Instruction Manual

Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual
OMM-0082_0J AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 192
GF-130 Ph.: 800-526-0288 05/21/2014
5.6.1 ACS External Field Wiring ........................................................................................................... 74
5.6.2 ACS Setup and Startup ................................................................................................................ 74
5.7 COMBINATION CONTROL SYSTEM (CCS) ........................................................................................... 74
5.7.1 Combination Control System Field Wiring.................................................................................. 75
5.7.2 Combination Control System Setup and Startup ........................................................................ 75
CHAPTER 6. SAFETY DEVICE TESTING .................................................................. 77
6.1 TESTING OF SAFETY DEVICES ............................................................................................................. 77
6.2 LOW GAS PRESSURE FAULT TEST ...................................................................................................... 78
6.3 HIGH GAS PRESSURE TEST ................................................................................................................. 79
6.4 LOW WATER LEVEL FAULT TEST ........................................................................................................ 80
6.5 WATER TEMPERATURE FAULT TEST .................................................................................................. 81
6.6 INTERLOCK TESTS .............................................................................................................................. 82
6.6.1 Remote Interlock Test ................................................................................................................ 82
6.6.2 Delayed Interlock Test ................................................................................................................ 82
6.7 FLAME FAULT TESTs .......................................................................................................................... 83
6.8 AIR FLOW FAULT TESTS ..................................................................................................................... 84
6.8.1 Blower Proof Switch Test ............................................................................................................ 84
6.8.2 Blocked Inlet Switch Test ............................................................................................................ 84
6.9 SSOV PROOF OF CLOSURE SWITCH ................................................................................................... 86
6.10 PURGE SWITCH OPEN DURING PURGE ........................................................................................... 87
6.11 IGNITION SWITCH OPEN DURING IGNITION ................................................................................... 87
6.12 SAFETY PRESSURE RELIEF VALVE TEST ............................................................................................ 88
CHAPTER 7. MAINTENANCE .................................................................................... 89
7.1 MAINTENANCE SCHEDULE ................................................................................................................ 89
7.2 IGNITER-INJECTOR REPLACEMENT .................................................................................................... 90
7.3 FLAME DETECTOR REPLACEMENT ..................................................................................................... 92
7.4 O
2
SENSOR REPLACEMENT ................................................................................................................ 93
7.5 COMBUSTION CALIBRATION ............................................................................................................. 93
7.6 SAFETY DEVICE TESTING .................................................................................................................... 93
7.7 BURNER ASSEMBLY INSPECTION ....................................................................................................... 93
7.8 CONDENSATE DRAIN TRAP MAINTENANCE ...................................................................................... 96
7.9 AIR FILTER CLEANING & REPLACEMENT ............................................................................................ 98
7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................. 99
7.11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................. 99
CHAPTER 8. TROUBLESHOOTING GUIDE ............................................................ 101
8.1 INTRODUCTION ............................................................................................................................... 101
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .......................................................... 113
CHAPTER 9. RS-232 COMMUNICATION ................................................................ 117
9.1 INTRODUCTION ............................................................................................................................... 117
9.1.1 Aquiring the PuTTY Application ................................................................................................ 117
9.1.2 Logging on to a Remote Machine Using PuTTY ........................................................................ 117
9.1.3 Running a Command on a Remote Machine Using PuTTY ....................................................... 118
9.2 RS-232 COMMUNICATION SETUP ................................................................................................... 119