Watts Benchmark Aerco OMM-0122 Installation And Start-Up Manual Download

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Benchmark 750-3000 Boiler Installation & Startup Manual

SECTION 3 - START SEQUENCE

OMM-0121_D

•

GF-205

•

5/9/2019

Technical Support

•

(800) 526-0288

•

Mon-Fri, 8 am - 5 pm EST Page 52 of 122

3.4 START/STOP LEVELS – AIR/FUEL & ENERGY INPUT

The Tables below show the relationship between the energy input and Air/Fuel Valve position
for the BMK models covered in this document.

3.4.1 BMK 750/1000 Air/Fuel Valve Position and Energy Input

TABLE 3-2a: BMK 750/1000 Air/Fuel Valve Position – NATURAL GAS

AIR/FUEL VALVE

POSITION (%

OPEN)

ENERGY INPUT

(BTU/HR)

BOILER ENERGY

INPUT (% OF FULL

CAPACITY)

BMK 750

BMK 1000

BMK 750

BMK 1000

10%

18% (Stop Level)

50,000 (14.7 kW)

6.7%

20%

52,000 (15.2 kW)

54,000 (15.8 kW)

6.9%

5.4%

30%

108,000 (31.7 kW)

140,000 (41.0 kW)

14%

40%

246,000 (72.1 kW)

297,000 (87.0 kW)

33%

30%

50%

369,000 (108.1 kW)

443,000 (126.9 kW)

49%

44%

60%

465,000 (136.3 kW)

564,000 (165.3 kW)

62%

56%

70%

554,000 (162.4 kW)

660,000 (193.4 kW)

74%

66%

80%

637,000 (186.7 kW)

789,000 (231.2 kW)

85%

79%

90%

733,000 (214.8 kW)

933,000 (273.4 kW)

98%

93%

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

100%

TABLE 3-2b: BMK 750/1000 Air/Fuel Valve Position – PROPANE GAS

Air/Fuel Valve

Position (%

Open)

Energy Input

(BTU/Hr)

Boiler Energy Input
(% of Full Capacity)

BMK 750

BMK 1000

BMK 750

BMK 1000

10%

18% (Stop Level)

50,000 (14.7 kW

6.7%

5.0%

20%

71,000 (20.8 kW)

9.5%

7.1%

30%

128,000 (37.5 kW)

181,000 (53.0 kW)

17%

18%

40%

373,000 (109.3 kW)

400,000 (117.2 kW)

50%

40%

50%

508,000 (148.9 kW)

562,000 (164.7 kW)

68%

56%

60%

565,000 (165.6 kW)

703,000 (206.0 kW)

75%

70%

621,000 (182.0 kW)

791,000 (231.8 kW)

83%

79%

80%

660,000 (193.4 kW)

865,000 (253.5 kW)

88%

87%

90%

723,000 (211.9 kW)

963,000 (282.2 kW)

96%

100%

750,000 (219.8 kW)

1,000,000 (293.1 kW)

100%

Summary of Contents for Benchmark Aerco OMM-0122

Page 1: ...hmark Power Guide Applies to serial number G 19 0001 and above Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warra...

Page 2: ...0 1000 Supply and Return Piping 21 2 6 2 BMK 1500 3000 Supply and Return Piping 21 2 7 PRESSURE RELIEF VALVE INSTALLATION 23 2 8 CONDENSATE DRAIN AND PIPING 24 2 9 GAS SUPPLY PIPING 26 2 9 1 Gas Suppl...

Page 3: ...REQUIREMENTS 57 4 2 TOOLS INSTRUMENTS FOR COMBUSTION CALIBRATION 57 4 2 1 Required Tools Instrumentation 57 4 2 2 Installing Gas Supply Manometer 58 4 2 3 Accessing the Analyzer Probe Port 60 4 3 FUE...

Page 4: ...ICK START CHART 100 6 3 BST IMPLEMENTATION INSTRUCTION 101 6 3 1 OPTION 1 Constant Setpoint With Direct Wired Header Sensor 101 6 3 2 OPTION 2 Constant Setpoint With Modbus Wired Header Sensor 102 6 3...

Page 5: ...29 3 kW 2 000 000 586 kW 86 000 25 2 kW 1 860 000 545 kW BMK 2500 167 000 48 9 kW 2 500 000 732 kW 144 000 42 2 kW 2 395 000 702 kW BMK 3000 200 000 58 6 kW 3 000 000 879 kW 174 000 51 0 kW 2 874 000...

Page 6: ...anagement 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 wate...

Page 7: ...ducts IP Internet Protocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 thousandth of an ampere MAX Max...

Page 8: ...x 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 Tempe...

Page 9: ...e 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 person...

Page 10: ...boilers in a location other than a boiler room provide a manually operated remote shutdown switch or circuit breaker marked for easy identification at a location readily accessible in the event of bo...

Page 11: ...d on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an ala...

Page 12: ...ign or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the...

Page 13: ...t from the FRONT ONLY NOTE AERCO is not responsible for lost or damaged freight Each unit has a Tip N Tell indicator on the outside of the crate This indicates if the unit has been turned on its side...

Page 14: ...ted below for all models However if Local Building Codes require additional clearances these codes shall supersede AERCO s requirements The minimum acceptable clearances required are as follows Sides...

Page 15: ...2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 15 of 122 Figure 2 1a BMK 750 1000 Clearances Figure 2 1b BMK 1500 2000 Clearances NOTE Ensure that condensate assembly is not located o...

Page 16: ...clear and free from all combustible materials and flammable vapors or liquids FOR MASSACHUSETTS ONLY For Massachusetts installations the unit must be installed by a plumber or gas fitter licensed wit...

Page 17: ...el housekeeping pad to ensure proper condensate drainage The pad thickness must be BMK 750 1000 4 to 6 inch 10 2 to 15 2 cm BMK 1500 3000 4 to 8 inch 10 2 to 20 3 cm If anchoring the unit refer to Fig...

Page 18: ...LATION OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 18 of 122 NOTES All holes are flush with the bottom surface of the frame All dimensions shown are in inches...

Page 19: ...ed below WARNING When using the lifting tab and bar ensure there is no load placed on the gas train or blower Attaching the Lifting Bar BMK 750 1000 Instructions 1 Remove the lifting bar from its ship...

Page 20: ...at exchanger as shown in Figure 2 3b Remove the front top panel from the unit to provide access to the lifting lugs Remove the four 4 lag screws securing the unit to the shipping skid Lift the unit of...

Page 21: ...clean AERCO recommends using Loctite 7649 to prime the mating surfaces and then Loctite 567 as pipe dope Do NOT use Teflon tape Figure 2 4a BMK 750 1000 Supply and Return Locations 2 6 2 BMK 1500 3000...

Page 22: ...9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 22 of 122 Figure 2 4b BMK 1500 2000 and BMK 2500 3000 Supply and Return Locations CONDENSATE DRAIN EXHAUST MANIFOLD BMK 1500 2000 BMK...

Page 23: ...be used on the threaded connections Any excess should be wiped off to avoid getting any joint compound into the valve body The relief valve must be piped to within 12 inches 30 5 cm of the floor to pr...

Page 24: ...t must be level with or lower than the exhaust manifold drain port The base of the condensate trap must be supported to ensure that it is level horizontal The trap must be removable for routine mainte...

Page 25: ...TRAP P N 24441 1 DIAM HOSE NOTE HOUSEKEEPING PAD MUST NOT EXTEND UNDER THE CONDENSATE ASSEMBLY 3 4 NPT NIPPLES UNION EXHAUST MANIFOLD T O FLOOR DRAIN TRAP INLET INTEGRAL ADAPTOR AND THUMBSCREW TOP COV...

Page 26: ...ar of the unit Benchmark 1500 2000 2500 3000 Features a 2 inch 5 08 cm NATURAL GAS gas inlet connection on the top of the unit Benchmark 1500P 2000P 2500P and 3000P Propane Features a 1 inch 2 54 cm P...

Page 27: ...ure to the unit must be sufficient to provide the volume of gas while maintaining gas pressure listed below while operating at maximum capacity TABLE 2 2 Minimum Gas Pressure Requirements Model Natura...

Page 28: ...1 0 kPa BMK 2500 3000 150 000 3 180 000 44 932 4 0 W C 1 0 kPa A lock up style regulator MUST be used when gas supply pressure will exceed 14 W C 3 49 kPa 2 9 3 1 Massachusetts Installations Only For...

Page 29: ...526 0288 Mon Fri 8 am 5 pm EST Page 29 of 122 Figure 2 7a BMK 750 1000 Manual Gas Shut Off Valve and Gas Regulator Figure 2 7b BMK 1500 3000 Manual Gas Shut Off Valve and Gas Regulator 1 MANUAL SHUTO...

Page 30: ...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 Afte...

Page 31: ...de the Power Box on the front of the unit Remove the front panel to access the Power Box which is mounted in the upper part of the unit as shown in Figure 2 8a and 2 8b The internal connections inside...

Page 32: ...gure 2 9a 2 9b and 2 9c does NOT remove power from the terminal blocks Figure 2 9a BMK 750 1000 Power Box Internal Components Figure 2 9b BMK 1500 2000 Power Box Internal Components 12V POWER SUPPLY F...

Page 33: ...exception of the transformer shown in Figure 2 9a 2 9b and 2 9c all of the components in the Power Box are mounted on a DIN rail All electrical conduit and hardware must be installed so that it does...

Page 34: ...assembly of the unit The location of the I O board is shown in Figure 2 10 The I O board terminal strip connections are shown in Figure 2 11 All field wiring is installed from the rear of the panel b...

Page 35: ...nable 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 a...

Page 36: ...up to three ignition cycles If the current is insufficient by the third try the controller will shut down and display a fault message 2 11 5 ANALOG IN The two ANALOG IN terminals and are used when an...

Page 37: ...ore Controller is Valve Position 0 10v and behaves as follows 0 10VDC must be selected for the voltage output used by the Controller to modulate the combustion blower via the I O Box terminals labeled...

Page 38: ...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 d...

Page 39: ...et 42 7m or 0 8 W C 199 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...

Page 40: ...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 th...

Page 41: ...ose 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 b...

Page 42: ...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...

Page 43: ...intenance Guide OMM 0122 GF 206 Sequencing Isolation Valve Installation Instructions 1 Install the sequencing isolation valve in the boiler s hot water outlet pipe Figure 2 15 Figure 2 15 Sequencing I...

Page 44: ...enchmark 750 3000 Boiler Installation Startup Manual SECTION 2 INSTALLATION OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 44 of 122 This page intentionally blank...

Page 45: ...it 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...

Page 46: ...tatus 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 1a through 3 1d for SSOV location Figure...

Page 47: ...iated and the following events will occur a The Blower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on...

Page 48: ...Figure 3 2a BMK 750 1000 Air Fuel Valve in Purge Position Figure 3 2b BMK 1500 3000 Air Fuel Valve In Purge Position 4 Next the blower proof switch on the Air Fuel Valve Figure 3 3a and 3 3b closes Th...

Page 49: ...ompletion 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 ign...

Page 50: ...to the IGNITION TRIAL the C More Controller will abort the Ignition Cycle and shut down the boiler Refer to Section 5 Troubleshooting Guide in the Benchmark 750 3000 Operation and Maintenance Guide OM...

Page 51: ...oad These levels are Factory preset as follows TABLE 3 1a Start Stop Levels NATURAL GAS BMK 750 BMK 1000 BMK 1500 BMK 2000 BMK 2500 BMK 3000 Start Level 22 22 24 24 24 20 Stop Level 18 18 16 18 16 14...

Page 52: ...40 246 000 72 1 kW 297 000 87 0 kW 33 30 50 369 000 108 1 kW 443 000 126 9 kW 49 44 60 465 000 136 3 kW 564 000 165 3 kW 62 56 70 554 000 162 4 kW 660 000 193 4 kW 74 66 80 637 000 186 7 kW 789 000 2...

Page 53: ...Stop Level 76 000 22 3 kW 5 0 20 127 000 37 2 kW 8 5 30 366 000 107 2 kW 24 4 40 629 000 184 3 kW 41 9 50 822 000 240 9 kW 54 7 60 977 000 286 2 kW 65 0 70 1 119 000 327 9 kW 74 5 80 1 255 000 367 7 k...

Page 54: ...8 Stop Level 100 000 29 3 kW 5 7 20 143 000 41 9 kW 11 30 388 000 113 7 kW 23 40 759 000 222 4 kW 37 50 1 069 000 313 2 kW 51 60 1 283 000 375 9 kW 61 70 1 476 000 432 5 kW 74 80 1 675 000 490 1 kW 83...

Page 55: ...NERGY INPUT OF FULL CAPACITY 16 Stop Level 167 000 48 9 kW 6 7 30 430 000 126 0 kW 17 40 770 000 225 7 kW 31 50 1 070 000 422 0 kW 43 60 1 440 000 422 0 kW 58 70 1 815 000 531 9 kW 73 80 2 030 000 594...

Page 56: ...ENERGY INPUT OF FULL CAPACITY 14 Stop Level 200 000 58 6 kW 6 7 30 520 000 152 kW 17 40 880 000 258 kW 29 50 1 270 000 372 kW 42 60 1 680 000 492 kW 56 70 2 100 000 615 kW 70 80 2 390 000 700 kW 80 9...

Page 57: ...AERCO factory trained start up and service personnel After performing the start up procedures below it will be necessary to perform the procedures in Section 5 Safety Device Testing below to complete...

Page 58: ...eam side of the SSOV during Combustion Calibration in Section 4 4 below install the 16 W C 4 0 kPa manometer s as described in the following steps Gas Supply Manometer Installation Instructions 1 Turn...

Page 59: ...c BMK 2500 1 4 Inch Gas Plug Location NATURAL GAS INLET SSOV TO AIR FUEL VALVE LEAK DETECTION BALL VALVE 1 4 NPT PLUG Install manometer here for Combustion Calibration HIGH GAS PRESSURE SWITCH LOW GAS...

Page 60: ...4 2a and 4 2b Prepare the port for the combustion analyzer probe as follows Analyzer Probe Port Access Instructions 1 Refer to Figure 4 2a or 4 2b and remove the 1 4 NPT plug from the exhaust manifold...

Page 61: ...e installer operator to switch between natural gas and propane gas onsite as needed Both fuel types require different combustion calibration values and so care should be taken to ensure the appropriat...

Page 62: ...art 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 The...

Page 63: ...eter 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 Controller until COMBUSTION CAL MENU appears on the display...

Page 64: ...e 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 a...

Page 65: ...e 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 i...

Page 66: ...6 2 0 2 20 ppm 100 ppm 40 6 3 0 2 30 6 0 0 2 20 ppm 50 ppm 30 6 3 0 2 20 5 8 0 2 20 ppm 50 ppm 16 6 0 0 2 16 6 0 0 2 20 ppm 50 ppm BMK 3000 70 5 1 0 2 85 5 4 0 2 20 ppm 100 ppm 50 6 1 0 2 65 5 5 0 2 2...

Page 67: ...Press the MENU key on the front panel of the C More Controller until COMBUSTION CAL MENU appears on the display 11 Press the Up arrow key until SET Stdby V Out Standby Voltage setting appears Verify t...

Page 68: ...e CO 750 1000 5 5 0 5 100 ppm 150 ppm 1500 2000 4 5 0 5 100 ppm 150 ppm 2500 5 0 0 4 100 ppm 150 ppm 3000 5 2 0 4 100 ppm 150 ppm 21 Next press the Down arrow key until CAL Voltage 100 is displayed 22...

Page 69: ...level up to 1 higher than the listed calibration range Record the increased O2 value on the Combustion Calibration sheet 30 Repeat steps 21 through 25 for valve positions shown in Table 4 6 The oxygen...

Page 70: ...ue designated as 16 NOTE If NOx readings exceed the target values in Table 4 6 increase the O2 level up to 1 higher than the listed calibration range shown in the table Record the increased O2 value o...

Page 71: ...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 This co...

Page 72: ...ing the CLEAR key 7 Set the ON OFF switch on the C More Controller to the ON position 8 Press the MENU key once SETUP MENU will be displayed 9 Press the arrow key once PASSWORD will be displayed 10 Pr...

Page 73: ...essing the CLEAR key 7 Apply AC power to the boiler 8 Press the MENU key once SETUP MENU will be displayed 9 Press the arrow key once PASSWORD will be displayed 10 Press the CHANGE key PASSWORD will b...

Page 74: ...ted The adjustable Temperature Limit switch is manually adjustable from 32 F 212 F 0 C 100 C This switch allows the boiler to restart once the temperature drops below the selected temperature setting...

Page 75: ...isplay 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...

Page 76: ...chmark 750 3000 Boiler Installation Startup Manual SECTION 4 INITIAL START UP OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 76 of 122 This page intentionally bla...

Page 77: ...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 AU...

Page 78: ...just the Air Fuel Valve position open between 25 and 30 7 While the unit is firing slowly close the external manual gas shut off valve not shown 8 The unit should shut down and display a GAS PRESSURE...

Page 79: ...Figure 5 1b BMK 1500 2000 LOW Gas Pressure Test Components SSOV GAS INLET TO AIR FUEL VALVE LOW GAS PRESSURE LEAK DETECTION BALL VALVE shown closed HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MA...

Page 80: ...ug shown in Figure 5 2 and install a hose barb fitting in that location 3 Attach one end of the plastic tubing to the port or barb fitting and the other end to a 16 W C 0 4 0 kPa manometer 4 Apply the...

Page 81: ...ppm 10 Take a reading of the inlet gas pressure If the inlet pressure is below the minimum calculated in step 4 above then increase the pressure to match the calculated minimum 11 Slowly turn the ind...

Page 82: ...manometer installed in step 2 and record the gas pressure reading 8 Slowly increase the gas pressure using the adjustment screw on the SSOV while counting the number of turns you make 9 The FAULT ind...

Page 83: ...on test completion close the ball valve and remove the manometer Replace the 1 4 NPT plug removed in step 2 Figure 5 3a BMK 750 1000 HIGH Gas Pressure Test Components Figure 5 3b BMK 1500 2000 HIGH Ga...

Page 84: ...of the plastic tubing to the port or barb fitting and the other end to a 0 16 W C 0 4 0 kPa manometer 3 Apply the reading of the manifold pressure taken in Step 15 of section 4 4 1 natural gas units...

Page 85: ...s Pressure Adjustment Screw to decrease the manifold pressure until it is at the maximum allowed 10 Press the RESET button on the High Gas Pressure switch see Figure 5 4 below 11 Slowly turn the indic...

Page 86: ...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...

Page 87: ...rature 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 sho...

Page 88: ...pport 800 526 0288 Mon Fri 8 am 5 pm EST Page 88 of 122 Water Temperature Fault Test Instructions Figure 5 5b Temperature Limit Switch Location BMK 750 1000 Digital Over Temperature Limit Controller R...

Page 89: ...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 interlo...

Page 90: ...ay 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 locate...

Page 91: ...BLOCKED INLET SWITCHES These tests check the operation of the Blower Proof switch and Blocked Inlet switch shown in Figure 5 6a and 5 6b 5 8 1 Blower Proof Switch Test Figure 5 6a Bare Boiler Partial...

Page 92: ...e switch setting indicator dial 0 3 in the Figure below COVER WITH LABEL COVER REMOVED Figure 5 7 Blower Proof Switch 4 Set the Controller s On Off switch to On and wait for the boiler to go into the...

Page 93: ...ligator 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 th...

Page 94: ...it should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press the CLEAR button 8 Set the ON OFF switch to the ON position to start the unit 9 Remove the wire again when the unit reaches th...

Page 95: ...in 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 Figure 5 10a Air Fuel Valve Co...

Page 96: ...Purge Switch Open During Purge Check Instructions Figure 5 11a Air Fuel Purge and Ignition Locations BMK 1500 3000 Figure 5 11b Air Fuel Purge and Ignition Locations BMK 750 1000 Purge Position Switch...

Page 97: ...MANUAL mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 5 10a or 5 10b above by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove o...

Page 98: ...mark 750 3000 Boiler Installation Startup Manual SECTION 5 SAFETY DEVICE TESTING OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 98 of 122 This page intentionally...

Page 99: ...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...

Page 100: ...orking 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 th...

Page 101: ...he 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 th...

Page 102: ...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...

Page 103: ...ream 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...

Page 104: ...m 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...

Page 105: ...rature 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 termin...

Page 106: ...t free and ungrounded 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...

Page 107: ...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...

Page 108: ...d 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...

Page 109: ...he 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 SHL...

Page 110: ...ft free and ungrounded 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...

Page 111: ...nits 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 Tem...

Page 112: ...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 Setpoi...

Page 113: ...ts 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...

Page 114: ...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 S...

Page 115: ...E DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 115 of 122 Appendix A Dimensional and Clearance Drawings Benchmark 750 1000 Dimension Drawing AP A 891 r...

Page 116: ...allation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 116 of 122 Benchmark 750 1000 Single Unit Cle...

Page 117: ...tallation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 117 of 122 Benchmark 750 1000 Zero Side Clea...

Page 118: ...stallation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 118 of 122 Benchmark 1500 2000 Dimension Dr...

Page 119: ...stallation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 119 of 122 Benchmark 1500 2000 Clearance Dr...

Page 120: ...stallation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 120 of 122 Benchmark 2500 3000 Dimension Dr...

Page 121: ...stallation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0121_D GF 205 5 9 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 121 of 122 Benchmark 2500 3000 Clearance Dr...

Page 122: ...achusetts Section 2 12 1 DIR 18 55 Changed Air Inlet Temp Sensor part number from 61024 to 123449 in Section 2 11 2 Reference PIR 1542 DIR 18 61 Updated Blower Proof Switch Test Section 5 8 1 DIR 18 6...

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