TECHNICAL INSTRUCTIONS

Transcription

1 TECHNICAL INSTRUCTIONS 460 VAC to 230 VAC Conversion for BMK 3000 Applies to: BMK 3000 Boilers Description of Document: This provides the instructions necessary to convert a BMK 3000 boiler from standard 460 VAC to 230 VAC. BMK 3000 Blower Wiring Compartment Created: 09/20/2012 MC: 09/13/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 1 of 16

2 Technical Support: (Mon Fri, 8am-5pm EST) Disclaimer The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 2 of 16

3 TABLE OF CONTENTS 1. OVERVIEW PARTS AND MATERIALS BMK VAC TO 230VAC CONVERSION PROCEDURE Preparation of Boiler for Conversion Zero Side Clearance Instructions Removing the Wire Harness and Transformer Replacing the Blower Unwiring the Blower Disassembly of Old Blower Assembling the New Blower Wiring the New Blower MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 3 of 16

4 1. OVERVIEW This document provides the instructions for converting a BMK 3000 boiler from 460 Volt AC operation to 230 Volts AC operation. This procedure requires removal of the wire harness, transformer, replacement of the blower, rewiring the blower, and finally, reassembly of all parts. WARNING! HIGH VOLTAGES ARE USED TO POWER THESE UNITS AND SO IT IS REQUIRED THAT ALL POWER APPLIED TO THESE UNITS IS REMOVED FIRST BEFORE PERFORMING ANY OF THE PROCEDURES DESCRIBED IN THIS DOCUMENT. SERIOUS PERSONAL INJURY OR DEATH MAY OCCUR IF THIS WARNING IS NOT OBSERVED. 2. PARTS AND MATERIALS The following parts are required to perform this procedure: Item Quantity Part Number Description Blower, VAC, Hz, 3 Phase Blower Outlet to Blower Plenum Gasket A/F Plenum Outlet to Blower Inlet O Ring Plastic Holding Ring 5 1 N/A 7-1/2 long 12 AWG wire 6 4 GP Elastic Lock Nut Supplementary materials are also required as follows: GF BMK3000 (O&M Manual for reference) Loctite-242 Thread Locker Dow Corning 111 Valve Lubricant and Sealant MC: 09/13/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 4 of 16

5 3. BMK VAC TO 230VAC CONVERSION PROCEDURE The conversion procedure is as follows: 3.1 Preparation of Boiler for Conversion 1. Turn OFF the gas supply by turning OFF external gas supply valve, then disconnect AC power from the Benchmark unit by turning OFF the external circuit breaker. 2. Open and remove the front panel door on the unit. 3. Remove the left side, right side, and top panels from the unit to provide access to the installed blower assembly, gas train, and electrical wiring connections. NOTE In units with zero side clearance, it is not possible to perform the procedure from the sides, so it is not necessary to remove the side panels. See Section 3.2 for zero side clearance preparation. 3.2 Zero Side Clearance Instructions When converting a BMK 3000 with zero side clearance, the procedure is the same as for units with side clearance, except it must be performed from the front. To provide proper access from the front of the unit, do the following: 1. Remove the front panel door and the top panel. 2. Remove each of the six connectors from the rear of the C-More controller (Figure 3-1) C-More Controller Rear Panel Figure 3-1: C-More Controller Rear Panel Showing the Six Cable Connectors MC: 09/13/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 5 of 16

6 3. The C-More control panel must be removed by removing the four nuts that affix the control panel to the right side boiler frame. See Figure 3-2. Four (4) Each Mounting Nuts Figure 3-2: C-More Controller Rear Panel Mounting Locations 4. After preparation for front access (if required), proceed to Section 3.3. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 6 of 16

7 3.3 Removing the Wire Harness and Transformer 1. Locate the power box cover per Figure 3-3, unscrew the two fastening screws at the cover top, and remove the cover. Power Box Cover Figure 3-3: Power Box Location Front Upper View 2. Refer to Figure 3-4 and remove wires #316 and #317 from the breaker/switch in the power wiring box. 3. Refer to Figure 3-4 and remove the Green ground wire, #319, the Black, #315, and the White, #314 wire from their locations in the power wiring box. 4. Strip approximately 1/2 insulation from both ends of the 7-1/2 jumper wire. Install the jumper where the Black wire, #315 was removed from the left most terminal of the breaker/switch in the power wiring box. See Figure 3-4. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 7 of 16

8 IMPORTANT NOTE! Solid wires shown in the diagram of Figure 3-4 should be removed from their connections in the power box. All wires NOT shown in the diagram should remain connected. The dotted wire is the jumper added per Step 4. Figure 3-4: AC Power Wiring Box Showing Wires to Be Disconnected MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 8 of 16

9 5. Locate the 500VAC to 120VAC step-down transformer per Figure 3-5. Remove all wires connected to the transformer, which include wires # 314, 315, 316, 317, and VAC to 120VAC Step-down Transformer Figure 3-5: 500VAC to 120VAC Step-Down Transformer Location Left Side View Step 6: Disassemble transformer from chassis by removing 2 bolts here and 2 bolts on other side. Figure 3-6: 500VAC to 120VAC Step-Down Transformer Disassembly from Chassis 6. Remove the power wiring harness from the unit and the transformer from the shell. NOTE It is recommended to remove ALL wires from the step-down transformer BEFORE disassembling it from the chassis. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 9 of 16

10 3.4 Replacing the Blower Unwiring the Blower 1. Refer to Figure 3-7, and remove the wiring compartment cover from the blower. Blower Wiring Compartment Cover Figure 3-7: Blower Wiring Compartment Location Signal Wiring Terminal Strip Jumper Wire (between PWM and GND) Signal Wiring Strain Relief GND (Wire #102, Black) 0-10VDC (Wire #101, Red) GRND (Green Wire) L1 (Wire #331) AC Wiring Strain Relief L2 (Wire #332) L3 (Wire #333) AC Wiring Terminal Strip Figure 3-8: Blower Wiring Compartment Showing Wires to Disconnect MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 10 of 16

11 2. Refer to Figure 3-8 and remove wire # s 331, 332, & 333 from terminals L1, L2 and L3. 3. Remove wire # 101 (red), and wire # 100 (black), from the blower s 0-10 VDC and GND terminals on the blower s signal input terminal strip (Figure Remove the green ground wire from its terminal between the 3 phase voltage and signal wiring terminal strips (Figure 3-8). 5. Loosen the strain reliefs attaching the wires to the blower and remove the wires from the blower wiring compartment Disassembly of Old Blower There are two ways to remove the blower; either from the left side, or in the case of having zero side clearance, from the front. However, the steps required are the same for both as follows. 1. Referring to figure 3-9, remove the air filter from the inlet side of the air/fuel valve to prevent damage to it during the conversion procedure. NOTE Though there is a sturdy U bolt that fastens the gas train to the boiler frame, it is recommended, as a precaution, to support the weight of the gas train, air/fuel valve and attached plenum before disassembling from the blower. A 2x4 piece of wood approximately 41.5 long or a modified clamp, as shown in Figure 3-9, should be inserted behind the gas train flange (upper support) and the boiler frame (lower support) AFTER removal of the Air Filter. Upper Brace Support (just behind the gas train flange to the air/fuel valve). Step 1: Remove Air Filter Brace made from 2x4 board or clamp. Lower Brace Support (on the chassis floor or rail) Figure 3-9: Filter Location and Air/Fuel Valve Support Brace Location MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 11 of 16

12 2. Remove the six bolts connecting the air/fuel valve plenum to the blower (Figure 3-10). Blower Plenum Step 4: Only loosen the top two cap screws as blower slips out of slots. Blower Step 3: Remove completely only the lower two cap screws, which secure the blower to the blower plenum. Step 2: Remove six bolts attaching blower to blower plenum A/F Valve Plenum Figure 3-10: Blower and Air/Fuel Valve Component Locations 3. Remove only the 2 lower cap screws securing the blower outlet to the blower plenum, (Figure 3-10). 4. Loosen the top two cap screws securing the blower outlet to the blower plenum but do NOT remove (Figure 3-10). NOTE The blower is heavy, weighing 52 lbs. 5. The upper portion of the blower plenum has slotted holes, so it is possible to just lift the blower up and towards the front of the unit to remove it from the blower plenum. Figure 3-9 shows the slotted holes in the blower plenum. Blower mounting slots in the blower plenum Figure 3-11: Blower Plenum Showing Upper Slots MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 12 of 16

13 3.4.3 Assembling the New Blower 1. To install the new 460VAC blower, first install the two hex head cap screws, two steel washers, one plastic holding ring, blower to blower plenum gasket, and a locking nut in the order and orientation shown in figure in Figure 3-12 into the upper bolt hole locations on the blower outlet flange. Use the poly locking washer to hold one of the steel gaskets against the head of the cap screw. Cap Head Bolt Steel Washer Plastic Washer Blower to Blower Plenum Gasket (P/N 81157) Leave gap for blower plenum to slide in between gasket and plastic washer Steel Washer Elastic Locking Nut Figure 3-12: Blower to Plenum Hardware Assembly Order NOTE When reinstalling the blower, it is recommended to replace the plastic holding rings (P/N 53044), and elastic lock nuts (GP ) on the blower outlet flange and the O ring (P/N 88015) between the Air/fuel Valve plenum and the blower inlet. Prior to installing, apply a small amount of Dow Corning 111 to the O ring. 2. Install the blower O ring into the groove on the inlet side of the blower then slide the blower into the slotted holes in the blower plenum. 3. Follow the previous Disassembly of Old Blower (Section 3.4.2) instructions in reverse to complete the blower installation. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 13 of 16

14 NOTE When installing the six (6) cap screws between the air/fuel valve plenum and the blower inlet it is recommended to apply Loctite 242 Thread Locker to the threads Wiring the New Blower 1. Refer to Figure 3-7 for reference, and remove the wiring compartment cover from the newly installed blower. Reinstall the 3 phase power and signal wires previously removed into the blower wiring compartment through their respective strain reliefs. 2. Refer to Figure 3-8 for reference, and wire the new blower as follows: # 331 to terminal L1 #332 to terminal L2 #333 to terminal L3 #101 - Red wire, to the 0 10v terminal # Black wire, to the GND terminal 3. Attach the Green ground wire between the 3 phase, and signal wiring terminal strips. 4. Ensure there is a jumper wire between the PWM and GND terminals in the blower s wring compartment. 5. Replace the blower wiring compartment cover. 6. Replace covers and return boiler to service. MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 14 of 16

15 NOTES: BMK 3000 Conversion from 460 VAC to 230 VAC MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 15 of 16

16 AERCO International, Inc., 2011 MC: 09/20/12 AERCO International, Inc. 100 Oritani Dr. Blauvelt, New York Phone: Page 16 of 16