BMK 5000-6000 Boiler Install and Startup Guide

BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
GF-207-I
USER MANUAL (1 of 2)
INSTALLATION and STARTUP GUIDE
®
Natural Gas Fired Modulating and Condensing Heating Boilers
5000 and 6000 MBH Heating Boilers
This Guide Applies to Models:
• BMK 5000
• BMK 6000
This manual applies to China low
pressure (0.9 bar) applications
only
See also:
Benchmark 5000 – 6000
OPERATION, SERVICE and
MAINTENANCE Guide
INTERNATIONAL,
OMM-0130 (GF-208-I)
Applies to Serial Numbers:
N-17-0850 and above
China Patent No. ZL 201280040168.4
Latest Update: 12/31/2017
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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
SECTION 2: INSTALLATION .................................................................. 11
2.1 INTRODUCTION................................................................................................................................... 11
2.2 RECEIVING THE UNIT ......................................................................................................................... 11
2.3 UNPACKING ......................................................................................................................................... 11
2.4 SITE PREPARATION ........................................................................................................................... 12
2.4.1 Installation Clearances ................................................................................................................... 12
2.4.2 Setting the Unit ............................................................................................................................... 14
2.4.3 LIFTING PROVISIONS .................................................................................................................. 15
2.4.4 MULTIPLE UNIT INSTALLATIONS ............................................................................................... 15
2.5 SUPPLY AND RETURN PIPING .......................................................................................................... 16
2.6 PRESSURE RELIEF VALVE INSTALLATION ..................................................................................... 17
2.7 PRESSURE/TEMPERATURE GAUGE INSTALLATION ..................................................................... 17
2.8 CONDENSATE DRAIN AND PIPING ................................................................................................... 18
2.9 GAS SUPPLY PIPING .......................................................................................................................... 20
2.9.1 Gas Supply Specifications .............................................................................................................. 20
2.9.2 Manual Gas Shutoff Valve .............................................................................................................. 21
2.9.3 External Gas Supply Regulator ...................................................................................................... 21
2.10 AC ELECTRICAL POWER WIRING ................................................................................................... 22
2.10.1 Electrical Power Requirements .................................................................................................... 23
2.11 FIELD CONTROL WIRING ................................................................................................................. 24
2.11.1 Outdoor Air & Air Sensor Common .............................................................................................. 25
2.11.2 AIR TEMP SENSOR .................................................................................................................... 26
2.11.3 O2 SENSOR (+ & –) ..................................................................................................................... 26
2.11.4 SPARK SIGNAL (+ & –) ............................................................................................................... 26
2.11.5 ANALOG IN .................................................................................................................................. 26
2.11.6 VALVE FEEDBACK...................................................................................................................... 26
2.11.7 SHIELD (SHLD & SHLD) ............................................................................................................. 27
2.11.8 ANALOG OUT .............................................................................................................................. 27
2.11.9 RS485 Comm (+, GND, & -) ......................................................................................................... 27
2.11.10 RS232 Comm (TxD & RxD) ....................................................................................................... 27
2.11.11 VFD/Blower (0-10 & AGND) ....................................................................................................... 27
2.11.12 Interlocks .................................................................................................................................... 27
2.11.13 Fault Relay (NC, COM, & NO) ................................................................................................... 28
2.11.14 Auxiliary Relay Contacts (NC, COM, & NO) .............................................................................. 28
2.12 FLUE GAS VENT INSTALLATION ..................................................................................................... 29
2.13 COMBUSTION AIR ............................................................................................................................. 29
2.13.1 DUCTED COMBUSTION AIR ...................................................................................................... 30
2.14 BENCHMARK PUMP RELAY ............................................................................................................. 30
2.15 SEQUENCING ISOLATION VALVE INSTALLATION ........................................................................ 31
SECTION 3: START SEQUENCE ........................................................... 33
3.1 INTRODUCTION................................................................................................................................... 33
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CONTENTS
3.2 START SEQUENCE ............................................................................................................................. 33
3.3 START/STOP LEVELS ......................................................................................................................... 38
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT ..................................................................... 38
3.4.1 Benchmark 5000 Air/Fuel Valve Position and Energy Input .......................................................... 38
3.4.2 Benchmark 6000 Air/Fuel Valve Position and Energy Input .......................................................... 39
3.5 BOILER ENERGY INPUT CHARTS ..................................................................................................... 40
SECTION 4: INITIAL START-UP ............................................................ 43
4.1 INITIAL START-UP REQUIREMENTS ................................................................................................. 43
4.2 TOOLS & INSTRUMENTS FOR COMBUSTION CALIBRATION ........................................................ 44
4.2.1 Required Tools & Instrumentation .................................................................................................. 44
4.2.2 Installing Gas Supply Manometer .................................................................................................. 44
4.2.3 Accessing the Analyzer Probe Port ................................................................................................ 45
4.3 PILOT IGNITION ................................................................................................................................... 46
4.4 COMBUSTION CALIBRATION ............................................................................................................. 46
4.5 REASSEMBLY ...................................................................................................................................... 49
4.6 OVER-TEMPERATURE LIMIT SWITCHES ......................................................................................... 50
4.6.1 Digital Alarm Switch Checks and Adjustments .............................................................................. 51
SECTION 5: SAFETY DEVICE TESTING ............................................... 53
5.1 TESTING OF SAFETY DEVICES ......................................................................................................... 53
5.2 LOW GAS PRESSURE TEST .............................................................................................................. 54
5.3 HIGH GAS PRESSURE TEST ............................................................................................................. 56
5.4 LOW WATER LEVEL FAULT TEST ..................................................................................................... 58
5.5 WATER TEMPERATURE FAULT TEST .............................................................................................. 59
5.6 INTERLOCK TESTS ............................................................................................................................. 60
5.6.1 Remote Interlock Test .................................................................................................................... 60
5.6.2 Delayed Interlock Test .................................................................................................................... 60
5.7 FLAME FAULT TEST............................................................................................................................ 61
5.8 AIR FLOW FAULT TESTS .................................................................................................................... 61
5.8.1 Blower Proof Switch Test ............................................................................................................... 62
5.8.2 Blocked Inlet Switch Test ............................................................................................................... 63
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK ................................................................................. 64
5.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................ 65
5.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................. 66
5.12 SAFETY PRESSURE RELIEF VALVE TEST ..................................................................................... 66
SECTION 6: BOILER SEQUENCING TECHNOLOGY ............................ 67
6.1 INTRODUCTION................................................................................................................................... 67
6.1.1 Installation Notes ............................................................................................................................ 68
6.2 AERCO BST QUICK START CHART................................................................................................... 68
6.3 BST IMPLEMENTATION INSTRUCTION ............................................................................................ 69
6.3.1 OPTION 1 - Constant Setpoint With Direct Wired Header Sensor ................................................ 69
6.3.2 OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor ............................................. 70
6.3.3 OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct Wired Outdoor Sensor
................................................................................................................................................................. 71
6.3.4 OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor ............. 73
6.3.5 OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma Setpoint Drive...... 75
6.3.6 OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And Modbus Setpoint Drive ..... 77
6.3.7 OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma Setpoint Drive............. 79
6.3.8 OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus Setpoint Drive ............ 81
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CONTENTS
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS ............ 83
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FORWARD
FOREWORD
(BMK) 5000 MBH (1465 kW) and 6000 MBH (1758 kW) natural gas fueled heating 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, their modulating capability relates energy input directly to fluctuating system
loads. The maximum turn down ratio for the BMK 5000 and 6000 is 15:1. These Benchmark
models provide extremely high efficiency, which makes them 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 Series
of heating boilers.
The Benchmark models operate within the input and output ranges listed below.
Benchmark 5000 and 6000 Heating boiler Intake and Output Ranges
INPUT RANGE (BTU/HR.)
MODEL
OUTPUT RANGE (BTU/HR.)
MINIMUM
MAXIMUM
MINIMUM
MAXIMUM
5000
400,000 (117 kW)
5,000,000 (1465 kW)
348,000 (102 kW)
4,750,000 (1392 kW)
6000
400,000 (117 kW)
6,000,000 (1758 kW)
348,000 (102 kW)
5,700,000 (1670 kW)
The output of Benchmark heating boilers 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 heating boilers
comply with the NOx emission standards outlined in: South Coast Air Quality Management
District (SCAQMD), Rule 1146.2.
Whether used in singular or modular arrangements, BMK 5000 and BMK 6000 heating boilers
offer the maximum venting flexibility with minimum installation space requirements. These
heating boilers are Category II and IV, positive pressure appliances. Single and/or multiple
breeched units are capable of operation in the following vent configurations:
•
•
Room Combustion Air:
o
Vertical Discharge
o
Horizontal Discharge
Ducted Combustion Air:
o
Vertical Discharge
o
Horizontal Discharge
These heating boilers are capable of being vented utilizing Polypropylene and AL29-4C 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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FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
A (Amp)
Ampere
ACS
AERCO Control System, AERCO’s boiler management systems
ADDR
Address
AGND
Analog Ground
ALRM
Alarm
ANSI
American National Standards Institute,
ASME
American Society of Mechanical Engineers
AUX
Auxiliary
BAS
Building Automation System, often used interchangeably with EMS (see
below)
Baud Rate
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.
BMK (Benchmark)
AERCO’s Benchmark series heating boilers
BMS or BMS II
AERCO Boiler Management Systems
BLDG (Bldg)
Building
BST
AERCO on-board Boiler Sequencing Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)
BTU/HR
BTUs per Hour (1 BTU/hr = 0.29 W)
CCP
Combination Control Panel
CCS
Combination Control System
C-More Controller
A control system developed by AERCO and currently used in all Benchmark
and Innovation product lines.
CFH
Cubic Feet per Hour (1 CFH = 0.028 m /hr)
CO
Carbon Monoxide
COMM (Comm)
Communication
Cal.
Calibration
3
CNTL
Control
CPU
Central Processing Unit
DBB
Double Block and Bleed, a gas trains containing 2 Safety Shutoff Valves
(SSOVs) and a solenoid operated vent valve.
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 heating boiler gas trains.
GF-xxxx
Gas Fired (an AERCO document numbering system)
GND
Ground
HDR
Header
Hex
Hexadecimal Number (0 – 9, A – F)
HP
Horse Power
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FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
HX
Heat Exchanger
Hz
Hertz (Cycles Per Second)
I.D.
Inside Diameter
IGN
Ignition
IGST Board
Ignition/Stepper Board, contained in the C-More Controller
INTLK (INTL’K)
Interlock
I/O
Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark and Innovation
products
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 thousand of an ampere)
MAX (Max)
Maximum
MBH
MIN (Min)
1000 BTUs per Hour
Minimum
Modbus®
A serial, half-duplex data transmission protocol developed by AEG Modicon
NC (N.C.)
Normally Closed
NO (N.O.)
Normally Open
NOx
Nitrogen Oxide
NPT
National Pipe Thread
O2
Oxygen
O.D.
Outside Diameter
OMM & O&M
Operation and Maintenance Manual
PCB
Printed Circuit Board
PMC Board
Primary Micro-Controller (PMC) board, contained in the C-More
P/N
Part Number
POC
PPM
Proof of Closure
Parts per Million
PSI
Pounds per Square Inch (1 PSI = 6.89 kPa)
PTP
Point-to-Point (usually over RS232 networks)
P&T
Pressure and Temperature
ProtoNode
Hardware interface between BAS and a heating boiler or water heater
th
PVC
Poly Vinyl Chloride, a common synthetic plastic
PWM
Pulse Width Modulation
REF (Ref)
Reference
RES.
Resistive
RS232
(or EIA-232)
A standard for serial, full-duplex (FDX) transmission of data based on the
RS232 Standard
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FORWARD
AERCO Technical Terminology
TERMINOLOGY
MEANING
RS422
(or EIA-422)
A standard for serial, full-duplex (FDX) transmission of data based on the
RS422 Standard
RS485
(or EIA-485)
A standard for serial, half-duplex (HDX) transmission of data based on the
RS485 Standard
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
A resistor placed at each end of a daisy-chain or multi-drop network in order
to prevent reflections that may cause invalid data in the communication
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
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)
µA
Micro amp (1 million 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 given 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 heating boilers and ANSI/NFPASB for LP gas-fired heating 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.
IMPORTANT!
This Guide 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 of 120, 380 and 24 volts AC 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 three-pole 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.
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 heating boiler if any part has been under water. Call a qualified service
technician to inspect and replace any part that has been under water.
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SECTION 1: SAFETY PRECAUTIONS
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
VALVE
OPEN
VALVE
CLOSED
Figure 1-1: Manual Gas Shutoff Valve
1.3 PROLONGED SHUTDOWN
If there is an emergency, turn off the electrical power supply to the unit and close the manual
gas valve located upstream the unit. The installer must identify the emergency shut-off device.
If the heating boiler needs to be shut down for a prolonged period, follow the instructions in
Section 4.12: Shutting Boiler Down For Extended Period in the Benchmark 5000 – 6000
Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF-208-I), and review the
procedures in Appendix J of the same manual.
After prolonged shutdown, it is recommended that the procedures in Section 4: Initial Startup
and Section 5: Safety Device Testing of this manual be performed to verify that all systemoperating parameters are correct.
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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 5000 and 6000 Benchmark heating boilers.
2.2 RECEIVING THE UNIT
Each Benchmark heating boiler is shipped as a single crated unit. The shipping weight for the
BMK 5000 and 6000 models is approximately 3500 pounds (1588 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.
NOTE:
AERCO is not responsible for lost or damaged freight. Check for indications that the unit has
been turned on its side during shipment. If you see any such signs, 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
The unit is shipped mounted on a skid and shrouded in a plastic wrap. It can be moved while on
the skid using a forklift.
Carefully remove the plastic wrap from the unit taking care not to damage the unit enclosure
panels when cutting away the plastic wrap.
After unpacking, make a close inspection of the unit to ensure there is no evidence of damage.
The freight carrier should be notified immediately if any damage is detected.
The following accessories come standard with each unit and are either packed 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)
•
2” Natural Gas Supply Shutoff Valve
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.
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SECTION 2: INSTALLATION
Figure 2-1: Benchmark 5000 & 6000 Mounted on Shipping Skid
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark heating boiler includes access to:
•
380 VAC, Three-Phase, 50/60 Hz @ 20 Amps following AC input power source
•
Access to 2 inch (2.54 cm) Natural Gas line with a minimum pressure of 14 inches
W.C. (3.49 kPa) with the unit at FULL FIRE (approximately 20” W.C. (4.98 kPa) static).
2.4.1 Installation Clearances
Benchmark 5000 and 6000 heating boiler dimensions and minimum acceptable clearances are
shown in Figure 2-2. The minimum clearance dimensions, required by AERCO, are listed below.
However, if Local Building Codes require additional clearances, these codes shall supersede
AERCO’s requirements. Minimum acceptable clearances required are as follows:
•
Front : 36 inches (91 cm)
•
Sides: 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.
NOTE:
Benchmark 5000 and 6000 units may be installed with zero side clearances in pairs only.
The perimeter clearances still apply (see Figure 2-2 and the drawings in Appendix A:
Dimensional Drawings).
IMPORTANT!
Ensure that adequate clearance exists at the rear of the unit to permit installation and service
maintenance of the AERCO Condensate Trap. Refer to Section 2.8 for Condensate Trap
installation details.
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SECTION 2: INSTALLATION
Housekeeping pad
should not extend
under the condensate
assembly
4” – 8” (10.2–20.3 cm)
MINIMUM
Figure 2-2: Benchmark Model 5000 & 6000 Clearances
WARNING!
Keep the unit area clear and free from all combustible materials and flammable vapors or
liquids.
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SECTION 2: INSTALLATION
2.4.2 Setting the Unit
The unit must be installed on a 4 to 8 inch (10.2 to 20.3 cm) thick housekeeping pad to ensure
proper condensate drainage. If anchoring the unit, refer to Figure 2-3 for anchor locations.
NOTE:
When using the AERCO Condensate Neutralizer Tank for proper condensate drainage, the
Neutralizer Tank must be stored in a pit, OR the boiler and AERCO Condensate Trap must
be elevated higher than 4” (10.2 cm) above the floor. Ensure that the condensate
assembly is not positioned above the housekeeping pad during installation so as not to
interference with condensate piping.
FRONT
REAR
•
All holes are flush with the bottom surface of the frame.
•
All dimensions shown are in inches [millimeters]
Figure 2-3. Benchmark 5000 and 6000 Anchor Bolt Locations
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SECTION 2: INSTALLATION
2.4.3 LIFTING PROVISIONS
Two (2) lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 24. The location of the lifting tabs is marked on the shrink-wrap coving the unit for shipping.
Remove the four (4) lag screws securing the unit to the shipping skid, and, if still in place,
remove the front Top Panel. Lift the unit off the shipping skid using a spreader bar and position
it on the (required) concrete Housekeeping Pad in the desired location.
WARNING!
When lifting or moving the heating boiler, do not attempt to manipulate the unit using the gas
train or blower. A spreader bar is required for all vertical lifts. Failure to use a spreader bar
can put excessive force on the unit and can cause boiler failure.
LIFTING LUGS
NOTE:
The rear top panel must be
removed to access the front
lifting lug.
Figure 2-4: Lifting Lug Locations
2.4.4 MULTIPLE UNIT INSTALLATIONS
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.
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SECTION 2: INSTALLATION
2.5 SUPPLY AND RETURN PIPING
The Benchmark 5000 and 6000 boiler utilizes 6” (15.24 cm) flanged fittings for the water system
supply and return piping connections. The physical location of the supply and return piping
connections are shown in Figure 2-5. Refer to Appendix A: Dimensional and Clearance
Drawings for additional 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.
See Sections 2.12 and 2.13 for information on the flue vent and air intake.
6” (15.24 cm) WATER OUTLET
14” (35.6 cm) AIR INLET
6” (15.24 cm)
WATER INLET
2” NATURAL
GAS INLET
EXHAUST
MANIFOLD
CONDENSATE
DRAIN
Figure 2-5: Supply and Return Locations
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2.6 PRESSURE RELIEF VALVE INSTALLATION
NOTE
Pressure relief valves are not required for low pressure applications, but we recommend that
they be installed as a safety measure to avoid the build-up of pressure inside the device
(although this rarely occurs). An Pressure Relief Valve is supplied with each Benchmark Boiler.
The following applies only to Benchmark 5000 and 6000 units that operate above 1.0 bar
pressure. This section can be ignored if the unit will operate at 0.9 bar pressure.
Depending on the pressure required, Benchmark 5000 and 6000 boilers are supplied with one
or more ASME rated Pressure Relief Valves. All pressure relief valves supplied with the boiler
must be installed to meet code and safety requirements. The pressure rating for the relief valve
must be specified on the sales order. Available pressure ratings range from 30 to 160 psi (207
to 1103 kPa). Each pressure relief valve is furnished as a kit (P/N 92102-TAB), which consists
of the relief valve for the pressure rating specified on the Sales Order. The appropriate size
reducing bushing and nipple are also included in the kit. The pressure relief valves, nipples and
bushings are connected to 45º street elbows already installed on the heat exchanger of the
boiler. The relief valves are installed on the top of the boiler as shown in Figure 2-6. A suitable
pipe joint compound should be used on all threaded connections. Any excess should be wiped
off to avoid getting any joint compound into the valve body. Each relief valve must be piped to
within 12 inches (30.5 cm) of the floor to prevent injury in the event of a discharge. The
discharge piping must be full size, without reduction. No valves or size reductions 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.
Figure 2-6. Pressure Relief Valve Installation Locations
2.7 PRESSURE/TEMPERATURE GAUGE INSTALLATION
A Pressure/Temperature Gauge is included in the Spare Parts kit, which must be installed in the
boiler outlet piping. It must be installed so that the sensing bulb is inserted into the hot water
outlet flow from the boiler. Refer to Figure 2-7 for sample installations.
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SECTION 2: INSTALLATION
CORRECT LOCATION
Typically located 6” to 18” (15.2 to 45.7 cm)
from the boiler outlet connection
Figure 2-7: Pressure/Temperature Gauge Installation Location
2.8 CONDENSATE DRAIN and PIPING
The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore,
the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port is located on the exhaust manifold (Figure 2-8) at the rear of the unit.
This drain port must be connected to the condensate trap (P/N 24441), which is packed
separately within the unit’s shipping container. The condensate trap outlet connection features a
tapped 3/4” NPT drain port.
2” NATURAL
GAS INLET
EXHAUST
MANIFOLD
ANALYZER PORTS
(2, ONE ON EACH SIDE)
CONDENSATE
DRAIN PORT
Figure 2-8: Condensate Drain Connection Location
A sample condensate trap installation is shown in Figure 2-9. However, the actual installation
details for the trap will vary depending on the available clearances, housekeeping pad height
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and dimensions and other prevailing conditions at the site. The following general guidelines
must be observed to ensure proper condensate drainage:
•
The condensate trap inlet (Figure 2-9) must be level with, or lower than the exhaust manifold
condensate 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:
Condensate Drain Installation Instructions
1. Connect the condensate trap inlet to the exhaust manifold drain connection using the
appropriate piping components (nipples, reducers, elbows, etc.) for the site.
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 secure 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
drain. The maximum condensate flow rate is 40 gallons (151 liters) per hour.
The condensate drain trap, associated fittings and drain line must be removable for routine maintenance.
WARNING!
Use PVC, stainless steel, aluminum or polypropylene for condensate drain piping. DO NOT
USE CARBON OR COPPER COMPONENTS.
TRAP INLET INTEGRAL
ADAPTOR AND THUMB-SCREW
COMBUSTION
ANALYZER
PROBE PORT
TOP COVER
THUMB SCREWS
(4 each)
CONDENSATE
TRAP (P/N 24441)
3/4” NPT NIPPLES
EXHAUST
MANIFOLD
HOSE CLAMP
1” (2.54cm)
DIAM. HOSE
4” (10cm)
NOTE
HOUSEKEEPING
PAD MUST NOT
EXTEND UNDER
THE CONDENSATE
ASSEMBLY.
4” – 8”
(10.2 – 20.3cm)
CONDENSATE
DRAIN PORT
Tilt down 2° for
gravity flow
TO
FLOOR
DRAIN
Figure 2-9: Sample Condensate Trap Installation
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SECTION 2: INSTALLATION
2.9 GAS SUPPLY PIPING
AERCO’s Benchmark Gas Components and Supply Design Guide, TAG-0086 (GF-2035) 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 5000 and 6000 Standard models contain a 2” NPT Natural Gas inlet connection on
the back 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, isolate the unit from the gas supply
piping. At no time should the gas pressure applied to the unit exceed 56” W.C. (2 psig,
13.8 kPa). Leak test all external piping thoroughly using a soap and water solution or suitable
equivalent. The gas piping used must meet all applicable codes.
2.9.1 Gas Supply Specifications
The gas supply input specifications to the unit for Natural Gas are as follows:
•
The maximum static pressure to the unit must not exceed 56” W.C. (2 psi, 13.8 kPa).
•
To ensure full rated input capacity, for FM gas trains the gas supply pressure to the unit
must be sufficient to provide the following volume of gas while maintaining a minimum
gas pressure of 14 inches W.C. (3.5 kPa) while in operation, as measured upstream
of the SSOV.
•
o
Benchmark 5000: 5000 CFH (142 m3/hr)
o
Benchmark 6000: 6000 CFH (170 m3/hr)
Both BMK 5000 and BMK 6000 units may be operated with inlet pressures less than 14”
W.C. (3.5 kPa) but will derate. The absolute minimum gas pressure for the BMK 6000
while in operation is 11” W.C. (2.7 kPa), and for the BMK 5000 is 10” W.C. (2.5 kPa).
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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 2-10.
2.9.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions. Regulators
must conform to the following specifications:
An external gas pressure regulator is required on the gas inlet piping under most conditions.
Regulators must conform to the following specifications:
•
The external natural gas regulator must be capable of regulating 300,000 – 6,000,000
BTU/Hr (88 – 1758 kW) of natural gas while maintaining a minimum gas pressure of
14” W.C. (3.49 kPa) to the unit.
•
A lock-up style regulator MUST be used.
•
For installations with 3 or more units that exceed 1 PSI (6.9 kW) gas pressure, a
separate external gas supply regulator is highly recommended (see Figure 2-10). No
regulator is required for gas pressures below 1 PSI (6.9 kW) of pressure, but above 2
PSI (13.8 kW) it is mandatory. Consult the Benchmark Gas Supply Design Guide,
TAG-0086, GF-2035, and 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
representative for more information.
NATURAL
GAS SUPPLY
2” MANUAL
GAS SHUT-OFF
VALVE
DRIP LEG
GAS PRESSURE
REGULATOR
Figure 2-10: Manual Gas Shut-Off Valve Location
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SECTION 2: INSTALLATION
2.10 AC ELECTRICAL POWER WIRING
The AERCO Benchmark Electrical Power Wiring Guide, TAG-0088, GF-2065, must be
consulted prior to connecting any AC power wiring to the unit. 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 right corner of the unit as shown in Figure
2-11. Loosen the two upper screws of the Power Box cover and remove cover to access the
internal connections shown in Figure 2-12.
POWER BOX
FRONT COVER
FRONT UPPER-RIGHT CORNER OF UNIT
Figure 2-11: Power Box with Closed Cover
WIRE CONDUITS
POWER
BREAKER
TRANSFORMER
24V POWER
SUPPLY
12V POWER
SUPPLY
FUSE BLOCKS (2)
TERMINAL BLOCKS
Figure 2-12: Power Box Internal Components (Cover Removed)
The Power Box contains terminal blocks as shown in Figure 2-12. With the exception of the
transformer, all of the components in the Power Box are mounted on a DIN rail.
NOTE:
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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2.10.1 Electrical Power Requirements
The Benchmark boiler is available in one voltage configuration:
•
380 VAC, three-phase, 50/60 Hz @ 15A
A label showing the required AC power connections is provided on the front cover of the Power
Box, as shown in Figure 2-13.
380VAC
Figure 2-13: Power Box Cover Label (P/N 72189)
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A double-pole switch must be installed on the electrical supply line in an easily accessible
location to quickly 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 AERCO Benchmark Electrical Power Guide, TAG0088, (GF-2065).
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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 Controller 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 unit’s
removable front panel. The I/O board is located in the I/O Box. The I/O board terminal strip
connections are shown in Figure 2-15. All field wiring is installed from the rear of the panel by
routing the wires through one of the four bushings provided on the sides of the I/O box.
Figure 2-14a: Input/Output (I/O) Box Location
TERMINAL STRIPS
I/O PCB
BOARD
Figure 2-14b: Input/Output (I/O) Box Interior
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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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 -
Remote Intl’k OUT
Remote Intl’k IN
NOT USED
Delayed Intl’k OUT
Delayed Intl’k IN
Not Used
DIP 1 Modbus Term
DIP 2 RS232 Enable
Fault Relay N.C.
Fault Relay COMM
Fault Relay N.O.
Aux Relay N.C.
Aux Relay COMM
Aux Relay N.O.
Not Used
Relay Contacts:
120 VAC, 30 VDC
5 Amps, Resistive
RS-232 - TxD
RS-232 - RxD
VFD/Blower +
VFD/Blower –
DANGER!
120 VAC USED
IN THIS BOX
NOTE:
Refer to the image above for connections rather than the silkscreen labels shown on the
PCB.
Figure 2-15: 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 5000 – 6000 Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF208-I).
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 2-15). 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.
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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 for free air circulation.
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 in the AIR TEMP setting in the
Operating menu (see Section 2.4: OPERATING Menu, item 4, of the Benchmark 5000 – 6000
Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF-208-I). A resistance chart
for this sensor is provided in APPENDIX C of the same 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 O2 concentration is displayed in the Operating menu of the C-More Controller
after a 60 second warm-up period. See Section 2.4: OPERATING Menu, item 13, of the
Benchmark 5000 – 6000 Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF208-I).
2.11.4 SPARK SIGNAL (+ & –)
Not in use on Benchmark 5000 and 6000.
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 – 5 VDC or a 0 to 20 mA/0 – 5 VDC signal may be used to vary the setpoint or air/fuel valve position. The factory default setting is 4 to 20 mA/1 to 5 VDC, however
this may be changed to 0 to 20 mA/0 – 5 VDC in the Configuration menu; see Section 2.6:
CONFIGURATION Menu, item 6, in the Benchmark 5000 – 6000 Operation and Maintenance
Guide-INTERNATIONAL OMM-0130 (GF-208-I).
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 Controller. 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 2-15) 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°C 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
Feedback signal does not match the Valve-Open or Valve-Close command for the time defined
in the "Valve Fdbk timer" entry, the C-More Controller will proceed as follows:
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(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 2-15, above).
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 setting in 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 C-More 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 open and close the isolation valve. 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 on the I/O Board MUST be installed.
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 terminals, 0-10 and AGND, send an analog signal to control the blower
speed.
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 2-15). Both interlocks, described below, are factory wired in the closed position using
jumpers.
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SECTION 2: INSTALLATION
NOTE:
Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to
fire.
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. 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: Boiler Sequencing Technology), 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, the second use is typically in conjunction with the
AUXILIARY RELAY CONTACTS described in section 2.11.14, below. This interlock
circuit is located 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
the Configuration menu (see Section 2.6: CONFIGURATION Menu, item 16, in the Benchmark
5000 – 6000 Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF-208-I).
2.11.13 Fault Relay (NC, COM, & NO)
The fault relay is a single pole double throw (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. The fault relay connections are shown in Figure 2-15.
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
unit status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 amps. Refer to
Figure 2-15 to locate the AUXILIARY RELAY terminals for wiring connections.
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2.12 FLUE GAS VENT INSTALLATION
AERCO’s Benchmark Venting and Combustion Air Guide, TAG-0089 (GF-2055) 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 minimum of 1/4" per foot (21mm per m) to
avoid any condensate pooling and to allow for proper drainage.
A 12 inch (30.5 cm) Flue Vent may be used for applications with less than 20 PPM NOx.
Installation with less than 9 PPM NOx require a 14 inch (35.6 cm) Flue Vent. Consult your vent
manufacturer for 12 inch (30.5 cm) vent adapters. See the Benchmark Combustion Venting and
Combustion Air Guide, TAG-0089 (GF-2055), for additional information.
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 1.9” W.C. (473 Pa).
Fittings as well as pipe lengths must be calculated as part of the equivalent length. 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.
2.13 COMBUSTION AIR
The Benchmark Venting and Combustion Air Guide, TAG-0089 (GF-2055) MUST be consulted
before any flue or 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 cm2) for each 4000 BTUs (1.17 kW) input for each unit, or 1,500 square inches
(0.96 m2) of free area for the BMK 6000, or 1,250 square inches (0.81 m2) of free area for the
BMK 5000. The free area must take 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.
NOTE:
The source of internal combustion air must be positive or neutral in pressure. Negative
pressure inside a boiler room may have an adverse effect on combustion equipment.
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SECTION 2: INSTALLATION
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-0089 (GF-2055) 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, each unit must have a minimum 14 inch (35.56
cm) diameter connection at the unit.
2.14 BENCHMARK PUMP RELAY
All Benchmark units ship with a pump relay (P/N 69102-3) 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. See Figures 2-17 and 2-18 for wiring details.
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.
POWER BOX
PUMP RELAY
Figure 2-16: Pump Relay Location
The Benchmark pump relay (SPDT) contact is rated for:
10 A Resistive @ 277 VAC/28 VDC
(Orange) – N/O
(Yellow) - COM
Pump Relay Terminals
1/3 HP N/O @ 120/240 VAC
1/6 HP N/C @ 120/240 VAC
Heating Pump
Figure 2-17: Schematic – System Pump Start using Boiler Pump Relay
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SECTION 2: INSTALLATION
If pump/valve load exceeds the above contact ratings, use a separate contact relay, as shown in
Figure 2-18.
(Orange) – N/O
(Yellow) - COM
Pump Relay Terminals
Contact Relay
(Supplied by Others)
N POWER PUMP(S) FROM
INDEPENDENT FUSED
H CIRCUITS
Heating Pump
Figure 2-18: 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 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 the site, designated 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 remains open for a programmed interval (default = 1 minute) then closes.
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.
The boiler is pre-wired to accept the sequencing isolation valve. Installation consists of installing
the sequencing isolation valve in the hot water outlet pipe, and then connecting it to the prewired connector on the shell harness, as described below.
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: CONFIGURATION Menu, item 16, in the
Benchmark 5000 – 6000 Operation and Maintenance Guide-INTERNATIONAL OMM-0130
(GF-208-I). 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 5000 – 6000 Operation
and Maintenance Guide-INTERNATIONAL OMM-0130 (GF-208-I).
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SECTION 2: INSTALLATION
Sequencing Isolation Valve Installation Instructions
1. Install the sequencing isolation valve in the boiler’s hot water outlet pipe (Figure 2-19).
SEQUENCING
ISOLATION VALVE
HOT WATER
OUTLET
Figure 2-19: 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 wire inserted in it (this jumper wire 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.
CAP
MOLEX CONNECTOR
JUMPER
Figure 2-20: 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 Controller, which is mounted on the front of the unit. It 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 equipment warranty. In addition, the following WARNINGS and
CAUTIONS must be observed at all times.
WARNING!
•
•
Electrical voltages in this system include 120, 380 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 must be completed before attempting to start
the unit.
3.2 START SEQUENCE
When the C-More Controller’s 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 checked prior to starting
the pre-purge.
If all of the above switches are closed, the READY light above the ON/OFF switch will light and
the unit will be in the STANDBY mode.
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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SECTION 3: START SEQUENCE
When there is a demand for heat, the following events will occur:
Start Sequence
1. The DEMAND LED status indicator will light.
2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety
Shut-Off Valve (SSOV) is closed. See Figure 3-1 for SSOV location.
UPSTREAM
SSOV
DOWNSTREAM
SSOV WITH
POC
TO AIR/FUEL
VALVE
MANUAL SHUTOFF VALVE
GAS INLET
HIGH GAS
PRESSURE SWITCH
- BMK 6000: 10.5” W.C., 2.6 kPa
- BMK 5000: 11.0” W.C., 2.7 kPa
UPSTREAM LOW GAS
PRESSURE SWITCH
- BMK 6000: 8.5” W.C., 2.1 kPa
- BMK 5000: 8.0” W.C., 2.0 kPa
Figure 3-1: SSOV Location
3. With all required safety device switches closed, a purge cycle will be initiated and the
following events will occur:
b. The Blower relay energizes and turns on the blower.
c. The Air/Fuel Valve rotates to the full-open purge position and closes purge position
switch. The dial on the Air/Fuel Valve (Figure 3-2) will read 100 to indicate that it is
full-open (100%).
d. The VALVE POSITION bargraph will show 100%.
TO BLOWER
STEPPER
MOTOR
AIR IN
Figure 3-2: Air/Fuel Valve In Purge Position
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Start Sequence
4. Next, the blower proof switch on the Air/Fuel Valve (Figure 3-3) closes. The display will
show PURGING and indicate the elapsed time of the purge cycle in seconds.
BLOCKED INLET
SWITCH
BLOWER
AIR/FUEL VALVE
ASSEMBLY
BLOWER PROOF
SWITCH
MANUAL SHUTOFF VALVE
Figure 3-3: Blower Proof Switch
5. Upon completion of the purge cycle, the C-More Controller initiates an ignition cycle and
the following events occur:
a. The Air/Fuel Valve rotates to the low-fire (Ignition Position) position and closes the
ignition switch. The dial on the Air/Fuel Valve will read between 45 and 50 (see
Figure 3-4) to indicate that the valve is in the low-fire position.
b. Power is supplied to the Spark Igniter.
c. Power is supplied to the Pilot Gas Solenoid.
d. The Pilot Flame Detectors prove the Pilot Flame and the red LED stops blinking and
changes to steady ON.
e. Ignition relay 1 (R1) closes allowing the main Burner ignition sequence to start.
TO BLOWER
STEPPER
MOTOR
AIR IN
Figure 3-4: Air/Fuel Valve in Ignition Position
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SECTION 3: START SEQUENCE
Start Sequence
6. Once the spark cleaning period is finished and ignition relay 1 (R1) closes, power is
supplied to the SSOVs and the following events occur in 7 seconds:
a.
b.
c.
d.
The SSOVs open allowing gas to flow into the Air/Fuel Valve.
The Main Burner ignites.
Main Burner flame is sensed by the C-More Controller.
The C-More Controller turns off power to the ignition transformer and Pilot solenoid
valve.
e. Relay 2 (R2) remains energized via the POC Normally Open (N.O.) contact of the
upstream SSOV actuator.
7. A maximum of 14 seconds are allowed for the entire ignition sequence, from applying
power to the ignition transformer through actual Burner flame establishment. The igniter
relay will be turned off one second after flame is detected.
8. After 2 seconds of continuous flame, FLAME PROVEN will be displayed and the flame
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 control circuitry. The
boiler’s VALVE POSITION will be continuously displayed on the C-More Controller’s front
panel bargraph.
10. Once the demand for heat has been satisfied, the C-More Controller will turn off the SSOV
gas valves, the blower relay will be deactivated, the Air/Fuel Valve will be closed and
STANDBY will be displayed.
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SECTION 3: START SEQUENCE
BMK 5000 & 6000 Function Timing Chart For Proved Pilot Control
System
Operating State
C-More
Pre-purge
PFEP
Standby
Component
T=0
T = 30
MFEP
T = 37
T = 44
PFEP
MFEP
Run
C-More Controller
Scanner Power
Ignition Power
SSOV Power
Pilot Valve Closed
Pilot Valve Open
Ignition Transformer Off
Ignition Transformer On
UV Scanner Powered
UV Scanner "Ignored"
UV Scanner In Use
Relay 1 Coil
Relay 1 C-NC
Relay 1 C-NO
Relay 2 Coil Power from R1
Relay 2 Coil Power from SKP 15 POC
Relay 2 C-NC
Relay 2 C-NO
SKP15 Power from R1 Contacts
SKP15 Power from R2 contact and
POC C-NO
SKP15 Proof of Closure C-NC
SKP15 Proof of Closure C-NO
SKP25
Power through R1
Power through R2 and AUX
Proof of Closure C-NC
Proof of Closure C-NO
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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 5000/6000 Start/Stop Levels for Natural Gas
Start Level:
24%
18%
Stop Level:
Normally, these settings should not require adjustment.
Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position.
3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT
The Tables in this section show the relationship between the energy input and Air/Fuel Valve
position for the BMK models covered in this document.
3.4.1 Benchmark 5000 Air/Fuel Valve Position and Energy Input
BMK 5000 Air/Fuel Valve Position and Energy Input
Air Fuel Valve
Position
(% Full Open)
Boiler Energy Input
% of Full
BTU/Hr
Capacity
Turndown
Ratio
0%
0
0%
0.0
10%
0
0%
0.0
18% (Stop Level)
400,000
(117 kW)
8%
12.5
30%
997,217
(292 kW)
20%
5.0
40%
1,667,848 (489 kW)
33%
3.0
50%
1,992,380 (584 kW)
40%
2.5
60%
2,486,881 (729 kW)
50%
2.0
70%
2,981,381 (874 kW)
60%
1.7
80%
3,780,230 (1108 kW)
76%
1.3
90%
4,375,500 (1282 kW)
88%
1.1
100%
5,000,000 (1465 kW)
100%
1.0
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BMK 5000 Gas Pressure De-Rating Chart
56”
14”
10”
Gas Pressure @ SSOV
in inches W.C. (kPa)
Inlet
Outlet
(13.9 kPa)
6.8” (1.70 kPa)
(3.49 kPa)
6.8” (1.70 kPa)
(3.23 kPa)
6.8” (1.70 kPa)
Energy Input in
BTU/hr
Oxygen
(%O2)
DeRating
(% Full Fire)
5,000,000 (1465 kW)
5,000,000 (1465 kW)
5,000,000 (1465 kW)
5.7
5.7
5.7
0%
0%
0%
3.4.2 Benchmark 6000 Air/Fuel Valve Position and Energy Input
BMK 6000 Air/Fuel Valve Position and Energy Input
Air Fuel Valve
Position
(% Full Open)
Boiler Energy Input
% of Full
BTU/Hr
Capacity
Turndown
Ratio
0%
0
0%
0.0
10%
0
0%
0.0
18% (Stop Level)
385,000
(113 kW)
6%
15.6
20%
400,000
(117 kW)
7%
15.0
30%
540,000
(158 kW)
9%
11.1
40%
770,000
(226 kW)
13%
7.8
50%
1,160,000 (340 kW)
19%
5.2
60%
1,650,000 (484 kW)
28%
3.6
70%
2,386,000 (699 kW)
40%
2.5
80%
3,515,000 (1030 kW)
59%
1.7
90%
4,650,000 (1362 kW)
78%
1.3
BMK 6000 Gas Pressure De-Rating Chart
56”
14”
13”
Gas Pressure @ SSOV
in inches W.C. (kPa)
Inlet
Outlet
(13.9 kPa)
8” (1.99 kPa)
(3.49 kPa)
8” (1.99 kPa)
(3.23 kPa)
8” (1.99 kPa)
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Energy Input in
BTU/hr
Oxygen
(%O2)
DeRating
(% Full Fire)
6,000,000 (1758 kW)
6,000,000 (1758 kW)
5,860,000 (1717 kW)
5.40
5.40
5.45
0%
0%
2%
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SECTION 3: START SEQUENCE
3.5 Boiler Energy Input Charts
Boiler Energy Input BMK 5000
Energy Input (BTU/hr)
5,000,000
4,000,000
3,000,000
2,000,000
Input Rate
1,000,000
0
0
10
20 30 40 50 60 70 80
Air/Fuel Valve Position (% Open)
90
100
Figure 3-5: Relationship Between BMK 5000 Air/Fuel Valve Position and Energy
Input
Boiler Energy Input BMK 6000
Figure 3-6: Relationship Between BMK 6000 Air/Fuel Valve Position and Energy
Input
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Figure 3-7: Burner Ignition Sequence Flow Chart
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SECTION 3: START SEQUENCE
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SECTION 4: INITIAL START-UP
SECTION 4: INITIAL START-UP
4.1 INITIAL START-UP REQUIREMENTS
The requirements for the initial start-up of the Benchmark boiler consists of the following:
•
Complete the installation (Section 2: Installation, above)
•
Set proper controls and limits (Section 2: Operation of the of the Benchmark 5000 –
6000 Operation and Maintenance Guide-INTERNATIONAL OMM-0130 (GF-208-I)
•
Perform combustion calibration (Section 4.4: Combustion Calibration, below)
•
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 in this section, below, you must perform the
procedures in Section 5: Safety Device Testing, below, before putting the unit into service.
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. 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.
NOTE
All applicable installation procedures in Section 2: Installation must be completed before
attempting to start the unit.
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SECTION 4: INITIAL START-UP
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 of the
unit:
•
Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and
Nitrogen Oxide (NOx) resolution to 1 PPM.
•
0 to 16” W.C. (0 to 4.0 kPa) manometer or equivalent gauge and plastic tubing.
•
OPTIONAL: 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
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 4.4
Combustion Calibration.
The gas supply manometer is installed at the upstream and/or downstream location shown in
Figure 4-1.
The gas supply manometer is installed at the downstream location shown in Figure 4-1.
TO AIR/FUEL
VALVE
MANUAL
SHUT-OFF
VALVE
DOWNSTREAM
SSOV WITH POC
UPSTREAM LEAK
DETECTION BALL VALVE
Alternative location for
manometer if hose
barb is preferred
UPSTREAM LOW
GAS PRESSURE SWITCH
- BMK 6000: 8.5” W.C. (2.1 kPa)
- BMK 5000: 8.0” W.C. (2.0 kPa)
Install manometer here
for Combustion
Calibration.
HIGH GAS PRESSURE SWITCH
- BMK 6000: 10.5” W.C. (2.6 kPa)
- BMK 5000: 11.0” W.C. (2.7 kPa)
Figure 4-1: Port Location for Combustion Calibration
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To monitor the gas pressure on the downstream side of the SSOV during Combustion
Calibration (in Section 4.5, below), install the 16” W.C. (4.0 kPa) manometer(s) as described in
the following steps:
Gas Supply Manometer Installation Instructions
1. Turn off the main gas supply upstream of the unit.
2. Remove the front panel from the boiler to access the gas train components.
3. To monitor the gas pressure on the downstream side of the SSOV during Combustion
Calibration (section 4.5, below), locate the port on the side of the High Gas Pressure
switch, as shown in Figure 4-1, 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 4-1, above, and install a hose barb fitting in that location.
4. Attach one end of the plastic tubing to the port or barbed fitting and the other end to the 0
to 16 inch W.C. (0 to 4.0 kPa) manometer.
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 4-2.
Prepare the port for the combustion calibration as shown below.
Analyzer Probe Port Access Instructions
1. Refer to Figure 4-2 and remove one of the three 1/4” NPT plug from the desired location on
the exhaust manifold. There are three 1/4” NPT ports, one in the front of the exhaust
manifold and two in the rear, on the left and right sides.
2. If necessary, adjust the stop on the combustion analyzer probe; if using the front port, the
probe should be inserted as far as possible. DO NOT install the probe at this time.
EXHAUST
MANIFOLD
CONDENSATE
DRAIN
FRONT
REAR
ANALYZER PROBE PORTS WITH 1/4” PLUGS
1 IN FRONT
2 IN REAR
PARTIAL RIGHT SIDE VIEW
Figure 4-2: Analyzer Probe Hole Locations
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SECTION 4: INITIAL START-UP
4.3 PILOT IGNITION
Benchmark 5000 and 6000 boilers are equipped with an interrupted pilot ignition system. The
pilot is ignited by a spark discharge within the Pilot Burner inside the combustion chamber. The
input of the Pilot flame is approximately 18,000 BTU/hr. (5.3 kW). The Pilot Burner flame will
stay ignited until the main Burner flame has stabilized and FLAME PROVEN appears in the CMore Controller’s display.
A Pilot gas supply regulator reduces the supply pressure from line pressure to 4.9” W.C. (1.2
kPa). An orifice (0.073” dia., 1.85 mm) further restricts the gas flow to the Pilot.
The Pilot Burner should be inspected at the beginning of each heating season, or every 6
months for continuous operation. It is constructed of high quality, heat resistant stainless steel,
however some darkening of the metal is expected. No adjustment of the Pilot should be
required, however the gas pressure downstream of the regulator should be checked if an
ignition issue is encountered. Refer to Figure 4-1 for test port location.
The Pilot flame is proven by two Pilot Flame Detectors, located above and below the Pilot. The
two Pilot Flame Detectors are optical sensors inserted into tubes with quartz windows; they
observe the Pilot through holes in the refractory. They have a red LED which changes from
flashing to steady-ON when they encounter the flicker of a flame that meets or exceeds the
internal sensing threshold. (Only one of the two detectors needs to sense the pilot flame
throughout the ignition period). The holes in the refractory should be checked annually to ensure
that the optical path to the Pilot Burner is clear.
NOTE:
The pilot flame detectors switch the signal to neutral when the flame is proven.
4.4 COMBUSTION CALIBRATION
The Benchmark boiler was combustion calibrated with either standard combustion (NOx
emissions of <20 ppm) or Ultra-Low NOx (NOx <9 ppm) at the factory prior to shipping,
depending on which was ordered.
However, 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
sheets 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 procedure below, as it will keep readjustments to a
minimum and provide optimum performance.
BRASS HEX HEAD
(Remove to access
Gas Pressure
Adjustment Screw).
TAC SCREW
Figure 4-3: Gas Pressure Adjustment Screw and TAC Screw Location
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SECTION 4: INITIAL START-UP
The instructions below apply only to units running on Natural Gas.
Natural Gas Combustion Calibration Instructions
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 and then slowly open the Pilot gas
valve.
3. Set the C-More Controller’s ON/OFF switch to the OFF position.
4. Turn external AC power to the unit ON. 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 ▼ arrow key and then pressing
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 to 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 50%. The unit should begin its
start sequence and fire.
14. Next, verify that the gas pressure downstream of the SSOV is within the range in Table 41, for the model you are calibrating. If gas pressure adjustment is required, remove the
brass hex nut on the SSOV actuator to access the gas pressure adjustment screw (Figure
4-3). Make gas pressure adjustments using a flat-tip screwdriver to obtain a gas pressure
in the range specified in Table 4-1.
TABLE 4-1: Gas Pressure Range @ 100% Fire Rate
Model
Single-Fuel
Dual-Fuel
5000
6.3” ± 0.2” W.C. (1.56 ± 0.05 kPa)
6.3” ± 0.2” W.C. (1.56 ± 0.05 kPa)
6000
7.9” ± 0.2” W.C. (1.97 ± 0.05 kPa)
7.9” ± 0.2” W.C. (1.97 ± 0.05 kPa)
15. Once the manifold gas pressure is within the range in Table 4-1, record this value; it will be
used later, in Section 5.2: Low Pressure Gas Test, and Section 5.3: High Pressure Gas
Test.
16. Press the Down▼ arrow key until SET Valve Position appears on the display, then press
CHANGE.
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SECTION 4: INITIAL START-UP
Natural Gas Combustion Calibration Instructions
17. Press the Up ▲ arrow key until the SET Valve Position reads 100%, then press ENTER.
18. With the valve position at 100%, insert the combustion analyzer probe into the exhaust
manifold probe opening (see Figure 4-2) and allow enough time for the combustion
analyzer reading to stabilize.
19. Compare the combustion analyzer’s oxygen readings to the O2 Sensor value displayed in
the Operating menu on the C-More Controller. If the values differ by more than ±1.5% and
your combustion 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. Also, ensure
that the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the
values shown in Table 4-2. If your target NOx value is 9 ppm or less, use the values in the
Ultra-Low NOx columns. If you are not in a “NOx-limited” area and/or do not have a NOx
measurement in your analyzer, set the oxygen (O2) at 5.5% ± 0.5%.
TABLE 4-2: Calibration Reading at 100% Valve Position
Valve
Position
100%
Standard NOx
Oxygen (O2)
Nitrogen
%
Oxide (NOx)
5.5% ± 0.5%
≤20 ppm
Ultra-Low NOx
Oxygen (O2)
Nitrogen
%
Oxide (NOx)
6.0% ± 1.0%
≤9 ppm
Carbon
Monoxide (CO)
<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 the 100% valve position should match the value in Table 4-2. Also,
ensure that the NOx and CO readings do not exceed the values in Table 4-2.
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 within 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 the downstream side of the SSOV
must be adjusted using the gas pressure adjustment screw on the SSOV (Figure 4-3).
Slowly rotate the gas pressure adjustment in 1/4-turn increments, clockwise to reduce O2
level or counterclockwise to increase it. Allow the combustion analyzer to stabilize following
each adjustment.
27. Once the oxygen level is within the specified range at 100%, record the O2, NOx and CO
readings on the Combustion Calibration Data Sheets provided with the unit.
28. Lower the valve position to 70% using the ▼arrow key.
NOTE:
Remaining combustion calibration steps are performed using the Combustion Cal menu in
the C-More Controller. 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.
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SECTION 4: INITIAL START-UP
Natural Gas Combustion Calibration Instructions
29. Repeat steps 21 through 25 for valve positions shown in Table 4-3. The O2, NOx and CO
should stay within the ranges shown Table 4-3.
TABLE 4-3: Final Valve Positions
Valve
Position
Standard NOx
Nitrogen
Oxide (NOx)
70%
Oxygen (O2)
%
5.5% ± 0.5%
50%
Ultra-Low NOx
Carbon
Monoxide
(CO)
<20 ppm
Oxygen (O2)
%
6.0% ± 1.0%
Nitrogen
Oxide (NOx)
≤9 ppm
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤9 ppm
<100 ppm
40%
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤9 ppm
<50 ppm
30%
5.5% ± 0.5%
<20 ppm
6.0% ± 1.0%
≤9 ppm
<50 ppm
18%
6.0% ± 1.0%
<20 ppm
6.5% ± 1.5%
≤9 ppm
<50 ppm
<100 ppm
NOTE:
If NOx readings exceed the target values in Table 4-3, increase the O2 level up to 1% higher
than the range shown in the table. Record the increased O2 value on the Combustion
Calibration sheet.
30. If the oxygen level at the 18% valve position is too high and the Blower voltage is at the
minimum value, you can adjust the TAC screw, which is recessed in the top of the Air/Fuel
Valve (see Figure 4-3). Rotate the screw 1/2 turn clockwise (CW) to add fuel and reduce
the O2 to the specified level. Recalibration MUST be performed again from 50% down to
the lowest valve position after making a change to the TAC screw.
This completes the Natural Gas combustion calibration procedure.
4.5 REASSEMBLY
Once the combustion calibration adjustments are properly set, the unit can be reassembled for
service operation.
Reassembly Instructions
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 and barbed fittings and reinstall the NPT plug using a suitable
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.
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SECTION 4: INITIAL START-UP
4.6 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 4-4. 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). This
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 4-4 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 4-4 and 4-5 is preset at the 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 OverTemperature Alarm can be checked or adjusted using the procedure in section 4.6.1.
ADJUSTABLE TEMPERATURE
LIMIT SWITCH (AUTO-REST)
DIGITAL OVER-TEMPERATURE
LIMIT CONTROLLER
RESET BUTTON FOR MANUAL
TEMPERATURE LIMIT SWITCH
MANUAL TEMPERATURE LIMIT
SWITCH
Figure 4-4: Over-Temperature Limit Switch Location
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SECTION 4: INITIAL START-UP
4.6.1 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 4-5 and
Table 4-4.
Figure 4-5: Digital Over-Temperature Alarm Switch Front Panel
TABLE 4-4: Over-Temperature Alarm Switch Controls and Display
CONTROL/DISPLAY
MEANING
LED Display
TEMP status
RST
RESET Button
SET
FUNCTION
Displays current water temperature or setpoint.
Resets the unit after an alarm condition.
UP Button
Increases the displayed temperature.
DOWN Button
Decreases the displayed temperature.
SET Button
Used to access and store parameters in the unit.
Perform the following steps to check or adjust the Over-Temperature Alarm switch settings:
Over-Temp Alarm Switch Check and Adjustment Instructions
1. Set the ON/OFF switch to the ON position.
2. Press the SET button on the Over-Temperature Alarm switch. SP will appear in the
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-Temperature 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 this
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) offset. Press SET to enter 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 mode has been exited, the display will show the current outlet
water temperature of the boiler.
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SECTION 4: INITIAL START-UP
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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 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 5000 – 6000 Operation and Maintenance Guide-INTERNATIONAL OMM0130 (GF-208-I).
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, 380 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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SECTION 5: SAFETY DEVICE TESTING
5.2 LOW GAS PRESSURE TEST
The steps and pressure setting required to check the Low Gas Pressure switch are described
below. This switch is in the normally open (N.O.) position. Refer to Figure 5-1 for the location of
the switch and where to connect the water column manometer or gauge when performing the
test.
The Low Gas Pressure switch is adjustable; the instructions below set it to the correct position.
LOW Gas Pressure Test Instructions
1. Shut off the external gas supply upstream to the unit by closing the external gas supply
ball valve (not shown).
2. Remove the front panel from the boiler to access the gas train components.
3. Locate the port on the top of the Low Gas Pressure switch (see Figure 5-1) 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 5-1 and install a hose barb fitting in that
location.
4. Attach one end of the plastic tubing to the port or barb fitting and the other end to a 0“
W.C. to 2 psi (0 – 14 kPa) manometer.
5. Apply the reading of the manifold pressure taken in Step 15 of Section 4.4 and plug it into
the following formulas, which calculate the minimum allowable gas pressure:
•
Natural Gas Pressure ____ x 0.5 + 6.0 = ______ min gas pressure
6. Remove the cover from the Low Gas Pressure switch and set the dial indicator to 2 (the
minimum).
7. Open the external gas supply ball valve upstream of the unit.
8. Place the unit in MANUAL mode and adjust the Air/Fuel Valve position (% open) to 100%.
9. While the unit is firing, read the CO value on the combustion analyzer and slowly decrease
the incoming gas supply pressure until the CO reading is approximately 300 ppm.
10. Take a reading of the inlet gas pressure. If the inlet pressure is below the minimum
calculated in step 5, above, then increase the pressure to match the calculated 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 prior 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.
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SECTION 5: SAFETY DEVICE TESTING
LOW Gas Pressure Test Instructions
Alternative location for manometer
if hose barb is preferred
TO
AIR/FUEL
VALVE
MANUAL
SHUT-OFF
VALVE
NATURAL GAS Low Gas
Pressure Test Port
Install manometer here
Figure 5-1: Low Gas Pressure Switch Locations & Test Ports
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SECTION 5: SAFETY DEVICE TESTING
5.3 HIGH GAS PRESSURE TEST
To simulate a high gas pressure fault perform the following steps:
HIGH Gas Pressure Test Instructions
1. Shut off the external gas supply by closing the external gas supply ball valve.
2. Locate the port on the top of the NATURAL GAS High Gas Pressure Switch (see Figure
5-3) 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 the top half of Figure
5-3 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 0 – 16”
W.C. (0 – 4.0 kPa) manometer.
4. Apply the reading of the manifold pressure taken in Step 15 of Section 4.4 and plug it into
the following formulas, which calculate the maximum allowable gas pressure:
•
Natural Gas Pressure  ______ x 1.5 = ______ max gas pressure
5. Remove the cover from the High Gas Pressure switch and set the dial indicator to 20 (the
maximum).
6. Open the external gas supply ball valve upstream of the unit.
7. Start the unit in MANUAL mode and adjust the Air/Fuel Valve position to bring the unit up
to 100%,
8. Slowly increase the manifold gas supply pressure by turning the Gas Pressure Adjustment
Screw in the Downstream SSOV (see Figure 5-2) while reading the CO level on the
combustion analyzer. Adjust the manifold pressure until the CO reading is 300 ppm. Note
the number of turns you make, as you will turn it back to its original position in step 11,
below.
BRASS HEX HEAD
(Remove to access
the Gas Pressure
Adjustment Screw).
Figure 5-2: SSOV with Gas Pressure Adjustment Screw Location
9. Take a reading of the manifold gas pressure. If the manifold pressure is greater than the
maximum calculated in step 3, then use the Gas Pressure Adjustment Screw to decrease
the manifold pressure until it is at the maximum allowed.
10. 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.
11. Readjust the manifold gas supply pressure to what it was before it was increased in step 8.
12. Press the CLEAR button on the Control Panel to clear the fault.
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SECTION 5: SAFETY DEVICE TESTING
HIGH Gas Pressure Test Instructions
13. Upon test completion, remove the manometer, and turn the NATURAL GAS High Gas
Pressure Switch port screw clockwise until port is closed.
NATURAL GAS HIGH GAS
PRESSURE SWITCH
- BMK 6000 – 10.5” W.C., 2.6 kPa
- BMK 5000 – 11.0” W.C., 2.7 kPa
Alternative location
for manometer if hose
barb is preferred
DOWNSTREAM
SSOV WITH POC
SWITCH
NATURAL GAS HIGH Gas
Pressure Port
Install manometer here for High
Gas Pressure test
Figure 5-3: High Gas Pressure Switch Locations & Test Ports
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SECTION 5: SAFETY DEVICE TESTING
5.4 LOW WATER LEVEL FAULT TEST
To simulate a low water level fault, proceed as follows:
LOW Water Fault Test Instructions
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 fault 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
should not start. If the unit does start, shut the unit off immediately and refer fault to
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 to 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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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 5-4, below.
Water Temperature Fault Test Instructions
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 Over-Temperature switch setting is approximately at, or just below,
the actual outlet water temperature, the unit should shut down. The FAULT indicator
should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be
displayed. It should not be possible to restart the unit until the water temperature is below
the new setpoint.
4. Reset the adjustable Over-Temperature switch to its original setting.
5. The unit should start once the adjustable Temperature Limit switch setting is above the
actual outlet water temperature.
OVER
TEMPERATURE
LIMIT DIGITAL
CONTROLLER
ADJUSTABLE
TEMPERATURE
LIMIT SWITCH
MANUAL
SWITCH
RESET
BUTTON
MANUAL TEMPERATURE
LIMIT SWITCH
Figure 5-4: Temperature Limit Switch Location
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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 (Figure 2-15) 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
Remote Interlock Test Instructions
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. If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the
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 message should
automatically clear and the unit should restart.
5.6.2 Delayed Interlock Test
Delayed Interlock Test Instructions
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. If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the
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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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:
Flame Fault Test Instructions
1. Set the ON/OFF switch to the OFF position.
2. Place the unit in the MANUAL mode and set the valve position between 25% and 30%.
3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV)
and the Air/Fuel Valve, as shown on Figure 5-5, below.
4. It may be necessary to jump out the High Gas Pressure switch.
5. Set the ON/OFF switch to the ON position to start the unit.
6. The unit should purge and light the Pilot flame and then shut down after reaching the main
Burner Ignition cycle and display FLAME LOSS DURING IGN.
7. Open the valve previously closed in step 3 and press the CLEAR button.
8. Restart the unit and allow it to prove flame.
9. Once flame is proven, close the manual gas valve located between the SSOV and the
Air/Fuel Valve (see Figure 5-5, below).
10. The unit should shut down and Lockout. A flashing FLAME LOSS DURING RUN should
appear in the display.
11. Open the valve previously closed in step 9.
12. Press the CLEAR button. The unit should restart and fire.
5.8 AIR FLOW FAULT TESTS
These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in
Figure 5-5.
BLOCKED INLET
SWITCH
AIR/FUEL VALVE
ASSEMBLY
MANUAL SHUTOFF VALVE
BLOWER
BLOWER PROOF
SWITCH
HEX SCREWS
HOLDING WYE DUCT
TO A/F VALVE
(1 OF 3)
Figure 5-5: Blower Proof & Blocked Inlet Switch Locations
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SECTION 5: SAFETY DEVICE TESTING
5.8.1 Blower Proof Switch Test
Complete the test below to check the operation of the Blower Proof switch shown in Figure 5-5.
Blower Proof Switch Test Instructions
1. Disable the blower output drive voltage as follows:
a) Press the MENU key until CONFIGURATION MENU is displayed.
b) Press the ▲ arrow key until the ANALOG OUTPUT 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 key until CONFIGURATION MENU is displayed.
b) Press the ▲ arrow key until the ANALOG OUTPUT 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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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.
Blocked Inlet Switch Test Instructions
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 5-5, 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 blower! 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) Use jumper wires to jump out the Low Gas Pressure switch and the Blower Proof
switch.
b) Remove the black connector boot from the Flame Detector.
c) Connect the Flame Signal Generator to the black connector boot.
FLAME DETECTOR
CONNECTOR BOOT
FLAME SIGNAL GENERATOR
TO WIRE HARNESS
Figure 5-6: 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 C-More Controller gets into the ignition phase, the control panel will
show IGNITION TRIAL. At that point attach the alligator clip (see Figure 5-6) to
any bare metal surface or ground. The C-More Controller should now show
FLAME PROVEN and begin to ramp up to 100% fire rate. Note that no gas 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. This step
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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SECTION 5: SAFETY DEVICE TESTING
5.9 SSOV PROOF OF CLOSURE SWITCH CHECK
The SSOV, shown in Figure 5-7, contains the Proof of Closure switch. The Proof of Closure
switch circuit is checked as follows:
SSOV Proof Of Closure Switch Check Instructions
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 cover from the SSOV by loosening the screw shown in Figure 5-7. Lift off the
cover to access the terminal wiring connections.
4. Disconnect wire #148 from the SSOV to “open” the Proof Of Closure switch circuit.
5. The unit should fault and display SSOV SWITCH OPEN.
6. Replace wire #148 and press the CLEAR button.
7. Set the ON/OFF switch to the ON position to start the unit.
8. Remove the wire again when the unit reaches the purge cycle and PURGING is displayed.
9. The unit should shut down and display SSOV FAULT DURING PURGE.
10. Replace the wire on the SSOV and press the CLEAR button. The unit should restart.
SSOV ACTUATOR
COVER
ACTUATOR
COVER SCREW
Figure 5-7: SSOV Actuator Cover Location
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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:
Purge Switch Open During Purge Check Instructions
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 5-8).
4. Remove one of the two wires (#171 or #172) from the Purge switch (Figure 5-9).
5. Initiate a unit start sequence.
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 button. The unit should
restart.
AIR/FUEL VALVE COVER
(ROTATE TO REMOVE)
Figure 5-8: Air/Fuel Valve Cover Location
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SECTION 5: SAFETY DEVICE TESTING
TO BLOWER
PURGE
POSITION
SWITCH
STEPPER
MOTOR
DIAL
IGNITION
POSITION
SWITCH
AIR IN
Figure 5-9: Air/Fuel Valve Purge and Ignition Switch Locations
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:
Ignition Switch Open During Ignition Check Instructions
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 5-8, above) by rotating the cover
counterclockwise to unlock and lift up to remove.
4. Remove one of the two wires (#169 or #170) from the Ignition switch (see Figure 5-9,
above).
5. Initiate a unit start sequence.
6. The unit should begin its start sequence and then shut down and display IGN SWITCH
OPEN DURING IGNITION.
7. Replace the wire on the Ignition switch and press the CLEAR button. The unit should
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 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 to 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 defined 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 status information, 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.
NOTE: Use either FFWD Header Sensor
or Modbus Header Sensor
Figure 6-1: Simplified BST Block Diagram
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, above)
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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 network in
I/O board.
b) Make sure that the Modbus load and bias resistors are properly configured for the system
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 sure that the Modbus load and bias resistors are properly configured 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.
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 5 – 4-20ma Drive AND Direct Wired Header
Complete Section 6.3.5
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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6.3 BST Implementation Instruction
6.3.1 OPTION 1 - Constant Setpoint With Direct Wired Header Sensor
OPTION 1 - Constant Setpoint With Direct Wired Header Sensor
Instructions
Step 1: Direct Wired Header Sensor Wiring
1. On the MANAGER Unit, Connect the Header Temperature Sensor (P/N 61040) to the Feed
Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled Header Temp
sensor in the I/O Box.
NOTES:
•
•
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
Shielded pair 18 - 22 AWG cable is recommended for header sensor wiring. There is no
polarity to be observed. The ground for the shield is at the “SHLD” terminal in the I/O
the Box. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 61040
HEADER TEMP SENSOR I/O BOX
Step 2: Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the desired Setpoint.
4. Go to the BST Setup menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Constant Setpoint.
6. Go to the Head Temp Source item and select FFWD Temp.
When ALL C-More units have been configured:
7. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.3.2 OPTION 2 - Constant Setpoint With Modbus Wired Header
Sensor
OPTION 2 - Constant Setpoint With Modbus Wired Header Sensor
Instructions
Step 1: MODbus Header Sensor Wiring
1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (P/N 65169)
terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of
the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler
units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
NOTES:
•
•
•
•
Polarity must be observed for the RS485 connections.
The ground for the shield is at the “SHLD” terminal in the I/O the Box.
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 24410
MODBUS TRANSMITTER
I/O BOX
Step 2: Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3.
4.
5.
6.
7.
8.
Go to the BST Setpoint item and enter the desired Setpoint.
Go to the BST Setup Menu item and set to Enabled.
Go to the BST Setpoint Mode item and select Constant Setpoint.
Go to the Head Temp Source item and select Network.
Go to the Header Temp Addr item and enter the Modbus Address (240).
Go to the Header Temp Point item and enter the Modbus Point (14).
When ALL C-More units have been configured:
9. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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6.3.3 OPTION 3 - Outdoor Reset With Direct Wired Header Sensor
And Direct Wired Outdoor Sensor
OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct
Wired Outdoor Sensor Instructions
NOTE:
Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User
Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080 (GF-129) for more
information.
Step 1 - Direct Wired Header Sensor Wiring
1. On the MANAGER Unit, connect the Header Temperature Sensor (P/N 61040) to the Feed
Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled Header Temp
sensor in the I/O Box.
NOTE:
The header sensor must be installed between 2 and 10 (0.61 and 3.1m) feet downstream of
the LAST boiler in the plant’s supply water header. Shielded pair 18 - 22 AWG cable is
recommended for header sensor wiring. There is no polarity to be observed. The ground for
the shield is at the “SHLD” terminal in the I/O the Box. The sensor end of the shield must be
left free and ungrounded.
TEMP SENSOR P/N 61040
HEADER TEMP SENSOR
I/O BOX
Step 2 - Direct Wired Outdoor Sensor
1. On the MANAGER Unit, Connect the Outdoor Temperature Sensor (P/N 61047) to the
“OUT” and “COM” terminals in the I/O Box.
NOTES:
•
•
Twisted shielded pair 18 - 22 AWG cable is recommended for header sensor wiring.
There is no polarity to be observed. The ground for the shield is at the “SHLD” terminal
in the I/O the Box. The sensor end of the shield must be left free and ungrounded.
When mounting the Outdoor 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. The outdoor sensor may
be wired up to 200 feet (61m) from the boiler.
TEMP SENSOR P/N 61047
I/O BOX
(Continued)
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 3 - Outdoor Reset With Direct Wired Header Sensor And Direct
Wired Outdoor Sensor Instructions
Step 3 - Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the Failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Outdoor Reset.
6. Go to the Head Temp Source item and select FFWD Temp.
7. Go to the BST Outdoor Sens item and select Enabled.
8. Go to the Outdoor Temp Source item and select Outdoor Temp.
When ALL C-More units have been configured:
9. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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6.3.4 OPTION 4 - Outdoor Reset With Modbus Header Sensor And
Modbus Outdoor Sensor
OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus
Outdoor Sensor Instructions
NOTE:
Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User
Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080 (GF-129) for more
information.
Step 1 - Modbus Header Sensor Wiring
1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (P/N 65169)
terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of
the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler
units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
NOTES:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
Temp Sensor P/N 24410
Modbus Transmitter
I/O Box
Step 2 - Modbus Outdoor Sensor Wiring
1. If you have not already done so when installing the Modbus Header Sensor, use Shielded
pair 18 - 22 AWG cable to connect the Temperature Transmitter terminal Pin B to the
RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature
Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
(Continued)
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 4 - Outdoor Reset With Modbus Header Sensor And Modbus
Outdoor Sensor Instructions
NOTES:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
When mounting the Outdoor 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. The outdoor sensor may
be wired up to 200 feet (61m) from the boiler.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 61043
MODBUS TRANSMITTER
I/O BOX
Step 3 - Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the Failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Outdoor Reset.
6. Go to the Head Temp Source item and select Network.
7. Go to the Header Temp Addr item and enter the Modbus Address (240).
8. Go to the Header Temp Point item and enter the Modbus Point (14).
9. Go to the BST Outdoor Sens item and select Enabled.
10. Go to the Outdoor Temp Source item and select Network.
11. Go to the Outdoor Temp Addr item and enter the Modbus Address (240).
12. Go to the Outdoor Temp Point item and enter the Modbus Point (15).
When ALL C-More units have been configured:
13. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.3.5 OPTION 5 - Remote Setpoint With Direct Wired Header Sensor
And 4-20ma Setpoint Drive
OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma
Setpoint Drive Instructions
NOTE:
Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller
User Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080 (GF-129) for
more information.
Step 1: Direct Wired Header Sensor Wiring
1. On the MANAGER Unit, Connect the Header Temperature Sensor (P/N 61040) to the Feed
Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled Header Temp
sensor in the I/O Box.
NOTES:
•
•
•
•
•
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
Shielded pair 18 - 22 AWG cable is recommended for header sensor wiring.
There is no polarity to be observed.
The ground for the shield is at the “SHLD” terminal in the I/O the Box.
The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 61040
HEADER TEMP SENSOR
I/O BOX
Step 2: Direct Wired 0-20ma or 4-20ma Wiring
1. Connect the 4-20ma or 0-20ma terminals from the Direct Drive source to the Ain+ and Ain-
terminals on the Manager Unit’s I/O Box.
NOTE:
•
•
Shielded pair 18 - 22 AWG cable is recommended for this connection. Polarity must be
observed.
The ground for the shield is at the driver signal source.
TEMP SENSOR P/N 61040
HEADER TEMP SENSOR
I/O BOX
(Continued)
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BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 5 - Remote Setpoint With Direct Wired Header Sensor And 4-20ma
Setpoint Drive Instructions
Step 3: Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the Failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Remote Setpoint.
6. Go to the Head Temp Source item and select FFWD Temp.
7. Go to the BST Remote Signal and select either 4-20ma or 0-20ma.
When ALL C-More units have been configured:
8. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.3.6 OPTION 6 - Remote Setpoint With Direct Wired Header Sensor
And Modbus Setpoint Drive
OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And
Modbus Setpoint Drive Instructions
NOTE:
Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User
Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080 (GF-129) for more
information.
Step 1 - Modbus Header Sensor Wiring
1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (P/N 65169)
terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of
the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler
units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
NOTES:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
Temp Sensor P/N 24410
Modbus Transmitter
I/O Box
Step 2 - Modbus Outdoor Sensor Wiring
1. If you have not already done so when installing the Modbus Header Sensor, use Shielded
pair 18 - 22 AWG cable to connect the Temperature Transmitter terminal Pin B to the
RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature
Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
(Continued)
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Page 77 of 85
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BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 6 - Remote Setpoint With Direct Wired Header Sensor And
Modbus Setpoint Drive Instructions
NOTES:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
When mounting the Outdoor 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. The outdoor sensor may
be wired up to 200 feet (61m) from the boiler.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 61043
MODBUS TRANSMITTER
I/O BOX
Step 3 - Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the Failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Outdoor Reset.
6. Go to the Head Temp Source item and select Network.
7. Go to the Header Temp Addr item and enter the Modbus Address (240).
8. Go to the Header Temp Point item and enter the Modbus Point (14).
9. Go to the BST Outdoor Sens item and select Enabled.
10. Go to the Outdoor Temp Source item and select Network.
11. Go to the Outdoor Temp Addr item and enter the Modbus Address (240).
12. Go to the Outdoor Temp Point item and enter the Modbus Point (15).
When ALL C-More units have been configured:
13. Go to the Boiler Sequencing Menu item of the Manager unit and set the BST Mode item to
BST MANAGER.
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.3.7 OPTION 7 - Remote Setpoint With Modbus Header Sensor And
4-20ma Setpoint Drive
OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma
Setpoint Drive Instructions
NOTE:
Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller
User Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080 (GF-129) for
more information.
Step 1: MODbus Header Sensor
1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (P/N 65169)
terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of
the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler
units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
NOTES:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 24410
MODBUS TRANSMITTER
I/O BOX
Step 2: Direct Wired 0-20ma or 4-20ma Wiring
1. Connect the 4-20ma or 0-20ma terminals from the Direct Drive source to the Ain+ and Ain-
terminals on the Manager.
NOTES:
•
•
Unit’s I/O Box. Shielded pair 18 - 22 AWG cable is recommended for this connection.
Polarity must be observed.
The ground for the shield is at the driver signal source.
I/O Box
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BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 7 - Remote Setpoint With Modbus Header Sensor And 4-20ma
Setpoint Drive Instructions
Step 3: Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the Failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Remote Setpoint.
6. Go to the BST Remote Signal and select either 4-20ma or 0-20ma.
7. Go to the Head Temp Source item and select Network.
8. Go to the Header Temp Addr item and enter the Modbus Address (240).
9. Go to the Header Temp Point item and enter the Modbus Point (14).
When ALL C-More units have been configured:
10. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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SECTION 6: BOILER SEQUENCING TECHNOLOGY
6.3.8 OPTION 8 - Remote Setpoint With Modbus Header Sensor And
Modbus Setpoint Drive
OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus
Setpoint Drive Instructions
NOTE:
Both Header Sensor AND ProtoNode SSD Device must be wired. See the C-More
Controller User Manual, OMM-0032 (GF-112) and ProtoNode User Manual, OMM-0080
(GF-129) for more information.
Step 1: MODbus Header Sensor
1. Using Shielded pair 18 - 22 AWG cable, Connect the Temperature Transmitter (P/N 65169)
terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of
the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler
units.
2. Using Shielded pair 18 - 22 AWG cable, connect the Modbus Header Temperature Sensor
(P/N 24410) to pins 2 and 3 of the Temperature Transmitter.
3. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter.
NOTE:
•
•
•
Polarity must be observed for the RS485 connections. The ground for the shield is at
the “SHLD” terminal in the I/O the Box.
The header sensor must be installed between 2 and 10 feet (0.61 and 3.1m)
downstream of the LAST boiler in the plant’s supply water header.
There is no polarity to be observed. The ground for the shield is at the power supply
ground. The sensor end of the shield must be left free and ungrounded.
TEMP SENSOR P/N 24410
MODBUS TRANSMITTER
I/O BOX
Step 2: Remote Setpoint with Network
1. Configure and Connect the SSD Device (ProtoNode) per the ProtoNode User Manual,
OMM-0080 (GF-129).
(Continued)
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Page 81 of 85
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BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
SECTION 6: BOILER SEQUENCING TECHNOLOGY
OPTION 8 - Remote Setpoint With Modbus Header Sensor And Modbus
Setpoint Drive Instructions
Step 3: Configure ALL C-More Units
On ALL Boilers:
1. Go to the Configuration menu and set the BST Menu item to Enabled.
2. Go to the Boiler Sequencing Menu and set the BST Mode item to BST Client (for now).
On MANAGER only:
3. Go to the BST Setpoint item and enter the failsafe Setpoint.
4. Go to the BST Setup Menu item and set to Enabled.
5. Go to the BST Setpoint Mode item and select Remote Setpoint.
6. Go to the BST Remote Signal and select either Network.
7. Go to the Head Temp Source item and select Network.
8. Go to the Header Temp Addr item and enter the Modbus Address (240).
9. Go to the Header Temp Point item and enter the Modbus Point (14).
When ALL C-More units have been configured:
10. Go to the Boiler Sequencing Menu of the Manager unit and set the BST Mode item to BST
MANAGER.
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APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS
Appendix A: Dimensional and Clearance Drawings
Drawing Number: AP-A-901 rev L
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BMK 5000-6000 Boiler Install and Startup Guide-INTERNATIONAL
APPENDIX A: DIMENSIONAL AND CLEARANCE DRAWINGS
Drawing Number: SD-A-919 rev F
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Change log:
Date
12/31/2017
Description
Changed By
Rev A: Initial release
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