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Benchmark 5000-6000 Boiler Installation & Startup Manual

SECTION 5:

SAFETY DEVICE TESTING

OMM-0123_E

• GF-207 • 12/17/2019 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page

5.12 SAFETY PRESSURE RELIEF VALVE TEST

Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel
Code, Section VI.

Содержание Aerco Benchmark OMM-0124

Страница 1: ...Power Guide Applies to serial numbers N 19 0001 and above Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty...

Страница 2: ...ATE DRAIN AND PIPING 20 2 9 GAS SUPPLY PIPING 22 2 9 1 Gas Supply Specifications 22 2 9 2 Manual Gas Shutoff Valve 22 2 9 3 External Gas Supply Regulator 22 2 10 AC ELECTRICAL POWER WIRING 24 2 10 1 E...

Страница 3: ...7 DUAL FUEL SWITCHOVER 58 4 7 1 Switchover from NATURAL GAS to PROPANE 59 4 7 2 Switchover from PROPANE to NATURAL GAS 60 4 8 OVER TEMPERATURE LIMIT SWITCHES 61 4 8 1 Digital Alarm Switch Checks and A...

Страница 4: ...tdoor Reset With Modbus Header Sensor And Modbus Outdoor Sensor 83 6 3 5 OPTION 5 Remote Setpoint With Direct Wired Header Sensor And 4 20ma Setpoint Drive 85 6 3 6 OPTION 6 Remote Setpoint With Direc...

Страница 5: ...rk 5000 and 6000 Intake and Output Ranges MODEL INPUT RANGE BTU HR 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 0...

Страница 6: ...ement 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...

Страница 7: ...rotocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 thousandth of an ampere MAX Max Maximum MBH 1000 B...

Страница 8: ...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 SPD...

Страница 9: ...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 p...

Страница 10: ...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 boiler mis operation Design the...

Страница 11: ...ed 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 al...

Страница 12: ...sign 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 th...

Страница 13: ...ight 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 shippe...

Страница 14: ...static PROPANE GAS Dual Fuel and Propane only units Access to 1 1 2 inch 3 8 cm 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...

Страница 15: ...equate 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 When using the...

Страница 16: ...s must be installed on a level 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 th...

Страница 17: ...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 Figure 2 4 Lifting Lug Locatio...

Страница 18: ...e 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 info...

Страница 19: ...ected to 45 street elbows already installed on the heat exchanger of the boiler The relief valve is installed on the top of the boiler as shown in Figure 2 6 A suitable pipe joint compound should be u...

Страница 20: ...hipping container The condensate trap outlet connection features a tapped 3 4 NPT drain port Figure 2 8 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2...

Страница 21: ...olypropylene 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...

Страница 22: ...ed 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 exce...

Страница 23: ...nstallations Except Massachusetts For installations with 3 or more units other than Massachusetts that exceed 1 PSI 6 9 kW gas pressure a separate external gas supply regulator as shown in Figure 2 10...

Страница 24: ...rical 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...

Страница 25: ...ocks 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 i...

Страница 26: ...d 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 ter...

Страница 27: ...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...

Страница 28: ...ory 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...

Страница 29: ...valve A 0 20 mA signal is used 20 mA closed 0 mA open NOTE When driving an isolation valve shorting jumper JP2 MUST be installed on the I O Board On older legacy Benchmark units the two ANALOG OUT te...

Страница 30: ...layed 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...

Страница 31: ...AG 0022 GF 2050 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...

Страница 32: ...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...

Страница 33: ...ratings use a separate contact relay as shown in Figure 2 17 Figure 2 17 Schematic System Pump Start using a Separate Contact Relay The Benchmark pump relay SPDT contact is rated for 10 A Resistive 27...

Страница 34: ...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 install...

Страница 35: ...d 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...

Страница 36: ...nchmark 5000 6000 Boiler Installation Startup Manual SECTION 2 INSTALLATION OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 36 of 95 This page intentionally blan...

Страница 37: ...ull water level can seriously damage the unit and may result in injury to personnel or property damage This situation will void any warranty CAUTION All of the installation procedures in Section 2 mus...

Страница 38: ...ty device switches closed a purge cycle will be initiated 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 p...

Страница 39: ...vents 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...

Страница 40: ...stream 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...

Страница 41: ...ore 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 Rela...

Страница 42: ...s 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...

Страница 43: ...Input BTU Hr of Full Capacity 0 0 0 10 0 0 18 Stop Level 385 000 113 kW 6 20 400 000 117 kW 7 30 540 000 158 kW 9 40 770 000 226 kW 13 50 1 160 000 340 kW 19 60 1 650 000 484 kW 28 70 2 386 000 699 k...

Страница 44: ...Energy Input Charts Figure 3 5 Relationship Between BMK 5000 Air Fuel Valve Position and Energy Input Figure 3 6 Relationship Between BMK 6000 Air Fuel Valve Position and Energy Input 0 1 000 000 2 00...

Страница 45: ...000 6000 Boiler Installation Startup Manual SECTION 3 START SEQUENCE OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 45 of 95 Figure 3 7 Burner Ignition Sequence...

Страница 46: ...chmark 5000 6000 Boiler Installation Startup Manual SECTION 3 START SEQUENCE OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 46 of 95 This page intentionally bla...

Страница 47: ...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...

Страница 48: ...se 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 g...

Страница 49: ...ively 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...

Страница 50: ...e 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 hole...

Страница 51: ...gure 4 3 Gas Pressure Adjustment Screw and TAC Screw Location 4 5 1 NATURAL GAS Combustion Calibration The instructions below apply only to units running on NATURAL GAS Instructions for doing combusti...

Страница 52: ...ve 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 specif...

Страница 53: ...ey 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...

Страница 54: ...5 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 50 65 5 5 0 5 20 ppm 6 0 1 0 9 ppm 100 ppm 40 45 5 5 0 5 20 ppm 6 0 1 0 9 ppm 50 ppm 30 30 5 5 0 5 20 ppm 6 0 1 0 9 ppm 50 ppm 18 18 6 0 1 0 20 ppm 6 5 1 5 9 ppm...

Страница 55: ...OV 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...

Страница 56: ...Nitrogen Oxide NOx Carbon Monoxide CO Single Fuel Dual Fuel 5000 5 5 0 5 5 5 0 5 100 ppm 100 ppm 6000 5 0 0 5 5 0 0 5 100 ppm 100 ppm 21 Next press the Down arrow key until CAL Voltage 100 is displaye...

Страница 57: ...osition Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO Single Fuel Dual Fuel 70 5 5 0 5 100 ppm 150 ppm 50 5 5 0 5 100 ppm 150 ppm 40 5 5 0 5 100 ppm 150 ppm 30 5 5 0 5 100 ppm 150 ppm 18 6 0 1 0 100...

Страница 58: ...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 ven...

Страница 59: ...sing 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 P...

Страница 60: ...ressing 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...

Страница 61: ...imit 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 on the dial Set the dial on this...

Страница 62: ...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 210 F is displayed pres...

Страница 63: ...ck 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 t...

Страница 64: ...ed 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...

Страница 65: ..._ max gas pressure Propane 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 s...

Страница 66: ...the PROPANE gas train starting with opening the port on the side of the PROPANE High Gas Pressure Switch as shown in Figure 5 3 Figure 5 3 High Gas Pressure Switch Locations Test Ports Alternative lo...

Страница 67: ...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 r...

Страница 68: ...he 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 indicato...

Страница 69: ...ition 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...

Страница 70: ...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 close...

Страница 71: ...rew drive to remove the front cover from the switch to reveal the switch setting indicator dial 0 3 in the Figure below COVER WITH LABEL COVER REMOVED Figure 5 6 Blower Proof Switch 4 Set the Controll...

Страница 72: ...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...

Страница 73: ...ween 25 and 30 3 Remove the cover from the SSOV by loosening the screw shown in Figure 5 8 Lift off the cover to access the terminal wiring connections 4 Disconnect wire 148 from the SSOV to open the...

Страница 74: ...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...

Страница 75: ...s 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 9 above by rotating the cov...

Страница 76: ...5 SAFETY DEVICE TESTING OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 76 of 95 5 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in...

Страница 77: ...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 Cli...

Страница 78: ...ce 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 Prot...

Страница 79: ...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 t...

Страница 80: ...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 Ther...

Страница 81: ...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...

Страница 82: ...em 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 Men...

Страница 83: ...erature 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 termi...

Страница 84: ...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...

Страница 85: ...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...

Страница 86: ...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...

Страница 87: ...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 SH...

Страница 88: ...eft 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 ite...

Страница 89: ...ler 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 th...

Страница 90: ...u 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 Setpo...

Страница 91: ...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...

Страница 92: ...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...

Страница 93: ...on Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 93 of 95 Appendix A Dimensional and Clearance Dra...

Страница 94: ...0 6000 Boiler Installation Startup Manual APPENDIX A DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0123_E GF 207 12 17 2019 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 94 of 95 Drawing Number S...

Страница 95: ...ion 5 8 1 DIR 19 04 Added additional requirements to Section 1 2 Emergency Shutdown DIR 19 15 Modified requirement for that housekeeping pad must be level in Section 2 4 2 DIR 19 34 Revised descriptio...

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