (NOx)
Carbon Monoxide (CO)
750 & 1000
5.5% ± 0.5%
<30 ppm
<100 ppm
1500/2000
4.5% ± 0.5%
≤50 ppm
<150 ppm
2500
5.0% ± 0.4%
≤100 ppm
<150 ppm
3000
5.2% ± 0.4%
≤100 ppm
<150 ppm
5. Also,
side of the SSOV must be adjusted using the gas pressure adjustment screw on the
turn increments)
e combustion
SECTION 4 – INITIAL START-UP
PROPANE Combustion Calibration Instr uc t ions
16. Press the Up ▲ arrow key until the SET Valve Position reads 100%
ENTER.
17. With the valve position at 100%, insert the combustion analyzer probe into the exhaust
manifold probe opening (see Figure 4-2a or 4-2b in Section 4.2.3) and allow enough time for the combustion analyzer reading to stabilize.
18. On Benchmark 3000 units only, record the gas pressure at 100% fire rate. This value wil l
be used when performing the High and Low gas pressure tests in secti
5.3.2, below.
19. Compare the combustion analyzer’s oxygen readings to the O2 Sensor value displayed
in the Operating menu on the C-More Control Panel. The offset value in the Calibration menu can be adjusted by ±3% to make the o n-board O
sensor match the value from the
2
combustion analyzer. If the values differ by more than ±3% analyzer is correctly calibrated, the on-board O2 sensor may be defective and need to be replaced
20. Compare the measured oxygen level to the oxygen range shown in Table 4-
ensure that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the values shown in Table 4-5. If you are not in a “NO NO
measurement in your analyzer, set the oxygen (O2) at 5.5% ± 0.5%.
x
-limited” area and/or do not have a
x
21. Next, press the Down ▼ arrow key until CAL Voltage 100% is displayed.
22. Press the CHANGE key and observe that CAL Voltage 100% is flashing.
23. The oxygen level at the 100% valve position should be as shown in Table 4-
ensure that the NOx and CO readings do not exceed the values shown in Table 4-5.
24. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼
arrow keys. This will adjust the output voltage to the blower motor as indicated on the
display. Pressing the Up ▲ arrow key increases the oxygen level and pressing the down
▼ arrow key decreases the oxygen level.
25. Once the oxygen level is wit hin the specified range at 100%, press the ENTER key to
store the selected blower output voltage for the 100% valve position. Record all readings on the Combustion Calibration Sheets provided.
26. With the unit running at 100% valve pos ition, if the oxygen level is not within the required
tolerance after adjusting the blower voltage, then the gas pressure on the downstream SSOV (Figure 4-3). Slowly rotate the gas pressure adjustment in 1/4-
Clockwise to reduce O2 level or counterclockwise to increase it. Allow th analyzer to stabilize following each adjustment.
27. Once the oxygen level is wit hin the specified range at 100%, record the O2, NOx and CO
readings on the Combustion Calibration Data Sheets provided with the unit.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
TABLE 4-6: Final Valve Positions – PROPANE
Valve Position
Oxygen (O2) %
Nitrogen oxide (NOx)
Carbon Monoxide (CO)
BMK 750/1000
80%
5.5% ± 0.5%
<30 ppm
<100 ppm
60%
5.5% ± 0.5%
<30 ppm
<100 ppm
45%
5.5% ± 0.5%
<30 ppm
<100 ppm
30%
6.3% ± 0.5%
<30 ppm
<100 ppm
18%
5.5% ± 0.5%
<30 ppm
<100 ppm
BMK 1500/2000
70%
4.5% ± 0.5%
≤50 ppm
<150 ppm
50%
5.5% ± 0.5%
<50 PPM
<150 PPM
40%
5.5% ± 0.5%
<50 PPM
<150 PPM
30%
6.3% ± 0.5%
<50 PPM
<150 PPM
18%
6.0% ± 0.5%
<50 PPM
<150 PPM
BMK 2500
70%
5.4% ± 0.4%
≤100 ppm
<150 ppm
45%
5.6% ± 0.3%
<100 PPM
<150 PPM
30%
6.0% ± 0.3%
<100 PPM
<100 PPM
22%
5.8% ± 0.3%
<100 PPM
<100 PPM
18%
6.0% ± 0.3%
<100 PPM
<100 PPM
BMK 3000
85%
5.2% ± 0.4%
≤100 ppm
<150 ppm
65%
5.4% ± 0.3%
<100 PPM
<150 PPM
45%
6.0% ± 0.3%
<100 PPM
<100 PPM
30%
6.4% ± 0.3%
<100 PPM
<100 PPM
18%
6.4% ± 0.3%
<100 PPM
<100 PPM
SECTION 4 – INITIAL START-UP
PROPANE Combustion Calibration Instr uc t ions
28. Press the Up ▲ arrow key until SET Valve Position appears and then press CHANGE.
29. Use the Down ▼arrow key to lower the valve position to one of the following:
BMK 750P & 1000P: 80%
BMK 1500/2000/2500 DF & P: 70%
BMK 3000 DF & P: 85%
NOTE:
Remaining combustion calibration steps are performed using the Combustion Cal menu in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve position percentages described in the steps below. These instructions assume that the inlet air temperature is between 50°F and 100°F (10°C – 37.8°C). If NOx readings exceed the target values in Table 4-5, above, increase the O2 level up to 1% higher than the listed calibration range. Record the increased O2 value on the Combustion Calibration sheet.
30. Repeat steps 21 through 25 for valve positions shown in Table 4-6. The oxygen (O2),
nitrogen oxide (NO Table 4-6.
) and carbon monoxide (CO) should stay within the ranges shown
x
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
from 60% down to the lowest valve position after making a change to the idle screw
SECTION 4 – INITIAL START-UP
PROPANE Combustion Calibration Instr uc t ions
* NOTE:
Set the Valve Position at 18% but make adjustments to the Combustion Calibration value designated as 16%.
NOTE:
If NOx readings exceed the target values in Table 4-6, increase the O2 level up to 1% higher than the listed calibration range shown in the table. Record the increased O2 value on the Combustion Calibration sheet.
31. If the oxygen level at the 18% valve posit ion is too high and the Blower voltage is at the
minimum value, you can adjust the idle screw (TAC valve) which is recessed in the top of the Air/Fuel Valve (see Figure 4-4). Rotate the screw 1/2 turn clockwise (CW ) to add fuel and reduce the O
(TAC valve ).
32. This completes the PROPANE gas combustion calibration procedure.
to the specified level. Recalibration MUST be performed again
2
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
REASSEMBLY Instructions
and barbed fittings and reinstall the NPT plug using a suitable
FUEL SELECTOR
SWITCH
C-MORE CONTROLLER
SECTION 4 – INITIAL START-UP
4.5 REASSEMBLY
Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation.
1. Set the ON/OFF switch in the OFF position.
2. Disconnect AC power from the unit.
3. Shut off the gas supply to the unit.
4. Remove the manometer pipe thread compound.
5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold and then replace the 1/4” NPT plug in the vent hole.
6. Replace all previously removed sheet metal enclosures on the unit.
7. This concludes reassembly of the unit after combustion calibration.
4.6 DUAL FUEL SWITCHOVER
Dual Fuel models contain a fuel selector switch, located on the Temperature Limit panel. The location of this panel on BMK 1500 – 3000 units is shown in Figure 4-5, below; for the location of this panel on BMK 750 and 1000 units see Figure 4-6a in Section 4.7.
Instructions for switching from one fuel to the other are in Sections 4.6.1 and 4.6.2.
PARTIAL FRO NT VIEW WITH FRONT COVER REMOVED
Figure 4-5: Dual Fuel Switch Location – BMK 1500-3000 Shown
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
Switchover from NATURAL GAS to PROPANE Instructions
will be displayed, indicating that the valid Level 1 password has been
SECTION 4 – INITIAL START-UP
4.6.1 Switchover from NATURAL GAS to PROPANE
1. Set the ON/OFF switch on the C-More Controller to the OFF position.
2. Close the external Natural Gas supply valves.
3. Open the external Propane gas supply valves.
4. Refer to Figure 4-5 and locate the Fuel Selector Switch on the unit, behind the front door.
5. Set the Fuel Selector Switch to the PROPANE position. A GAS PRESSURE FAULT message will be displayed on the Control Box.
6. Clear the Gas Pressure Fault by pressing the CLEAR key.
7. Set the ON/OFF switch on the C-More /control Box to the ON position.
8. Press the MENU key once. SETUP MENU will be displayed.
9. Press the ▲ arrow key once. PASSWORD will be displayed.
10. Press the CHANGE key. PASSWORD will begin to flash.
11. Using the ▲ arrow key, increment the display and stop at 159.
12. Press the ENTER key to store the displayed password.
13. PASSWORD 1 stored.
14. Next, access the Configuration menu by pressing the MENU key once.
15. Using the ▲ and ▼ arrow keys, scroll through the Configuration menu and stop at Fuel Type.
16. Press the CHANGE key. FUEL TYPE will begin to flash.
17. Press the ▲ arrow key. PROPANE will be displayed.
18. Press the ENTER key to store the Propane Fuel type.
19. Replace the front door panel previously removed from the boiler.
20. This completes the switchover from NATURAL GAS to PROPANE.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
Switchover from PROPANE to N ATURAL GAS Instructions
will be displayed, indicating that the valid Level 1 password has been
This completes the steps necessary to switch from PROPANE Gas to NATURAL
SECTION 4 – INITIAL START-UP
4.6.2 Switchover from PROPANE to NATURAL GAS
1. Set the ON/OFF switch on the C-More Controller to the OFF position.
2. Close the external Propane Gas supply valves.
3. Open the external Natural Gas supply valves.
4. Refer to Figure 4-5 and locate the Fuel Selector Switch on the front of the unit.
5. Set the Fuel Selector Switch to the NATU RAL G AS position. A GAS PRESSURE FAULT message will be displayed on the Control Box.
6. Clear the Gas Pressure Fault by pressing the CLEAR key.
7. Apply AC power to the boiler.
8. Press the MENU key once. SETUP MENU will be displayed.
9. Press the ▲ arrow key once. PASSWORD will be displayed.
10. Press the CHANGE key. PASSWORD will begin to flash.
11. Using the ▲ arrow key, increment the display and stop at 159.
12. Press the ENTER key to store the displayed password.
13. PASSWORD 1 stored.
14. Next, access the Configuration menu by pressing the MENU key once.
15. Using the ▲ and ▼ arrow keys, scroll through the Configuration menu and stop at FUEL TYPE.
16. Press the CHANGE key. FUEL TYPE will begin to flash.
17. Press the ▼ arrow key. NATURAL GAS will be displayed.
18. Press the ENTER key to store the Natural Gas Fuel type.
19. Replace the front door panel previously removed from the boiler.
20.
GAS.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
MANUAL TEMPERATURE LIMIT
DIGITAL OVER­RESET BUTTON FOR MANUAL
MANUAL
LIMIT SWITCH
ADJUSTABLE
DIGITAL OVER-TEMPERATURE LIMIT CONTROLLER
ADJUSTABLE TEMPERATURE LIMIT SWITCH (AUTO-REST)
RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH
SECTION 4 – INITIAL START-UP
4.7 OVER-TEMPERATURE LIMIT SWITCHES
The unit contains three (3) types of over-temperature limit controls. These controls consist of a
Manual Reset button, a rotary adjustable Temperature Limit switch and a digital Over­Temperature Alarm button. These controls are mounted on a plate as shown in Figure 4-6a
and 4-6b. They can be accessed by opening the front panel door of the unit . The Manual Reset button is not adjustable and is permanently fixed at 210°F (98.9°C). Thi s
button will shut down and lock out the boiler if the water temperature exceeds 210°F (98.9°C). Following an over-temperature condition, it must be manually reset by pressing the Manual Reset button shown in Figure 4-6a and 4-6b before the boiler can be restarted.
The adjustable Temperature Limit switch is manually adjustable from 32ºF - 212ºF (0ºC – 100ºC). This switch allows the boiler to restart, once the temperature drops below the selected temperature setting on the dial. Set the dial on this switch to the desired setting.
The digital Over-Temperature Alarm switch shown in Figure 4-6a, 4-6b and 4-7 is pre s et at t h e factory to 210ºF (98.9°C) and should not be changed. If an over-temperature condition is detected, this switch automatically shuts down the boiler and sounds an audible alarm. If desired, the Over-Temperature Alarm can be checked or adjusted using the procedure in section 4.7.1.
Figure 4-6a: BMK 750 & 1000 Over-Temperature Limit Switch Location
TEMPERATURE
TEMPERATURE
LIMIT SWITCH
(AUTO-REST)
TEMPERATURE LIMIT SWITCH
TEMPERATURE LIMIT CONTROLLER
Figure 4-6b: BMK 1500 – 3000 Over-Temperature Limit Switch Location
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SWITCH
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
CONTROL/DISPLAY
MEANING
FUNCTION
LED Display
TEMP status
Displays current water temperature or setpoint.
RST
RESET Button
Resets the unit after an alarm condition.
UP Button
Increases the displayed temperature.
DOWN Button
Decreases the displayed temperature.
SET
SET Button
Used to access and store parameters in the unit.
OVER-TEMP ALARM SWITCH CHECK and ADJUSTMENT Instructions
will appear in the
mode has been exited, the display will show the current outlet
SECTION 4 – INITIAL START-UP
4.7.1 Digital Alarm Switch Checks and Adjustments
The Over-Temperature Alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4-7 and Table 4-9.
Figure 4-7: Digital Over-Temperature Alarm Switch Front Panel
Table 4-9: Over-Temperature Alarm Switch Controls and Display
Perform the following steps to check or adjust the Over-Temperature Alarm switch settings:
1. Set the ON/OFF switch to the ON position.
2. Press the SET button on the Over-Temperature Alarm switch. SP
display.
3. Press the SET button again. The current over-temperature limit value stored in memory will
be displayed. (Default = 210°F, 98.9°C).
4. If the display does not show the required over-temperature alarm setting, press the ▲ or ▼
arrow button to change the display to the desired temperature setting.
5. Once the desired over-temperature alarm setting (210ºF) is displayed, press the SET
button to store the setting in memory.
6. To calibrate the offset (P1), press and hold the SET button on the Over-Temperatur e Alarm
switch for 8 seconds. Access code value 0 should appear in the display. The switch comes from the factory with the code set at 0. AERCO recommends that you do not change t his code.
7. Press the SET button again to enter the code. The first parameter label, SP, will appear in the display.
8. Using the ▲ and ▼ arrow keys, select parameter P1.
9. Press SET to view the value stored in memory.
10. If the desired value is not displayed, modify the setting using the ▲ and ▼ arrow keys. The
value can be changed from -10° to +10° (-5.5°C to + 5.5°C) of fset. Press SET to en ter the value and exit to the text parameter.
11. To exit the programming mode, press the SET and ▼ buttons simultaneously or simply
wait one minute and the display will automatically exit the programming mode.
12. Once the programming
water temperature of the boiler.
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SECTION 4 – INITIAL START-UP
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SECTION 5 – SAFETY DEVICE TESTING
SECTION 5: SAFETY DEVICE TESTING
5.1 TESTING OF SAFETY DEVICES
Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion­related safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.
Operating controls and safety devices should be tested on a regular basis or following service or replacement. All testing must conform to local codes such as ASME CSD-1.
NOTES:
MANUAL and AUTO modes of operation are required to perform the following tests. For a complete explanation of these modes, see Section 3: Modes of Operation in the Benchmark 750 – 3000 Platinum Operation and Maintenance Guide, OMM-0116 (GF-201).
It is necessary to remove the front door and side panels from the unit to perform the tests described below.
WARNING!
Electrical voltages in this system include 120 VAC (BMK 750 – 20000) or 208 or 460 VAC (BMK 2500/3000) and 24 volts AC. Power must be removed prior to performing wire removal or other test procedures that can result in electrical shock.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
LOW GAS PRESSURE TEST Instructions: BMK 750 – 2500
TABLE 5-1: LOW Gas Pressure,
Benchmark Model
Natural Gas
Propane
BMK 2500 DBB Dual-Fuel
7.5” W.C. (1,868 Pa)
3.6” W.C. (897 Pa)
SECTION 5 – SAFETY DEVICE TESTING
5.2 LOW GAS PRESSURE TEST
Complete the instructions in Section 5.2.1 for BMK 750 – 2500 units, or in Section 5.2.2 for BMK 3000 units, which have different Low and High Gas Pressure swi tches.
5.2.1 LOW GAS PRESSURE TEST: BMK 750 – 2500
To simulate a low gas pressure fault, refer to Figure 5-1a, 5-1b or 5-1c and perform the following steps:
1. Close the leak detection ball valve located at the Low Gas Pressure switch.
2. Remove the 1/4" NPT plug from the ball valve at the Low Gas Pressure switch.
3. Install a 0 - 16” W.C. (0 – 4.0 kPa) manometer or gauge where the 1/4" plug was removed.
4. Slowly open the ball valve near the Low Gas Pressure switch.
5. Press the MENU key on the front panel of the C-MORE and access the Setup menu, enter the password 6817 and then press the ENTER key.
6. Place the unit in MANUAL mode and adjust the Air/Fuel Valve position (% open) between 25% and 30%.
7. While the unit is firing, slowly close the external manual gas shut-off valve (not shown).
8. The unit should shut down and display a GAS PRESSURE fault message at approximately the pressure shown in Table 5-1 (the pressure setting of the LOW Gas Pressure switch):
± 0.2” W.C. (± 50 Pa)
BMK 750/1000 FM & DBB Single-Fuel 2.6” W.C. (648 Pa) 7.5” W.C. (1,868 Pa) BMK 1500/2000 FM & DBB Single-Fuel 3.6” W.C. (897 Pa)
BMK 1500/2000 Dual-Fuel 4.4” W.C. (1,096 Pa) 2.6” W.C. (648 Pa) BMK 1500/2000 DBB Dual-Fuel 2.6” W.C. (648 Pa) 2.6” W.C. (648 Pa)
BMK 2500 FM & DBB Single-Fuel 3.6” W.C. (897 Pa) – BMK 2500 Dual-Fuel 7.5” W.C. (1,868 Pa) 3.6” W.C. (897 Pa)
BMK 3000 FM & DBB Single-Fuel 2.6” W.C. (648 Pa) – BMK 3000 Dual-Fuel 7.5” W.C. (1,868 Pa) 2.6” W.C. (648 Pa) BMK 3000 DBB Dual-Fuel 7.5” W.C. (1,868 Pa) 2.6” W.C. (648 Pa)
9. Fully open the external manual gas shut-off valve (not shown) and press the CLEAR button on the Control Box.
10. The fault message should clear and the FAULT indicat or should go off. The unit should restart.
11. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
LOW GAS PRESSURE TEST Instructions: BMK 750 – 2500
SSOV
GAS INLET
(shown closed)
LOW GAS PRESSURE SWITCH
1/4” NPT PLUG
NATURAL GAS INLET
1/4” NPT PLUG
LOW GAS BALL VALVE
SECTION 5 – SAFETY DEVICE TESTING
TO AIR/FUEL
MANUAL SHUT-OFF
VALVE
HIGH GAS PRESSURE
SWITCH
VALVE
Install manometer here for LOW gas pressure fault test.
Figure 5-1a: BMK 750/1000 LOW Gas Pressure Test Components
MANUAL SHUT-OFF VALVE
TO
AIR/FUEL
VALVE
HIGH GAS
PRESSURE
SWITCH
LOW GAS PRESSURE LEAK DETECTION BALL VALVE
SSOV
LOW GAS PRESSURE SWITCH
Install manometer here for LOW gas pressure fault test.
Figure 5-1b: BMK 1500/2000 LOW Gas Pressure Test Components
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
LOW GAS PRESSURE TEST Instructions: BMK 750 – 2500
Figure 5-1c: BMK 2500 LOW Gas Pressure Test Components
LOW GAS PRESSURE TEST Instructions: BM K 3 0 0 0 Only
LOW GAS BALL VALVE
NATURAL GAS INLET
SECTION 5 – SAFETY DEVICE TESTING
HIGH GAS PRESSURE SWITCH
SSOV
TO AIR/FUEL
VALVE MANUAL SHUT-OFF VALVE
LOW GAS PRESSURE SWITCH
1/4” NPT PLUG Install manometer here for LOW gas pressure fault test.
5.2.2 LOW GAS PRESSURE TEST: BMK 3000 Only
To simulate a low gas pressure fault on BMK 3000 units, refer to Figure 5-2, below, and perform the following steps:
1. Close the external gas supply ball valve (not shown) upstream of the unit.
2. Locate the port on the top of the Low Gas Pressure switch (see Figure 5-2, below) and loosen the screw inside a few turns to open it. Do not remove this screw completely. Alternatively, you can remove the 1/4 inch plug shown in Figure 5-2 and install a hose barb fitting in that location.
3. Attach one end of the plastic tubing to the port or barb fitting and the other end to a 16” W.C. ( 0 – 4.0 kPa) manometer.
4. Apply the reading of the manifold pressure taken in Step 18 of sectio n 4. 4.1 (nat ur al g as units) or Step 18 of section 4.4.2 (propane units) and plug it into the following formula, which calculates the minimum allowable gas pressure:
FM Natural Gas pressure ____ x 0.5 + 0.7 = ______ min gas pressure
DBB Natural Gas pressure ____ x 0.5 + 1.6 = ______ min gas pressure
Propane Gas pressure ____ x 0.5 + 0.6 = ______ min gas pressure
5. Remove the cover from the Low Gas Pressure switch and set the dial indicator to 2 (the minimum).
6. Open the external gas supply ball valve (not shown) upstream of the unit.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
LOW GAS PRESSURE TEST Instructions: BM K 3 0 0 0 Only
Place the unit in MANUAL mode and adjust the Air/Fuel Valve position (% open) to
While the unit is firing, read the CO value on the combustion analyzer and slowly
Take a reading of the inlet gas pressure. If the inlet pressure is below the minimum calculated in step 4, above, then increase the pressure to match the calculated
TO
MANUAL SHUT-
SSOV
LOW Gas
Low Gas Pressure test
Alternative
Pressure Port
NATURAL GAS INLET
SECTION 5 – SAFETY DEVICE TESTING
7. Press the MENU key on the front panel of the C-MORE and access the Setup menu, enter the password 6817 and then press the ENTER key.
8. 100%.
9. decrease the incoming gas supply pressure until the CO reading is approximately 300 ppm.
10. minimum.
11. Slowly turn the indicator dial on the Low Gas Pressure switch until the unit shuts down due to a gas pressure fault.
12. Readjust the inlet gas pressure to what it was pr ior to the test.
13. Press the CLEAR button on the control panel to clear the fault.
14. The fault message should clear and the FAULT indicator should go off. The unit should now restart.
OFF VALVE
AIR/FUEL
VALVE
Pressure Port
Install manometer here for
LOW GAS PRESSURE SWITCH
LOW GAS BALL VALVE
HIGH GAS
PRESSURE
SWITCH
Figure 5-2: BMK 3000 LOW and HIGH Gas Pressure Test Components
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LOW Gas
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
HIGH GAS PRESSURE TEST Instructi ons : BMK 750 – 2500
indicator should start flashing and the unit should shut down and display a
TABLE 5-2: HIGH Gas Pressure, ± 0.2” W.C. (± 50 Pa)
Benchmark Model
Natural Gas
Propane
BMK 750/1000 FM & DBB Single-Fuel
4.7” W.C. (1.17 KPa)
4.7” W.C. (1.17 KPa)
BMK 1500/2000 Single-Fuel
4.7” W.C. (1.17 KPa)
BMK 1500/2000 DBB Single-Fuel
4.7” W.C. (1.17 KPa)
BMK 1500/2000 Dual-Fuel
4.7” W.C. (1.17 KPa)
4.7” W.C. (1.17 KPa)
BMK 1500/2000 DBB Dual-Fuel
3.5” W.C. (0.87 kPa)
3.5” W.C. (0.87 kPa)
BMK 2500 FM & DBB Single-Fuel
3.0” W.C. (0.75 kPa)
BMK 2500 Dual-Fuel
7.0” W.C. (1,74 kPa)
2.6” W.C. (0.65 kPa)
BMK 2500 DBB Dual-Fuel
7.0” W.C. (1,74 kPa)
2.6” W.C. (0.65 kPa)
BMK 3000 FM & DBB Single-Fuel
3.0” W.C. (0.75 kPa)
BMK 3000 Dual-Fuel
6.6” W.C. (1,64 kPa)
2.6” W.C. (0.65 kPa)
BMK 3000 DBB Dual-Fuel
6.6” W.C. (1,64 kPa)
2.6” W.C. (0.65 kPa)
by returning the SSOV adjustment screw back to its position
SECTION 5 – SAFETY DEVICE TESTING
5.3 HIGH GAS PRESSURE TEST
Complete the instructions in Section 5.3.1 for BMK 750 – 2500 units, or in Section 5.3.2 for BMK 3000 units, which have different High Gas Pressure switches.
5.3.1 HIGH GAS PRESSURE TEST: BMK 750 – 2500
To simulate a high gas pressure fault, refer to Figure 5-3a through 5-3c and perform the following steps:
1. Close the leak detection ball valve located at the High Gas Pressure switch.
2. Remove the 1/4" NPT plug from the High Gas pressure leak detection ball valve shown in Figures 5-3a through 5-3c.
3. Install a 0 - 16” W.C. (0 – 4.0 kPa) manometer or gauge where the 1/4" plug was removed.
4. Slowly open the leak detection ball valve.
5. Press the MENU key on the front panel of the C-MORE and access the Setup menu, enter the password 6817 and then press the ENTER key.
6. Start the unit in MANUAL mode at a valve position (firing rate) between 25% and 30%.
7. With the unit running, monitor the gas pressure on the manometer installed in step 2 and record the gas pressure reading.
8. Slowly increase the gas pressure using the adjustment screw on the SSOV while counting the number of turns you make.
9. The FAULT GAS PRESSURE fault message at approximately the value shown in Table 5-2 (the pressure setting of the HIGH Gas Pressure switch):
10. Reduce the gas pressure before starting step 7 (the value recorded in step 6). This pressure should be within the range used during combustion calibration, shown in Table 4-1 (Natu r a l G as ) and Table 4-4 (Propane gas).
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HIGH GAS PRESSURE TEST Instructi ons : BMK 750 – 2500
11. Press the CLEAR button on the Control Box to clear the fault.
SSOV
HIGH GAS PRESSURE
BALL VALVE
Test)
1/4" NPT PLUG
NATURAL GAS INLET
SWITCH
SECTION 5 – SAFETY DEVICE TESTING
12. The fault message should clear and the FAULT indicator should go off. The unit should restart (if in MANUAL mode).
13. Upon test completion, close the ball valve and remove the manometer. Replace the 1/4" NPT plug removed in step 2.
MANUAL SHUT-OFF
VALVE
GAS INLET
TO AIR/FUEL
VALVE
HIGH GAS PRESSURE SWITCH
LOW GAS PRESSURE SWITCH
1/4” NTP PLUG (Install manometer here for High Gas Pressure
Figure 5–3a: BMK 750/1000 HIGH Gas Pressure Test Components
HIGH GAS
MANUAL
SHUT-OFF
VALVE
TO
AIR/FUEL
VALVE
SSOV
HIGH GAS BALL VALVE
PRESSURE
LOW GAS PRESSURE SWITCH
(Install manometer here for HIGH gas pressure fault test)
Figure 5-3b: BMK 1500/2000: HIGH Gas Pressure Fault Test
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
HIGH GAS PRESSURE TEST Instructi ons : BMK 750 – 2500
HIGH GAS PRESSURE TEST Instructi ons : BM K 3 0 0 0 Only
up to 100%.
TO VALVE
NATURAL GAS INLET
SECTION 5 – SAFETY DEVICE TESTING
1/4” NPT
PLUG
(install
manometer
here for HIGH
GAS
PRESSURE
FAUL T T EST)
HIGH GAS
BALL VALVE
MANUAL
SHUT-OFF
VALVE
HIGH GAS PRESSURE SWITCH
AIR/FUEL
Figure 5-3c: BMK 2500: HIGH Gas Pressure Fault Test
SSOV
LOW GAS PRESSURE SWITCH
5.3.2 HIGH GAS PRESSURE TEST: BMK 3000 Only
To simulate a high gas pressure fault, refer to Figure 5-4 and perform the following steps:
1. Locate the port on the side of the High Gas Pressure switch (see Figure 5-4, below) and loosen the screw in the port a few turns to open it. Do not completely remove the screw. Alternatively, you can remove the 1/4 inch plug shown in Figure 5-4 and install a hose barb fitting in that location.
2. Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0 – 16” W.C. (0 – 4.0 kPa) manometer.
3. Apply the reading of the manifold pressure taken in St ep 1 8 of section 4.4.1 ( nat ur al g as units) or Step 18 of section 4.4.2 (propane units) and plug it into the following formula, which calculates the maximum allowable gas pressure:
Gas Pressure  ______ x 1.5 = ______ max gas pressure
4. Remove the cover from the High Gas Pressure switch and set the dial indicator to 20 (the maximum).
5. Open the external gas supply ball valve upstream of the unit.
6. Press the MENU key on the front panel of the C-MORE and access the Setup menu, enter the password 6817 and then press the ENTER key.
7. Start the unit in MANUAL mode and adjust the Air/Fuel Valve position to bring the unit
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
HIGH GAS PRESSURE TEST Instructi ons : BM K 3 0 0 0 Only
y pressure by turning the Gas Pressure
maximum calculated in step 3, then use the Gas Pressure Adjustment Screw to
TO
MANUAL SHUT-
OFF VALVE
HIGH Gas
Pressure test
HIGH GAS
SWITCH
Alternative
SSOV
NATURAL GAS INLET
SECTION 5 – SAFETY DEVICE TESTING
8. Slowly increase the manifold gas suppl Adjustment Screw in the Downstream SSOV (Figure 4-3) while reading the CO level on the combustion analyzer. Adjust the manifold pressure until the CO reading is approximately 300 ppm. Note the number of turns you make, as you will turn it back to its original position in step 10, below.
9. Take a reading of the manifold gas pressure. If the manifold pressure is greater than the decrease the manifold pressure until it is at the maximum allowed.
10. Press the RESET button on the High Gas Pressure switch (see Figure 5-4, below).
11. Slowly turn the indicator dial on the High Gas Pressure switch until the unit shuts down due to a gas pressure fault. This is the setpoint.
12. Readjust the manifold gas supply pressure to what it was before it was increased in step
7.
13. Press the CLEAR button on the control panel to clear the fault.
14. Upon test completion, close the ball valve and remove the manometer fitting from the port, and then turn the port screw clockwise till the port is closed.
AIR/FUEL
VALVE
PRESSURE
Pressure Port
Install manometer here for High Gas
HIGH GAS
BALL VALVE
Figure 5-4: BMK 3000 HIGH Gas Pressure Test Components
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LOW GAS PRESSURE SWITCH
HIGH Gas
Pressure Port
Page 86
BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
LOW WATER FAULT TEST Instructions
should not start. If the unit does start, shut the unit off immediately and refer fault to
SECTION 5 – SAFETY DEVICE TESTING
5.4 LOW WATER LEVEL FAULT TEST
To simulate a low water level fault, proceed as follows:
1. Set the ON/OFF switch to the OFF position
2. Close the water shut-off valves in the supply and return piping to the unit.
3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened to aid in draining.
4. Continue draining the unit until a LOW WATER LEVEL f ault message is displayed and the FAULT indicator flashes.
5. Place the unit in the MANUAL mode and raise the valve position above 30%.
6. Set the ON/OFF switch to the ON position. The READY light should remain off and the unit qualified service personnel.
7. Close the drain and pressure relief valve used in draining the unit.
8. Open the water shut-off valve in the return piping to the unit.
9. Open the water supply shut-off valve to the unit to refill.
10. After the shell is full, press the LOW WATER LEVEL RESET button t o reset the low water cutoff.
11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message.
12. Set the ON/OFF switch to the ON position. The unit is now ready for operation.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
WATER TEMPERATURE FAULT TEST Instr uc t ions
Temperature switch setting is approximately at, or just below,
T indicator
The unit should start once the adjustable Temperature Limit switch setting is above the
MANUAL
BUTTON
OVER
CONTROLLER
SECTION 5 – SAFETY DEVICE TESTING
5.5 WATER TEMPERATURE FAULT TEST
A high water temperature fault is simulated by adjusting the automatic Over-Temperature switch. This switch is accessible from the front of the unit as shown in Figure 5-5a and 5-5b.
1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint.
2. Lower the adjustable Over-Temperature switch setting to match the displayed OUTLET TEMPERATURE.
3. Once the adjustable Over­the actual outlet water temperature, the unit should shut down. The FAUL should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be displayed. It should not be possible to restart the unit.
4. Reset the adjustable Over-Temperature switch to its original setting.
5.
actual outlet water temperature.
TEMPERATURE LIMIT DIGITAL
ADJUSTABLE TEMPERATURE LIMIT SWITCH
SWITCH RESET
MANUAL TEMPERATURE LIMIT SWITCH
Figure 5-5a: Temperature Limit Switch Location – BMK 1500-3000
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
WATER TEMPERATURE FAULT TEST Instr uc t ions
Digital Over-
Reset button for
Manual
Adjustable Temperature
SECTION 5 – SAFETY DEVICE TESTING
Figure 5-5b: Temperature Limit Switch Location – BMK 750-1000
Temperature
Limit Switch
Limit switch (auto-rest)
Manual Temperature Limit Switch
Temperature Limit Controller
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
REMOTE INTERLOCK TEST Instr uctions
If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the
message should
DELAYED INTERLOCK TEST Instr uctions
If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the
.
SECTION 5 – SAFETY DEVICE TESTING
5.6 INTERLOCK TESTS
The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (shown in Figure 2-
12) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut
down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumpered (closed). However, each of these interlocks may be utilized in the field as a remote stop and start, an emergency cut-off, or to prove that a device such as a pump, gas booster, or louver is operational.
5.6.1 Remote Interlock Test
1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals.
2. Start the unit in the MANUAL mode and set the valve position between 25% and 30%.
3. jumper. If the interlock is being controlled by an external device, either open the interlock via the external device or disconnect one of the wires leading to the external device.
4. The unit should shut down and display INTERLOCK OPEN.
5. Once the interlock connection is reconnected, the INTERLOCK OPEN
automatically clear and the unit should restart.
5.6.2 Delayed Interlock Test
1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals.
2. Start the unit in the MANUAL mode at a valve position between 25% and 30%.
3. jumper. If the interlock is connected to a proving switch of an external device, disconnect one of the wires leading to the proving switch.
4. The unit should shut down and display a DELAYED INTERLOCK OPEN fault message The FAULT LED should be flashing.
5. Reconnect the wire or jumper removed in step 3 to restore the interlock.
6. Press the CLEAR button to reset the fault
7. The unit should start.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
FLAME FAULT TEST Instructi ons
should not start. If the unit does start, shut the unit off immediately and refer fault to
SECTION 5 – SAFETY DEVICE TESTING
5.7 FLAME FAULT TEST
Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows:
1. Set the ON/OFF switch to the OFF position.
2. Close the water shut-off valves in the supply and return piping to the unit.
3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened to aid in draining.
4. Continue draining the unit until a LOW WATER LEVEL f ault message is displayed and the FAULT indicator flashes.
5. Place the unit in the MANUAL mode and raise the valve position above 30%.
6. Set the ON/OFF switch to the ON position. The READY light should remain off and the unit qualified service personnel.
7. Close the drain and pressure relief valve used in draining the unit.
8. Open the water shut-off valve in the return piping to the unit.
9. Open the water supply shut-off valve to the unit to refill.
10. After the shell is full, press the LOW WATER LEVEL RESET button t o reset the low water cutoff.
11. Press the CLEAR button to reset the FAULT LED and clear the displayed error message.
12. Set the ON/OFF switch to the ON position. The unit is now ready for operation.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
IGNITER/INJECTOR
ASSEMBLY
BLOWER
PLENUM
GAS
INLET
SECTION 5 – SAFETY DEVICE TESTING
5.8 AIR FLOW FAULT TESTS - BLOWER PROOF & BLOCKED
INLET SWITCHES
These tests check the operation of the Blower Pro of switch and Blocked Inlet switch shown in Figure 5-6a and 5-6b.
5.8.1 Blower Proof Switch Test
BLOWER
A/F VALVE
PLENUM
BLOWER
PROOF
SWITCH
AIR/FUEL
VALVE
BLOCKED
INLET
SWITCH
HEAT EXCHANGER
MANUAL SHUT-OFF VALVE
SSOV
AIR
FILTER
GAS
TRAIN
Figure 5-6a: Bare Boiler – Partial View – BMK 1500 – 3000 Shown
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
BLOWER PROOF SWITCH TEST Instructions
SECTION 5 – SAFETY DEVICE TESTING
BLOCKED
INLET SWITCH
BLOWER PROOF SWITCH
AIR/FUEL
VALVE
Figure 5-6b: Bare Boiler – Partial View – BMK 750/13000 Shown
1. Disable the blower output drive voltage as follows:
a) Press the MENU k ey until CONFIGURATION MENU is displayed. b) Press the ▲ arrow key until the ANALOG O UTPUT function is displayed, then press
the CHANGE key.
c) Press the ▼ arrow key until OFF is displayed, then press the ENTER key.
2. Start the unit in the MANUAL mode at a valve position between 25% and 30%.
3. The unit should shut down and lockout, showing AIRFLOW FAULT DURING PURGE in the display.
4. The unit should perform one IGNITION RETRY cycle and then shut down, since the blower is disabled. The unit will then display AIRFLOW FAULT DURING PURGE.
5. Re-enable the blower output drive voltage by performing the following steps:
a) Press the MENU k ey until CONFIGURATION MENU is displayed.
b) Press the ▲ arrow key until the ANALOG O UTPUT function is displayed, then press
the CHANGE key.
c) Press the ▲ arrow key until VALVE POSITION 0-10V is displayed, then press the
ENTER key.
d) Press the CLEAR button to clear the airflow fault.
6. Once the unit has proved flame, turn off the blower again by going to the Configuration menu, Analog Output menu item and select OFF.
7. The Blower Proof switch will open and the blower should stop. The unit should shut down and display AIRFLOW FAULT DURING RUN.
8. Go to the Configuration menu, Analog Output item and select VALVE POSITION 0-10v.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
BLOCKED INLET SWITCH TEST Instructions
Use jumper wires to jump out the Low Gas Pressure switch and the Blower Proof
will show
. This step
TO WIRE HARNESS
FLAME DETECTOR FLAME SIGNAL GENERATOR
SECTION 5 – SAFETY DEVICE TESTING
5.8.2 Blocked Inlet Switch Test
This test will be run in simulated fire mode, with the Blocked Inlet switch isolated from the rest of the control circuitry.
1. Turn the main ON/OFF switch on the front of the control panel to the OFF position.
2. Remove the air filter (see Figure 5-6a or 5-6b, above).
WARNING!
The blower suction is very strong and can pull nearby objects into the blower’s fan blades. Do NOT allow anything to be pulled into the blow er! Do not wear anything that could get caught and pull you into the blower.
3. Turn off the gas supply ball valve to the boiler and then complete the following steps:
a)
switch. b) Remove the black connector boot from the Flame Detector. c) Connect the Flame Signal Generator to the black connector boot.
CONNECTOR BOOT
Figure 5-7: Connecting the Flame Signal Generator
d) Keep the alligator clip away from bare metal parts until step 4c.
4. Complete the following with the boiler operating in MANUAL mode: a) Ramp the boiler up to 100% fire rate and then turn the main ON/OFF switch on the
front of the control panel to the ON position. b) Push the BACK button three (3) times to return to the upper level menu. c) When the Controller gets into the ignition phase, the control panel
IGNITION TRIAL. At that point attach the alligator clip (see Figure 5-7) to any bare
metal surface or ground. The C-More display should now show FLAME PROVEN
and begin to ramp up to 100% fire rate. Note that no g as or flame is present in the
boiler at this time.
5. Wait for the boiler to ramp up to at least 90% before continuing.
6. Cover the combustion air inlet opening with a solid, flat object, such as a piece of thick plywood or a thick metal plate.
7. The unit should shut down and display AIRFLOW FAULT DURING RUN confirms proper operation of the Blocked Inlet switch.
8. Remove the cover from the air inlet opening and reinstall the Combustion Air Duct or air filter.
9. Remove the jumper wires installed in step 3 and replace the black connector boot on the Flame Detector.
10. Press the CLEAR button. The unit should restart.
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
SSOV PROOF OF CLOSURE SWITCH CHECK Instructions
PURGE SWITCH OPEN DURING PURGE CHECK Instructions
SSOV
SECTION 5 – SAFETY DEVICE TESTING
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK
The SSOV, shown in Figure 5-8, contains the Proof of Closure switch. The Proof of Closure switch circuit is checked as follows:
1. Set the unit’s ON/OFF switch to the OFF position.
2. Place the unit in MANUAL mode and set the valve position between 25% and 30%.
3. Refer to Figure 5-1a through 5-1c o r 5-2 (BMK3000), above, and locate the SSOV.
4. Remove the cover from the SSOV by loosening the screw shown in Figure 5-8. Lift off the cover to access the terminal wiring connections.
5. Disconnect wire #148 from the SSOV to “open” the Proof Of Closure switch circuit.
6. The unit should fault and display SSOV SWITCH OPEN.
7. Replace wire #148 and press the CLEAR button.
8. Set the ON/OFF switch to the ON position to start the unit.
9. Remove the wire again when the unit reaches the purge cycle and PURGING is displayed.
10. The unit should shut down and display SS OV FAULT DURING PURGE.
11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart.
ACTUATOR
COVER
ACTUATOR COVER SCREW
Figure 5-8: SSOV Actuator Cover Location
5.10 PURGE SWITCH OPEN DURING PURGE
The Purge switch (and Ignition switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:
1. Set the unit’s ON/OFF switch to the OFF position.
2. Place the unit in MANUAL mode and set the valve position between 25% and 30%.
3. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it (see Figure 5-9a and 5-9b).
4. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5-10a and 5­10b).
5. Initiate a unit start sequence.
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PURGE SWITCH OPEN DURING PURGE CHECK Instructions
button. The unit should
BLOCKED
AIR/FUEL VALVE COVER
SECTION 5 – SAFETY DEVICE TESTING
6. The unit should begin its start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE.
7. Replace the wire on the Purge switch and depress the CLEAR restart.
BLOWER PROOF
SWITCH
AIR/FUEL VALVE COVER
(Rotate Counter-Clock-Wise
to Remove)
Figure 5-9a: Air/Fuel Valve Cover Location – BMK 1500 – 3000
INLET SWITCH
AIR/FUEL VALVE
(Rotate counter-clockwise to remove)
Figure 5-9b: Air/Fuel Valve Cover Location – BMK 750/1000
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
PURGE SWITCH OPEN DURING PURGE CHECK Instructions
Purge Position
AIR IN
VALVE
Ignition Position
TO BLOWER
Ignition Position Switch
Purge Position Switch
AIR IN
TO BLOWER
SECTION 5 – SAFETY DEVICE TESTING
Switch
170
169
POSITION DIAL
AIR/FUEL VALVE SWITCH WIRING
BREAKOUT
172
171
Switch
Figure 5-10a: Air/Fuel Purge and Ignition Locations– BMK 1500 – 3000
Figure 5-10b: Air/Fuel Purge and Ignition Locations– BMK 750/1000
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IGNITION SWITCH OPEN DURING IGNITION CHECK Instructions
7b, above) by rotating the cover
IGN SWITCH
button. The unit should
SECTION 5 – SAFETY DEVICE TESTING
5.11 IGNITION SWITCH OPEN DURING IGNITION
The Ignition switch (and the Purge switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:
1. Set the unit’s ON/OFF switch to the OFF position.
2. Place the unit in MANUAL mode and set the valve position between 25% and 30%.
3. Remove the Air/Fuel Valve cover (Figure 5-7a or 5­counterclockwise to unlock and lift up to remove.
4. Remove one of the two wires (#169 or #170) from the Ignition switch (see Figure 5-8a or 5­8b, above).
5. Initiate a unit start sequence.
6. The unit should begin its start sequence and then shut down and display OPEN DURING IGNITION.
7. Replace the wire on the Ignition switch and press the CLEAR restart.
5.12 SAFETY PRESSURE RELIEF VALVE TEST
Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.
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SECTION 5 – SAFETY DEVICE TESTING
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BMK 750-3000 Platinum Boiler INSTALL and STARTUP GUIDE
NOTE: Use either or Modbus Header
SECTION 6 – BOILER SEQUENCING TECHNOLOGY
SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.1 INTRODUCTION
The Boiler Sequencing Technology system (BST) is built into the C-More controller. BST is an integrated 8 boiler control system. It has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up t o 8 boilers while achieving maximum operational efficiency.
BST is designed to ensure that all Boilers in the system operate at maximum efficiency. This is accomplished by lighting off boilers only when all ignited boilers reach or exceed a defined Valve Position (Fire Rate). Operating all boilers below the def ined Fire Rate “Next on VP” (for Next Turn on Valve Position) insures that they are firing at their most efficient Fire Rate. One unit the BST network is defined as the “Manager” unit and all other units on the network are defined as “Client” units. The Manager monitors the system Header Temperature, and also monitors all Client unit’s statu s i nf ormatio n, efficiently controlling all units in order to achieve and maintain the required BST Setpoint Temperature.
When there is a demand, the Manager will light off one of the boilers based on the BST Sequencing selection in the BST menu. As system load increases and the valve position of the ignited unit(s) reach the Next On VP (% valve position), the Manager will light off the next available unit. A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 6-1 below.
Figure 6-1: Simplified BST Block Diagram
FFWD Header Sensor
NOTE:
After the boiler load is satisfied, the isolation valve remains open for a programmed interval (default = 2 minutes) before closing. When the system load is satisfied, the panel will open the
isolation valves for all of the boilers. The BST controls the valves via a 0-20 mA signal (see section 2.11.8)
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Option 5 – 4-20ma Drive AND Direct Wired Header
Complete section 6.3.5
SECTION 6 - BOILER SEQUENCING TECHNOLOGY
6.1.1 INSTALLATION NOTES
If you are installing a BST system that also includes a ProtoNode SSD (Client-Client Device), you must adhere to the procedure listed below. Failure to complete these steps can result in the failure of the BST system.
a) Do NOT install the ProtoNode device at the outset of the installation. If the ProtoNode
Device is already installed, you must physically disconnect it from the Modbus net work in I/O board.
b) Make sure that the Modbus load and bias resistors are properly configured f or t he sys tem
to operate without the ProtoNode installed.
c) Temporarily set the BST system for CONSTANT SETPOINT mode of operation (see
below).
d) Turn on and completely test the installation to verify that it is operating proper. e) Once the installation is working properly as a BST system, install the ProtoNode device. f) Make sur e that the Modbus load and bias resistors are properly conf igured for the system
to operate with the ProtoNode installed.
g) Set the BST system for desired mode of operation (SETPOINT mode). h) Test the system completely with the ProtoNode installed.
6.2 AERCO BST QUICK START CHART
Select the single option that suites your installation and then complete the instructions in the corresponding sub-sections of section 6.3 BST Implementation Instructions.
Constant Setpoint (choose option 1 or 2)
Option 1 – Direct Wired Header Complete section 6.3.1 Option 2 – Modbus Header Complete section 6.3.2
Outdoor Reset (choose option 3 or 4)
Option 3 – Direct Wired Header AND Direct Wired Outdoor Air Complete section 6.3.3 Option 4 – Modbus Header AND Modbus Outdoor Air Complete section 6.3.4
Remote Setpoint (choose option 5 through 8)
Option 6 – Modbus Drive AND Direct Wired Header Complete section 6.3.6 Option 7 – 4-20ma Drive AND Modbus Header Complete section 6.3.7 Option 8 – Modbus Drive AND Modbus Header Complete section 6.3.8
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