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BMK1500-2000 Installation, Operation & Maintenance Manual

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1. 19 CONNECTOR 16 PIN CONNECTOR 9 PIN CONNECTOR 7 5 4 32 1 19 18 17 16 15 14 13 121110 9 876 5 4321 16 15 14 13 12 11 10 9 8 765 4 3 2 1 9 8 7 6 5 4 32 1 N AAA ANTA 21221 N BR 5 ass ie als 8 8 9 5 141 AS 28 IGNITOR 2 XFMER 8 pm 9 EXHAUST HEADER INLET OUTLET H CD x TEMP TEMP TEMP TEMP 8 153 gt 151 Swe SENSOR SENSOR SENSOR SENSOR t ala lt 5 5 2 s g mm TI 55 4 Er 52 225 3505 e amp o o 59 9 5 5 z 8 z i s AIR FUEL VALVE 152 150 5 8 zo 95 8 A N FLAME ROD Y 154 135 AMPIHER FHE pog NZ MAN Y 143 271 Z t T 270 270 17 209 oO n 136 TOVOBOX 613 123456789 364 ant MANUAL RESET AUTO RESET OE TOMO BOX CA
2. ACS AERCO Control System ADDR Address AGND Analog Ground ALRM Alarm ASME American Society of Mechanical Engineers AUX Auxiliary BAS Building Automation System often used interchangeably with EMS see below Symbol rate or simply the number of distinct symbol changes Baud Rate signaling events transmitted per second It is not equal to bits per second unless each symbol is 1 bit long BMK Benchmark series boilers BMS or BMS Il AERCO Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Management Technology BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound of water 1 F CCP Combustion Control Panel C More Controller or Control Box A control system developed by AERCO and currently used in all Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide COMM Comm Communication Cal Calibration CNTL Control Double Block and Bleed Used to define boiler gas trains DBB containing 2 Safety Shutoff Valves SSOVs and a solenoid operated vent valve Also known as IRI gas trains see below DIP Dual In Line Package EMS Energy Management System often used interchangeably with BAS FM Factory Mutual Used to define boiler gas trains GND Ground HDR Header HX Heat Exchanger Hz Hertz Cycles Per Second I D Inside Diameter IGN Ignition Page 8 of 188 AERCO In
3. Warmup Prop Band Range 1 120 Default 95 Warmup Int Gain Range 1 200 Default 50 Warmup PID Timer Range 1 240 Default 20 Reset Defaults Allows Tuning Menu options to be reset to their Factory Default values Page 136 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Appendix B STARTUP STATUS amp DISPLAY MESSAGES Table B 1 Startup And Status Messages MESSAGE DESCRIPTION DEMAND DELAY XX sec Displayed if Demand Delay is active DISABLED Displayed if ON OFF switch is set to OFF The display also HH MM pm pm shows the time am or pm and date that the unit was MM DD YY disabled Displayed after flame has been detected for a period of 2 FLAME PROVEN seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL Displayed during ignition trial of startup sequence The XX sec duration of cycle counts up in seconds PURGING Displayed during the purge cycle during startup The XX sec duration of the purge cycle counts up in seconds Displayed when ON OFF switch is in the ON position but STANDBY there is no demand for heat The time and date are also displayed WAIT Prompts the operator to wait Displayed for 2 minutes
4. 61002 8 LOW GAS PRESSURE SWITCH 4 4 W C 34 124149 3 WIRE ASSY JUMPER O T SWITCHES Not shown on drawing A component of item 6 p n 64048 ACTUATOR SSOV W REGULATOR Item Part Description Item Qty Part Description 1 1 123542 FLANGE 2 125 2 NPT 18 1 63109 GAS TRAIN HARNESS 2 1 93069 BUSHING REDUCING 1 1 2 TO 2 190 1 124862 RESISTOR ASSY 94060 3 1 2 50 NIPPLE 1 1 2 NPT X 2 50 LG 20 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 4 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 21 1 93035 ELBOW STREET 1 4 NPT 50 1 99015 DAMPING ORIFICE SSOV 22 1 9 420 TEE REDUCING 1 1 2 X 1 2 X 1 1 2 6 1 64048 ACTUATOR SSOV W REGULATOR ASSY 23 2 94060 3 NIPPLE 1 1 2 X 3 00 LG 7 2 12951 2 BUSHING CONTROL BOX 24 2 94060 8 NIPPLE 1 1 2 NPT X 8 00 LG 8 1 9 43 BUSHING REDUCING 1 2 X 1 4 25 2 9 323 ELBOW 90 DEGREE 1 1 2 9 3 92077 1 4 NPT MXF BRASS BALL VALVE 26 1 124150 VALVE SSOV 1 1 2 NPT 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 27 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 11 1 99017 SNUBBER PRESSURE 1 4 28 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 12 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 29 1 93382 2 NPT CAP 13 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 30 2 94060 2 NIPPLE 1 1 2 NPT X 2 00 LG 14 1 97005 5 FLEXIBLE GAS TUBING 18 LONG 31 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 15 2 124083 TEE 1 4 1508 32 1 9 294 UNION 2 3008 16 2 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 33 1 93456 TEE
5. v 9c6 v av A38 Wd A8 NMQ TWNOISNSWIG X31108 Qq34l SVD 0000 0061 9 160 AN yoAnerg IVNOLLVNH3LNI em 3OlLON LNOHLIM SNOISN3NIG 331108 AJIQOW OL S3AN3S3M OO33V 1N3AdIHS NI ATSLVYVdIS GSGNIONI 38v dVYL 31VSN3dNOO YOLVOIGIML IANYA 33ras Z SH313WIIN39 S3HONI NI NMOHS SNOISN3NWIG TY L 31 5 30 02 170 061 9 OLI 3NNOO LdN 0102 0 913 081 ol g6 ss zz m 8 0000 9 0061 0 91 fosi s NNOO 1310 LOH 6z 11 1 Li 1 NOLLV9O1 3AWA 331133 dWVLS Al NOILO3S 3000 Ad 8 3ASV 0002 061 Ove 012 091 8 0000 0061 401 Ove 012 091 5 9 0061 43134 32 4405 9H SS3Hd 1531 ALIOVdVO 1405 9189 3 dW31l 91Sd SS33d WOINIXVW SGYVONVLS NOISSG 338AVHO NOILLSQSWOO SH3ONVHOX3 1 3 8 MO 9 lt 6 5713315 NOBMVO v L TI3HS SS6tv 6vc VS TIVM 6v0 X 00 91 6 1331S SS31INIVIS S38nL SS6 v OvZ VS 1331S SS3INIVIS t l 133HS38nl M3MO1 SS6 v Ovc vs 133iS 5531 15 v b 133HS38nl N3ddn 339NVHOX3 1V3H sv 41 c
6. 9v SONVN3LNIVN 318155322 38 OL V3NV SIHL SALON HSNI LINN 135 313399N09 v 8 11 86 3 pl os 4 6 1 61 NOHL23NNOO LINGNOD WILNA 9 6 556 0 2 5113315 5531 15 1 NOISNVdX3 04 49 916 513316 NOBNVO 2 1 0 3 SS6 OrZ VS 1331S SS3INIVIS v L M3NNI TI3HS 8 49 eS VS 13318 NOS8NVO 1 31 0 TI3HS MJ38NVHO NOILSQY8NOO zz NOLLONYLSNOD 40 SIVINJLYW 6 8 BNVd 104402 936 Drawing Number Page 151 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS V 466 05 2176176 A8 NMG 129 3108 03415 SVD 0002 0061 uVAHON38 8101 AN 9 ONI IVNOLLVNH3LLNI 5 04 400 411 SNOILONYLSNI MNVL 31VSN3QNOO 33S 330014 JHL 3AO8V NVHL YSHOIH G3l1VA313 38 LSAW 31VSN3qQNOO OON3V X31108 JHL YO V 38 LSAW NVL M3ZIIVMIQ3N 39VNIVHO 31VSN30NOO M3dOMd X04 5INVL YSZNVYLNSN 31vVSN3QNO9 OOM3V JHL ONISN N3HM 310N JOILON LNOLIM SNOISNSWIG 331l08 AJIGOW OL LHOIY 3Hl
7. Analog Output If Boiler Mode Outdoor Reset Wr Reset Ratio 12 If Boiler Mode Outdoor Reset Outdoor Sensor Disabled System Start Tmp 60 F If Outdoor Sensor Enabled Setpt Lo Limit 60 F Setpt Hi Limit 195 F Temp Hi Limit 195 F Max Valve Position 100 Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Valve Position 0 10V CAUTION DO NOT Change Lo Fire Timer 2 0097 00 GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 143 of 188 Benchmark 1500 2000 Boilers APPENDIX D BOILER DEFAULT SETTINGS Appendix D Boiler Default Settings MENU amp OPTION FACTORY DEFAULT Configuration Menu Cont Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min Page 144 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING Appendix E RECOMMENDED PERIODIC TESTING WARNING Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed Precautions shall be taken while tests are being performed to prot
8. When ALL C More units have been configured 10 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 128 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive 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 AERCO P N 65169 terminal Pin B to the RS485 terminal 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 AERCO PN 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 e Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e There is no polarity to b
9. YOSN3S N30v3H S V JHL TIVISNI 38 5 53002 TWOO1 SNIMV3G NOLLVTIVISNI TWOIdAL V SI SIHL Wd9 0 30 WAWININ S H3108 XHYAHON3S NIVINIVA 1SnW dW d 331108 3371108 30 17 NISJA 1 3lViNdONddYv 3Hl 3O0l OMd OL 03215 38 15 dnd 531108 LLL N QS 9 4 05 SZL vV QS 2 05 44 05 24 05 NOLLYTIVISNI 9Nidid 2153400 O3QN3AWOO38 803 SONIMVYEC NOLVTIVISNI 3lvldlNvWS OL 3438 ONIZIS 1 34408 0101 45 30 09 SNOUuVOrlddv 3lvldlNVWS OL 334338 ONIMVHO IVNOISN3MIG MBVWHON38 3lviBdOMddV 33S 831108 OL SNOILOSNNOD ONidid 30 SNOLLV2O1 S3ZIS 19 WO 80013 JHL 3A08V 81 V OL ATIVOILY3ZA Q3dld 38 01 5 3S3VHOSIQ JAVA 33134 318v IVAV SI 380014 ON N3HM NIVMO 3800134 1S33V3N JHL OL G3did 38 AINOHS JATA 33 138 NIVSO V OL ALIAVHO AT3383 OL 5010713 JHL liWH3d OL Q39NwveBY 38 5 3SOH 31VSN3QNOO 3ATVA NIVNO Tl3HS 51130 STOMINOO NOlLvOllddv BLIIdNOD lt 88 05 WYHOVIC 9NIMIM 0S00 9vi 30109 SNOLVOllddY H31VM OIS3AOQ 9NUV3H NOLLVNIBWOO 335 AlddNS W31SAS y W3lSAS dVML 31VSN30NOO JATA TI3HS 310N MOlvin934 5 9 5 SVD TWONVN vL 3HnsS3Hd SVO 1Y 3
10. gt e Enter the desired value or setting for the option and press lt Rtn gt Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning Menus The Calibration and Diagnostic Menus should only be used by Factory Trained service personnel f Menu changes will be stored in non volatile memory 9 To redisplay the menu and view the option which was just changed in step 5 enter D and press lt gt 10 To display the Fault F Log Sensor S Log or Time T Line Log press F S or T followed by lt Rtn gt Refer to section 9 4 for descriptions and samples of these data logs 11 To log off and terminate the RS 232 communication link press L followed by lt Rtn gt 9 4 DATA LOGGING During operation the C More Control Panel continuously monitors and logs data associated with operational events faults and sensor readings associated with the boiler system Descriptions of these data logs are provided in the following sections The procedure for accessing specific data logs is described in section 9 3 step 10 Page 114 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 9 RS232 COMMUNICATION 9 4 1 Fault Log The C More Control Panel logs the last 20 faults 0 19 starting with the most recent 0 They can be viewed in the fron
11. 585 i i J lt lt z lt 2 bc 2 g o x x 5 gt a x x 2 u 2 lt 2 lt E oz lt 2 2 lt Z gt a Tox 5 z z 8 507 2 o 8 5 z gt 3 z 5 9 INPUT OUTPUT BOX 5 3 8 2 iu SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX 63156 6 PIN CONNECTOR SEQ VALVE ACTUATOR CONTROL CABLE 63155 cevas s 290 INTERNATIONAL INC c 100 ORTANI DR BLAUVELT ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE WIRING SCHEMATIC BMK 1500 2000 FM V ASS X DAMES ONA CONNOR AR 951O1AL MATL SPEC THESE DRAWINGS AND OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE ISSUED IN STRICT CONFIDENCE AND anne DIS TOTAL 6 050 SHALL NOT BE REPRODUCED COPIED OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER ALL DIMENSIONS ARE AFTER FINISH OR PLATING SHEET 1 OF 1 Drawing Number 68050 rev B page 2 of 2 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 169 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS This page intentionally blank Page 170 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142
12. CONFIGURATION MENU Cont Deadband High Deadband High and Deadband Low settings create an Deadband Low Outlet Temperature Zone in which no Valve Position corrections will be attempted The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint Deadband High and Active Setpoint Deadband Low When the Outlet Temperature reaches Active Setpoint and remains there for a period of 15 seconds the unit will go into DEADBAND MODE at which point no Valve Position corrections will be attempted while the Outlet Temperature remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 to 25 Default is 2 for both Deadband High and Deadband Low IGST Version Displays the version of the IGST Board installed IGN Time Setting Displays the MAX Ignition time of 4 Seconds or 7 Seconds as set in the Safety String Harness Slow Shutdown Enables or Disables the slow shutdown feature Default is Disabled Slow Sht Duration With the Slow Shutdown feature Enabled sets the time a boiler will continue to run at the Stop Level after running above the Slow Sht Threshold level for 60 Seconds Span is 0 to 9999 Seconds Default is 60 Seconds Slow
13. Position Switch AIR IN Figure 6 7 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI Page 84 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE CHAPTER 7 MAINTENANCE 7 1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability For best operation and life of the unit the following routine maintenance procedures should be performed in the time periods specified in Table 7 1 For a complete inspection check list see ASME CSD 1 chart In order to perform the maintenance tasks specified in Table 7 1 the following maintenance kits are available through your local AERCO Sales Representative e 12 Month Maintenance Kit Part No 58025 01 e 24 Month Waterside Fireside Inspection Kit Part No 58025 13 See NOTE below NOTE The 24 Month Waterside Fireside Inspection Kit also includes the items contained in the Annual Maintenance Kit 58025 01 Therefore only Kit Part No 58025 13 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare Z WARNING Z TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED e DIS
14. measured by the sensor y 2 Run Cycles Displays the total number of run cycles from 0 to 999 999 Run Hours Displays total run time of unit in hours from 0 to 9 999 999 Fault Log Displays information on the last 20 faults OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 131 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION SETUP MENU Password Allows Level 1 or Level 2 password to be entered Entering the Level 1 Password 159 allows options in the Setup Configuration and Tuning Menus to be modified Entering the Level 2 Password 6817 allows options in the Calibration and Diagnostics Menus to be changed or activated in addition to all Level 1 Menu options Language Permits selection of English Spanish or French for displayed messages Default is English Time Displays time from 12 00 am to 11 59 pm Date Displays dates from 01 01 00 to 12 31 99 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C Default is F Comm Address Baud Rate For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min U
15. Drawing Number 68071 rev B page 2 of 2 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 173 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS This Page Is Intentionally Blank Page 174 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS PIPING DRAWINGS Appendix J 31vq 686 V OS SIN IWS A38 16180 31V0 7553 A8 NMQ NOLLVTIVISNI LIND 319NIS MOI HEW 0000 006 MNVNHON38 23 235 dVHl NIVYG 31VSN3QNOO AlddNs WALSAS ONLLVSH SAWA 33r138 71400 W901 A8 SSFINN TWNOWdO SI YOLVINDAY SV9 V MOT38 YO 1V 5 400 011 SNOILONYLSNI 31VSN30NOO 33S YOO1d JHL 3AO8V NVHL M3H9IH G31VA313 38 5 dV3l 3lVSN3QNOO OOM3V ONY 33108 3Hl YO V NI Q3TIVISNI 38 LSNW 1 2 SOVNIVYG 31VSN3qQNOO 33dOHd NVl YSZMVYLNAN 31VSN3QNOO OONSV JHL ONISN N3HA SS31 YO 1 OL NMOG 3YNSS3Yd SVD JHL ONING OL SATIVA 4JOl1nHS TIWANVW JHL 30 WV3SYLSNMOG GATIVISNI 38 LSNW YOLVINDAY 3115 201 V tl NVHL 331V33899 SI JYNSSAYd SVS 318VIIVAV N3HA ST1T3NVd 3015 WOMJ 9 38 35 GINOHS S3XO8 LINGNOD
16. IW 35055339 SVD WOWININ a 109 YHN WOWIXVN ANVWIMNd JAVA 33 133 3009 1 201 A8 SSIINN TvNOILdO SI HOlv1n93H SVD MOT3H YO OM 1 8 STIV130 303 400 011 SNOILONYLSNI NYL SLVSNSGNOD 33S 740014 JHL JAO8V NVHL M3H9IH Q31V 313 38 LSNW 31VSN30NOO OON3V 3HL 331l08 JHL V NI Q3TWISNI 38 LSNW ANYL M3ZIIVMIn3N 39VNIVHO 31vSN3Q0NOO 3H3dOMd NO3 MNVL MN3ZITVMIDn3N 31VSN30NO9 OOM3V JHL ONISN N3HM 5531 HO 1 OL NMOG 3H SS3Hd SVD ONING OL 3ATWA 1 TWNNVN JO Wv3MISNMOQ 38 5 NOlvin93H8 JIMS 4 201 1 NWHL N31v3N9 SI 3B SS3Hd SVO JIBVIIVAV N3HM 79 S13Nvd M3lv3H JO TVAON3N 3ON333JH31NI IN3 3Hd OL SONILLIJ M3IV3H N31VM WON3 9 WAWININ v 213 SAO81T3 SNOIN 9 SONILLIS 131100 N31VM 31 201 5 38 GINOHS 53002 WOOT SNIMVHO NOLLVTTVISNI TVOIdAL V SI SIHL 1N3WdIHS AT31vsvd3s 38V SWALI TW 40014 81 LHOISH V OL ATIVOLLN3A Q3dld 38 GINOHS JAWA 33h38 318v1IvAv SI 0013 ON N3HM NIVHO X00743 I1S3HV3N JHL OL Q3did 38 Q1n0HS 3ATVA 30074 V OL ALIAVH9 Al3384 NIV3G OL 501013 JHL LINYSd OL 38 5 ISOH 31vVSN30NOO 3 VA 5 Z 9NIMVHO OV
17. s valve position from 0 to 100 A 4 mA 1V signal is equal to a 0 valve position while a 20 mA 5V signal is equal to a 100 valve position When a 0 20 mA 0 5 Vdc signal is used zero is equal to a 0 valve position In addition to the current and voltage signals described above the Direct Drive mode can also driven by a RS 485 Modbus Network signal from an EMS or BAS When in a Direct Drive mode the unit is a slave to the EMS or BAS and does not have a role in temperature control Direct Drive can be used to drive single or multiple units NOTE If a voltage rather than current signal is used to control the remote setpoint a DIP switch adjustment must be made on the CPU Board located in the Control Box Assembly Contact your local AERCO representative for details To enable the Direct Drive Mode the following menu setting must be made in the Configuration Menu Menu Option Setting Boiler Mode Direct Drive Remote Signal 4 20mA 1 5V 0 20mA 0 5V or Network Refer to section 3 3 for instructions on changing menu options If the Network setting is selected for RS 485 Modbus operation a valid Comm Address must be entered in the Setup Menu Refer to Modbus Communication Manual GF 114 for additional information Page 66 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION 5 5 1 Direct Drive Field
18. 055344 SVO WAWININ NIVLNIVN JAVA i3nas INANI YH NLE WAWIXWN 1v W31SAS 3555349 W3LSAS S310N Drawing Number SD A 993 rev A Page 179 of 188 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS v 766 45 a T sie A33 719021 Uva Sy A8 NMO SIVA 403 200 l SNOLLOQMISNI 31VSN3QNOO 33S HOO14 JHL 3IVidbivWS ONY XNVL 9 NVHL M3H9IH Q31VA313 38 5 dvHl 31vSN3QNOO OOM3V X30109 EO Lid V NI Q3TWISNI 38 1SNW 33308 1904 2 NOILVTIVISNI 420 ANVL M3ZIIVMIDn3N 39VNIVMO 31 5 30 02 N3dONd 1 Y3ZIWWYLNSN 31VSN30NOO 093V JHL ONISN N3HM GSLINSNOO 38 GINOHS SALLIYOHLNY ONY 53002 SNIMVHQO NOLLVTIVISNI TvO9IdAL V SI SIHL Sul d Z 3ONVSv31O 3015 0432 INN 0000 7 0051 5HVNWHON38 Ov 508431108 MNVWHON38 NIVINIVW 15004 331 08 531089 LV 1530 JHL 1 3iViMdOSddV JHL OL 03215 38 15 531108 ONI IVNOLLVNH3LLNI LLL N QS 92 05 6 06 05 05 ZLL v QS NOLLVTWISNI ONIdld 21153000 G3dN3WAO09338 SONIMVYO NOLIVTIVISNI 31V1dlsvWS Ol X343 216 1 333308 0101 45 30109 SNOILYONddY SLVIdLYWNS Ol X343 ST3NVd 30
19. APPENDIX L RECOMMENDED SPARES This page left intentionally blank Page 184 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers NOTES OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 187 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers Change Log Date Description Changed By Rev C 11 21 2013 PIR 934 5 Revised the regulator requirements PIR 934 2 revised Analog Output amp VFD Blower terminal descriptions PIR 934 2 changed sealed combustion to ducted combustion PIR 934 5 added AERCO RS 232 cable info to C More section PIR 934 8 changed p n 122790 to GM 123525 in section 2 10 1 Misc Updated graphics and format updated Warranty to version 11 22 13 Curtis Harvey 03 20 2014 Rev D PIR 780 replaced mechanical latch with magnetic PIR 934 14 Corrected labels of Blower Proof and Blocked Inlet switches in diagrams in chapter 7 PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Valve Installation addition of section 3 9 BST Menu addition of Chapter 10 Boiler Sequencing Technology replaced all wiring schematics in Appendix addition of 24V Sequencing Valve amp Flame Rod Amplifier PIR 934 33 Modified step 13 in Combustion Calibration regarding defective O Sensor PIR 934 37 Modifie
20. DIGITAL 43 1 64088 CONTROLLER BURNER AIR FUEL VALVE AND HEAT EXCHANGER 44 1 60019 DISCONNECT FUSIBLE 9 1 24378 BURNER ASSY BMK 1500 45 1 65156 FLAME ROD SIGNAL AMPLIFIER 1 24388 BURNER ASSY BMK 2000 46 1 65162 24V POWER SUPLY SEQUENCING VALVE 10 1 46042 BURNER BMK 1500 470 2 124512 FUSE 4 AMP 1 46044 BURNER BMK 2000 48 1 123449 SENSOR TEMPERATURE 11 1 24277 STAGED IGNITION ASSY 49 1 93359 THERMOWELL 12 1 81166 BURNER GASKET 500 1 63105 1 0 SENSOR COMM HARNESS 13 2 81183 BURNER RELEASE GASKET 510 1 63104 1 0 INTERLOCK HARNESS 14 1 43090 AIR FUEL VALVE PLENUM 520 1 63090 HARNESS ASSY TEMP LIM CONT PWR 15 1 24220 3 AIR FUEL VALVE ASSY BMK 1500 530 1 63150 HARNESS FLAME ROD 1 24220 10 AIR FUEL VALVE ASSY BMK 2000 54 1 33170 MOUNTING PANEL 55 1 124324 GROUND BAR HOSES amp INSULATION 560 1 63156 POWER CABLE 24V SEQUENCE VALVE 16 1 97005 9 FLEX GAS TUBE 48 570 1 63103 SHELL HARNESS 17 1 80089 SHELL INSULATION 580 1 63109 GAS TRAIN HARNESS BMK 3000 59 1 61024 AIR INLET TEMPERATURE SENSOR BLOWER 60 1 123449 SENSOR TEMPERATURE 18 1 69078 BLOWER 61 1 61030 SENSOR OUTLET TEMPERATURE 19 1 81057 BLOWER GASKET 62 1 69151 PCB ASSY 20 1 81100 GASKET BLOWER MOTOR 21 1 66020 FLAME DETECTOR 640 1 65104 CABLE H V IGNITION 22 1 61026 SENSOR 02 650 1 63058 HARNESS BLOWER SIGNAL 23 1 59104 OBSERVATION PORT 660 1 63083 HARNESS O2 SENSOR 24 1 66026 IGNITOR INJECTOR 670 1 63111 HARNESS CONTROL 25 1 59138 AIR FILTER 26 1 43095 BLOWER PLENUM 69 1
21. If the desired value is not displayed modify the setting using the A and Y arrow keys The value can be changed from 10 to 10 offset Press SET to enter the value and exit to the text parameter To exit the programming mode press the SET and Y buttons simultaneously or simply wait one minute and the display will automatically exit the programming mode Once the programming mode has been exited the display will show the current outlet water temperature of the boiler Page 62 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5 1 INTRODUCTION The boiler is capable of being operated in any one of six different modes The following sections in this Chapter provide descriptions of each of these operating modes Each boiler is shipped from the factory tested and configured for the ordered mode of operation All temperature related parameters are at their factory default values which work well in most applications However it may be necessary to change certain parameters to customize the unit to the system environment A complete listing and descriptions of the temperature related parameters are included in Appendix A Factory defaults are listed in Appendix D After reading this chapter parameters can be customized to suit the needs of the specific application 5 2 INDOOR OUTD
22. REDUCING 2x1 5x2 1 1 o e Benchmark 1500 2000 Gas Train 10 30 2013 Blauvelt NY 10913 22188 rev B Sheet 1 of 1 International Inc Page 162 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Benchmark 1500 2000 DBB Gas Train p n 22199 rev Item Qty Part Description Item Qty Part Description 1 1 123542 FLANGE 2 125 2 NPT 25 1 124142 VALVE SSOV DOUBLE BODY 2 NPT BUSHING REDUCING 1 1 2 TO 2 2 1 93069 NPT 26 1 69038 ACTUATOR SSOV W O P O C SWITCH 3 2 94060 2 NIPPLE 1 1 2 NPT X 2 00 LG 27 1 93456 TEE REDUCING 2x1 5x2 4 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 28 2 9 469 ELBOW 90 3 4 NPT 50 1 99015 DAMPING ORIFICE SSOV 29 2 94061 3 00 NIPPLE 3 4 NPT X 3 00 LG 6 1 64048 ACTUATOR SSOV W REGULATOR 30 1 124094 UNION 3 4 NPT 150 7 2 12951 2 BUSHING CONTROL BOX 31 1 123148 BUSHING 1 NPT X 3 4 NPT 8 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 32 1 122774 VALVE VENT 3 4 NPT 94061 9 1 97005 2 TUBING FLEXIBLE GAS 12 33 1 10
23. S3HOIIMS JOIANIS SNOLLO3NNOO 21519313 Nidid TIY SH3AOO SI3Nvd 831108 40 1VAOW3H 39N3334331NI 1N3 A3Sd OL SONILLIJ 33lv3H 9 JO WANININ V 013 SMOHT3 SNOIN Y SONILLIJ 131100 LIINI 3831VA 31V901 31115 02 38 GINOHS 5 53002 71 201 SNIMVMQO NOILVTIVLSNI 1IVOIdAL V SI SIHL 1N3AdIHS NI Al3lvavd3s GSGNIONI 33v SW3ll HOO14 JHL 3AO8V 81 1H9I3H V OL ATIVOILYSA Q3dld 38 GINOHS 39NVHOSIGQ JAYA 33l134 JHL 318VIIVAV SI NIVHO NOOT13 ON N3HM NIVMO 3OO14 LSSYVAN JHL OL QO3dld 38 GINOHS 39MVHOSIG SATIVA 431134 NIV3G 3OO14 V OL ALIAVSO AT33MJ NIVYG OL 5 JHL llWM3d OL 38 GINOHS 3SOH 31VSN3QNOO 3AlVA TI3HS TWNOISNANIG 33S M31V3H JHL OL SNOLO3NNOO YSHLO 9NIdld JO SNOILVOO1 53215 WALOV TO sb O S31ON 0 Nauni3s WALSAS JAVA TISHS 8 310N MOlv1n93M Sv9 rL 3NnsS3Hd SVO XV 3JO1nHS RARE m sv 0 lv 3unss3Md Svo WANINIW NIVLNIVA 3H D18 WANIXWN 1v Drawing Number SD A 989 rev A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 175 of 188 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS 066 05 30402 AH SSFINN TVNOILdO SI YOLVINDIY SV9 V W0138 NO tl
24. see section 4 3 1 or 4 3 2 step 10 the 3 Defective High Gas Pressure SSOV Actuator may be defective Switch 3 Remove the leads from the high gas pressure switch Measure continuity across the common C and normally closed NC terminals with the unit not firing Replace the switch if continuity does not exist HIGH WATER TEMP 1 Faulty Water temperature switch 1 Test the temperature switch to insure it trips at its actual water SWITCH OPEN temperature setting 2 Incorrect PID settings 2 Check PID settings against Menu Default settings in Appendix D If the settings have been changed record the current readings then reset them to the default values 3 Faulty shell temperature sensor 3 Using the resistance charts in the Appendix C Measure the resistance of Shell sensor and BTU sensor at a known water temperature 4 Unit in Manual mode 4 If unit is in Manual Mode switch to Auto Mode 5 Unit setpoint is greater than Over 5 Check setpoint of unit and setpoint of Temperature Switch Temperature Switch setpoint Ensure that the temperature switch is set higher than the unit s setpoint 6 System flow rate changes are 6 If the system is a variable flow system monitor system flow occurring faster than units can changes to ensure that the rate of flow change is not faster respond than what the units can respond to HIGH WATER 1 See HIGH WATER 1 See HIGH WATER TEMPERATURE SWITCH OPEN TEMPERATURE TEMPERATURE SWITCH O
25. transmission of data based on or EIA 485 the RS 485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 9 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers FORWARD Phrases Abbreviations and Acronyms Continued Phrase Abbreviation or Acronym Meaning 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 uA Microamp 0 000001 amp one millionth of an amp VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column W C Page 10 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 1 SAFETY PRECAUTIONS CHAPTER 1 SAFETY PRECAUTIONS 1 1 WARNINGS amp 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 un
26. 1 Digital Alarm Switch Controls and Display eoru MEANING FUNCTION LED Display TEMP status 2 current water temperature RST RESET Button Resets the unit after an alarm condition A UP Button Increases the displayed temperature x DOWN Button Decreases the displayed temperature SET SET Button og to access and store parameters in the Perform the following steps to check or adjust the digital alarm switch settings Digital Alarm Settings Set the ON OFF to the ON position Press the SET button on the Digital Alarm Switch SP will appear in the display Press the SET button again The current over temperature limit value stored in memory will be displayed default 210 F If the display does not show the required over temperature alarm setting press the A or V arrow button to change the display to the desired temperature setting Once the desired over temperature alarm setting 210 F is displayed press the SET button to store the setting in memory To calibrate the offset P1 press and hold the SET button for 8 seconds on the Digital Alarm Switch 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 Press the SET button again to enter the code The first parameter label SP will appear in the display Using the A and Y arrow keys select parameter P1 Press SET to view the value stored in memory
27. 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS This page intentionally blank Page 168 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX WIRING DIAGRAMS CONTROL BOX CONNECTORS 24 PIN CONNECTOR 16 PIN CONNECTOR 123 465 6 7 8 9 10 11121314151617 18 19 20 21 222324 16 15 14 13 12 11 10 9 8765432 1 5 S 18 5 18 18 5 519 IS 9 19 19 S 9 8 a 41812 S3 ee NIN IN QN N IN IN IN e IN v IN IN IN IN N N IN IN N NIN NL N NI n OOOOOOOOOOOO OOO O O O O O O O s ae 600060000000 1 213 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 3 4 5 6 7 8 9 10 11 12 AN an an TN 152 151 z z z G a gt z lt a 9 go 28 z 3 5 28 8 OOD DODO 099909099 22999 OZA o F gt gt 2 lt ee 223 Z wx 2 8 z 8 8 90 g 5 5 9 9 S 2 a zz z Zo 20 4 2 z E lt g
28. 5 16 x 1 3 4 BOLTS 5 16 INJECTOR meg WASHERS amp ASSEMBLY NYLOCK NUTS BON 4 each BLOWER A F VALVE PLENUM 3 8 16 HEX NUTS 8 each 7 AIR FUEL VALVE FILTER 1 2 NUTS amp BOLTS 4 each GAS TRAIN Figure 7 4a Burner Assembly Mounting Details Page 92 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE Burner Assembly Inspection and Maintenance Procedure Continued BLOWER PLENUM 5 16 x 1 3 4 BOLTS 5 16 WASHERS amp NYLOCK NUTS 4 each BLOWER 3 8 16 AIF V MTS HEX NUTS VALVE N T 8 each PLENUM SS GAS INLET BLOWER PIPE PROOF 32 SWITCH MANUAL SHUT OFF VALVE AIR FUEL VALVE BLOCKED INLET SWITCH AIR FILTER Figure 7 4b Burner Assembly Mounting Details NOTE IMPORTANT The LOWER RELEASE Use ALL THREE gaskets provided even if there GASKET P N 81186 features is only one existing gasket being replaced four tabs around its periphery 81183 UPPER RELEASE x 81166 MIDDLE BURNER GASKET 81186 LOWER RELEASE GASKET BARE BURNER INSTALLED IN HEAT EXCHANGER ASSY Figure 7 5 Bare Burner and Replacement Gaskets Location OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 93 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boi
29. 69087 3 58088 W150 150 PSI KIT WATTS 92023 14 69087 4 58088 W160 160 PSI KIT KUNKLE 92023 15 69087 4 Benchmark 1500 2000 Kits Available Part Description 24311 4 AIR FUEL VALVE KIT BMK 2000 24311 3 AIR FUEL VALVE KIT BMK 1500 24356 1 FLAME DETECTOR KIT 58023 IGNITOR INJECTOR REPLACEMENT KIT AERCO Benchmark 1500 2000 Part List 02 01 2014 International Inc Blauvelt NY 10913 Whole Boiler 29313 1 29337 1 Sheet 2 of 7 Page 156 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS AERCO Benchmark 1500 2000 Part List 02 01 2014 International Inc Blauvelt NY 10913 Whole Boiler 29313 1 29337 1 Sheet 3 of 7 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 157 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Benchmark 1500 2000 Burner Air Fuel Valve Assembly P N 24378 amp 24388 See full part lists below AERCO Benchmark 1500 2000 Part List 02 01 2014 International Inc Blauvelt NY 10913 Whole Boiler 29313 1 29337 1 Sheet 4 of 7 Page 158 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS
30. 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1 Blower stopped running due to thermal or current overload Blocked Blower inlet or inlet air filter Blockage in Blower Proof switch Blockage in Blocked Inlet switch Defective Blower Proof switch Defective Blocked Inlet switch Loose temperature to AUX connection in I O Box 1 2 3 4 5 7 Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices Inspect the inlet to the combustion blower including the air filter at the air fuel valve for signs of blockage Remove the Blower Proof switch and inspect for signs of blockage clean or replace as necessary Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary Check the continuity of the Blower Proof switch with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch Turn off unit and check the continuity of the Blocked Inlet switch If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch Check the actual inlet air temperature and measure voltage at AUX input in the I O Box Verify that the voltage con
31. 8 WS 6180 54 9 303 400 011 SNOLLONYLSNI MNVL 31VSN3GNOO 33S 30014 JHL 3AO8V NVHL LINN 2 M3H9IH G31VA313 38 5 3IVSN3ONOO OON3V 83108 Y G3TIISNI 38 5 3ONVNV312 3015 0437 INN YAZMVYELNAN 39VNIVHO 31 5 30 02 NOS ANYL H3ZIIVHIn3N 31VSN30NOO 0283 ONISN N3HM 4 0002 3 001 MMUVWHON38 SS31 MO bL OL NMOG 330SS33d 5 9 ONING Ol JATWA 5 TWNNVW 3HL 30 WY3HISNMOG 38 LSNW 3O1vin93N 31ALS dQ 3901 V Yl NVHL M31V3N9 SI 3 055384 SVD JISVIIVAV N3HM 9 mE an 5 3015 WONJ 9 38 3SIM3 Il GINOHS S3X08 LINGNOD SSHOLIMS 32148435 IVNOLLVNH3LNI SNOILO3NNOO 21410373 9Nldld SM3AOO ST3NVd H31l08 TWAONSY 39N3N33N31NI IN3A33d OL SONILLIJ M31V3H 9 JO WNWININ V 913 SWO813 SNOINn 9 59 131100 137 N31VM 31V901 831115 02 38 GINOHS 53002 1 201 9 NOLLYTIVISNI TVOIdAL V SI SIHL LN3WdIHS NI 1 5 GSGNTIONI 33v SW3ll HOO14 3HL 3AO8V 81 V OL ATIVOILYSA 03919 38 Q1nOHS 39MVHOSIQ JAYA 33 33 318V1lVAV SI YOONA ON N3HM NiVMQ 30014 1S33V3N JHL OL Q3dld 38 GINOHS 39SvHOSIQ JAWA 331134 NIVSO MO0014 V OL ALAVHO A8 A13334 OL 501
32. Benchmark 1500 2000 Boilers APPENDIX WIRING DIAGRAMS 9 PIN CONNECTOR CONTROL BOX CONNECTIONS 7 PIN CONNECTOR A 7 AAA 7654321 16 PINCONNECTOR 153 151 149 145 T T T HELD 19 PIN CONNECTOR 16 15 14 13 12 11 10 98 7 5 4 3 2 1 11 5 19 18 17 16 15 14 13 211109 87 65 432 1 R RAB RAB iter B E sep bas bes fb be EXHAUST HEADER INLET OUTLET A 141 TEMP TEMP TEMP TEMP AN 4999 991 SENSOR SENSOR SENSOR SENSOR GAS olo 2149 148 IGNITOR 2 153 gt 0 gt z 5 e 10K 55 55 4 8 4 lt lt j gt lt 8 2 m z 55 2 59 5 z rr z 5 825 5 amp 2 5 3 5 2 zl m 88 3 2 2 5
33. Benchmark 1500 2000 Standard FM Gas Train P N 22188 See full part lists below Benchmark 1500 2000 Double Block amp Bleed Gas Train P N 22199 See full part lists below AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List Whole Boiler 29313 1 29337 1 02 01 2014 Sheet 5 of 7 OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 159 of 188 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS LEFT SIDE VIEW FRONT VIEW AERCO Benchmark 1500 2000 Part List 02 01 2014 International Inc Blauvelt NY 10913 Whole Boiler 29313 1 29337 1 Sheet 6 of 7 Page 160 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Power Box P N 24386 PARTIAL FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 7 of 7 OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 161 of 188 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Benchmark 1500 2000 Standard Gas Train p n 22188 rev B
34. COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES N WARNING N ELECTRICAL VOLTAGES UP TO 480 VAC 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 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 11 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 1 SAFETY PRECAUTIONS Z WARNING N 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 N 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 CAUTION N DO NOT use this boiler if any part has been under water Call a qualified service technician to inspect and replace any part that has been under water 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 E VALVE
35. Chapter OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 33 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION o o C 0 OO E D D Figure 3 1 Control Panel Front View NOTE If there is a requirement to use the RS232 port Item 4 on the C More controller front panel contact AERCO to purchase the RS232 Adaptor Cable P N 124675 which is designed for this purpose This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports Page 34 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097 0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Table 3 1 Operating Controls Indicators and Displays ITEM CONTROL NO INDICATOR OR FUNCTION E DISPLAY LED Status Indicators Four Status LEDs indicate the current operating status as follows COMM Lights when RS 232 communication is occurring Lights when the valve position fire rate is being controlled using 1 MANUAL the front panel keypad This mode of operation is for service technician use only Lights when the unit is being controlled by an external signal from REMOTE an Energy Management System DEMAND Lights when there is a demand for
36. Gas Safety Shut off Valve SSOV and the C More displays the PRE IGNITION message When the SSOV indicates the Gas Valve is OPEN POC the C More displays the IGNITION TRIAL message If no spark is present 3 seconds into the IGNITION TRIAL the C More will abort the Ignition Cycle and shut down the boiler Refer to Chapter 8 Troubleshooting for guidance if this occurs TO BLOWER STEPPER IGNITION VALVE POSITION DIAL AT 25 to 35 AIR IN Figure 3 6 Air Fuel Valve In Ignition Position 6 Up to 4 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 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 With the unit firing properly it will be controlled by the temperature controller circuitry The boilers VALVE POSITION will be continuously displayed on the front panel bargraph Once the demand for heat has been satisfied the Control Box will turn off the SSOV gas valve The blower relay will be deactivated and the Air Fuel Valve will be closed Standby will be displayed OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 49 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION 3 11 START STOP LEVELS The
37. Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into unit is 1 Stabilize gas pressure going into unit If necessary fluctuating troubleshoot Building Supply Regulator 2 Damping Orifice not installed 2 Check to ensure that the Damping Orifice is installed in the SSOV Actuator shown in Figure 8 2 For IRI DBB Gas Trains the Damping Orifice is installed in the downstream SSOV Actuator Air Fuel Valve hunting at 1 IGST and Power Supply Boards 1 Check to ensure that the IGST and Power Supply Boards the 80 Valve Position in Control Box are outdated are Rev E or higher OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 109 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE BLOWER INJECTOR PLENUM IGNITOR ASSY WITH INDEXING FLAME CLOCKING OBSER WASHERS VATION 0 3 as PORT needed O2 SENSOR amp WASHER FLAME DETECTOR amp GASKET BURNER PLATE FLANGE Figure 8 1 Igniter Injector amp Flame Detector Mounting Details DAMPING ORIFICE BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw Figure 8 2 SSOV Actuator with Gas Pressure Adjustment Page 110 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 9 RS232 COMMUNICATION CHAPTER 9 RS
38. Off Valve to ensure it is opening If the valve does not open check for 120VAC at the valve input terminals If 120VAC is not present the IGST board in the Control Box may be defective Refer fault to qualified service personnel OMM 0097 0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 101 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 6 Carbon or other debris on 6 Remove View Port and inspect Burner with Boroscope If Burner it is fouled or black with soot remove the Burner and inspect for any carbon build up or debris Clean and reinstall 7 Staged ignition solenoid valve 7 When unit goes to ignition listen for a clicking sound at doesn t open the staged ignition solenoid valve to ensure it is opening 8 Clogged staged ignition piece 8 Remove and inspect staged ignition piece for blockage FLAME LOSS 1 Worn Flame Detector or cracked 1 Remove and inspect the Flame Detector for signs of wear DURING RUN ceramic or cracked ceramic Replace if necessary 2 Defective Regulator 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Poor combustion calibration 3 Check combustion calibration using proce
39. Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 12 COMBUSTION AIR The AERCO Benchmark Boiler Venting and Combustion Air Guide GF 2050 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 The more common methods of combustion air supply are outlined in the following sections For combustion air supply from ducting consult the AERCO GF 2050 Gas Fired Venting and Combustion Air Guide 2 12 1 Combustion From Outside the Building Air supplied from outside the building must be provided through two permanent openings For each unit these two openings must have a free area of not less than one square inch for each 4000 BTUs input of the equipment or 375 square inches of free area for the BMK 1500 or 500 square inches of free ar
40. Password option which must be entered if other menu options will be changed Continue pressing the MENU key until the desired menu is displayed 4 With the desired menu displayed press the or Y arrow key The first option in the selected menu will be displayed Continue to press the or Y arrow key until the desired menu option is displayed Pressing the arrow key will display the available menu options in the Top Down sequence Pressing the Y arrow key will display the options in the Bottom Up sequence The menu options will wrap around after the first or last available option is reached To change the value or setting of a displayed menu option press the CHANGE key The displayed option will begin to flash Press the or Y arrow key to scroll through the available menu option choices for the option to be changed The menu option choices do not wrap around To select and store a changed menu item press the ENTER key OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 37 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION OPERATING LEVEL 1 PWD SETUP COHFIGURATIOH Y CALIBRATIOH HOT USED IH THIS 0 amp SEE GF 112 FOR ITEM DESCRIPTIOHS wv DIAGHOSTICS HOT USED IH THIS 0 amp SEE GF 112 FOR ITEM DESCRIPTIOHS v A Only if BST is enabled see Chapter 10 Figu
41. Remove to access the Gas Pressure Adjustment Screw Figure 4 3 Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4 4 TAC Valve Adjust Idle Screw OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 57 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP BMK 2000 Natural Gas Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running Open the natural gas supply valve to the unit Set the control panel ON OFF switch to the OFF position 4 Turn on external ac power to the unit The display will show loss of power and the time and date 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 96 Also the MANUAL LED will light Adjust the air fuel valve position to 096 by pressing the Y arrow key Ensure that the leak detection ball valve downstream of the SSOV is open Set the ON OFF switch to the ON position Change the valve position to 30 using the A arrow key The unit should begin its start sequence and fire Next verify that the gas pressure downstream of the SSOV is set to 3 9 0 2 W C 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
42. S3AN3S3M OOYSV 2861 8 S 81 001 1H93IH 9NI1I3O EZARREN TC NOMJ 2 53015 29 1331 SMOTIOdJ SV _NOILONYLSNOO 1 Ol S3ONVSV3IO WNNININ 31911509009 NO Q3TIVISNI 38 AVW SIHL S3ONVSV3IO NOLVTIVISNI pes 33S dvd 99 Ac 3015 ti Drawing Number AP A 995 rev A GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Page 152 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS 9 ava ddv aos Agu 715120 S d A8 NMG 868 V s 3ONV3HV3IO 3015 04034 M3llog8 93415 SV9 0009 0052 BNVAHON38 S601 AN SEM 7 ONI IVNOLLVNHBLLNI 5135 LINN NI Q3AO1dN3 38 AINO NVO NOlLdO 3ONv3V31O 3015 0432 JHL S310N 1NO3J 019 2 1019 019 rz ff LN lel XY c 09 z 114 82 3OLLON SNOISN3WIG 3 3108 AJIGON OL S3A33S33 OOH3V OOL LHOSIH 9 476 V3 1NOHJ 54015 LHS 9 1331 SMOTIOJ SV _NOILONYLSNOO OL S3ONVSV3IO WAWININ d ONIYOO1S FIGILSNENOD NO Q3TIVISNI 38 AVN 3ONVvlIdav SIHL 1 SSONVAVATO NOLIVTI
43. SET Valve Position will begin to flash Press the A arrow key until the SET Valve Position reads 80 Press the ENTER key Next press the down arrow key until CAL Voltage 80 is displayed Press the CHANGE key and observe that CAL Voltage 80 is flashing OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 55 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP BMK 1500 Natural Gas Combustion Calibration Cont 25 The oxygen level at the 8096 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the following values Combustion Calibration Readings 80 valve Position Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 80 5 9 0 5 lt 20 ppm lt 100 ppm If the oxygen level is not within the specified range adjust the level using the A and Y arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the A arrow key increases the oxygen level and pressing the down Y arrow key decreases the oxygen level Once the oxygen level is within the specified range at 80 press the ENTER key to store the selected blower output voltage for the 8096 valve position Record all readings on the Combustion Calibration Sheets provided Repeat steps 20 through 27 for valve position
44. 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 10 12 2 Delayed Interlock In OUT amp IN The Delayed Interlock terminals can be used in one of two ways conjunction with the optional external sequencing valve see section 2 14 and Chapter 10 BST a component of AERCO s on board Boiler Sequencing Technology BST solution By default a cable of the boiler s wiring harness is connected to these terminals If BST is implemented the other end of that cable is connected to the sequencing valve e f BST is NOT implemented the second use is typically in conjunction with the AUXILIARY RELAY CONTACTS described in section 2 10 14 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 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 29 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 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 harn
45. Ver 0 00 Ver 9 99 3 6 CONFIGURATION MENU The Configuration Menu shown in Table 3 4 permits adjustment of the Internal Setpoint Setpt temperature regardless of whether the valid password has been entered Setpt is required for operation in the Constant Setpoint mode The remaining options in this menu require the valid password to be entered prior to changing existing entries This menu contains a number of other configuration settings which may or may not be displayed depending on the current operating mode setting NOTE The Configuration Menu settings shown in Table 3 4 are Factory Set in accordance with the requirements specified for each individual order Therefore under normal operating conditions no changes will be required Page 40 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Table 3 4 Configuration Menu Available Choices or Limits Menu Item Display Default Minimum Maximum Internal Setpt Lo Temp Limit Hi Temp Limit 130 F KC Boiler KC Boiler LN BMK Boiler Std BMK Boiler LN Bir Std Dual Bir LN KC Unit Type Water Heater BMK Boiler LN KC Wtr Heater LN Innovation WH Bir LN Dual Unit Size 750 MBH 800 MBH 1000 MBH 1500 MBH Only the unit sizes 1500 MBH 2000 MBH or available for the Unit 2500 MBH
46. a eo 2 lt 2 B s NOT ust o N O O I 507 506 SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX INPUT OUTPUT BOX 152 151 e o g zz z x gt gt 2 28 5 6 5 our NOT USED s iN our O _ IN os DELAYED INTLK EXHAUST TEMP lt 507 50 lt 508 509 510 6 PINCONNECTOR SEQ VALVE AGIUATOR CONTROL CABLE 63155 2 n O dono REMOTE INTLK THIRD ANGLE PROJECTION e c D Ocio er om CEVANS 12 3 13 AERC INTERNATIONAL INC 100 ORITANI DR BLAUVELT N Y TRE SEE SHT 1 FOR REVISIONS REV ECO REVISIONS DATE BY ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS FOLLOWS UNLESS OTHERWISE SPECIFIED XX 015 XXX 005 FRACTIONS 1 32t ANGLES 31 DIAMETERS ON A COMMON AXIS V A 015 TOTAL CKD CRITICAL DIMENSION THESE DRAWINGS AND OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE ISSUED IN STRICT CONFIDENCE AND SHALL NOT BE REPRODUCED COPIED OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER PERPENDICULARITY PARALLEUSM FLATNESS 015 TOTAL ALL DIMENSIONS ARE AFTER FINISH OR PLATING WIRING SCHEMATIC BMK 1500 2000 DB amp B MATL SPEC DWG NO 68071 SHEET 1 OF 1
47. 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 6 6 1 Remote Interlock Test Remote Interlock Test Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals Start the unit in the Manual Mode and set the valve position between 25 and 30 If there is a jumper across the REMOTE 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 Once the interlock connection is reconnected the INTERLOCK OPEN message should automatically clear and the unit should restart 6 6 2 Delayed Interlock Test Delayed Interlock Test Remove the cover from the I O Box and locate the DELAYED INTL K IN terminals Start the unit in the Manual Mode at a valve position between 25 and 30 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 The unit should shut down and display a DELAYED INTERLOCK OPEN fault message The FAULT LED should be flashing Reconnect the wire or jumper removed i
48. has been designed to hold up the blower and Air Fuel Valve assembly while the blower plenum is removed to allow the burner assembly to be removed for maintenance Using this support will relieve the blower s weight from bearing down upon the connection to the gas train This support rig prevents having to dismantle the entire blower and A V Valve assembly from the gas train The support rig is available as an after market The following parts will be required for reassembly after burner inspection Part No Description 81166 Burner Gasket 1 each 88183 Burner Release Gasket 1 each 81186 Burner Lower Release Gasket 1 each 81048 Flame Detector Gasket 1 each To inspect or replace the burner assembly proceed as follows Burner Assembly Inspection and Maintenance Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit and turn off the gas supply Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Disconnect the lead wire from the flame detector installed on the burner plate See Figure 7 2 Remove the two 2 screws securing the flame detector to the plate The flame detector is secured to the burner plate with one 1 10 32 screw and one 1 8 32 screw Remove the flame detector and gasket from the burner plate Disconnect the cable from the igniter
49. injector Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly see Figure 7 2 Disconnect the staged ignition assembly from the igniter injector Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Retrieve the blower support rig and attach it to the blower and unit as described in the instructions provided with the rig Loosen and remove the four 5 16x1 3 4 bolts washers and nuts from the burner plenum where it is attached to the blower see Figure 7 4a amp 7 4b Page 90 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE Burner Assembly Inspection and Maintenance Procedures Cont Remove the eight 8 3 8 16 nuts using a 9 16 wrench attaching the blower plenum to the burner beneath see Figure 7 4a amp 7 4b Remove the blower plenum from between the blower and the burner and set aside for later reassembly O2 sensor and flame observation port remain assembled to the plenum flange NOTE The burner assembly is heavy weighing approximately 65 Ibs Remove the burner by pulling straight up Remove and replace the burner gasket s see Figure 7 5 IMPORTANT ALL THREE gaskets provided for maintenance MUST be installed during th
50. no polarity to observe when terminating these wires The shield is to be connected only to the terminals labeled SHIELD the I O Box PCB The sensor end of the shield must be left free and ungrounded 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 OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 27 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 10 2 COMBUSTION AIR Terminal The COMBUSTIAN AIR terminal is used to monitor the combustion air temperature sensor This input is always enabled and is a to view only input that can be seen in the operating menu The sensor is an AERCO BALCO wire sensor P N 12449 A resistance chart for this sensor is provided in APPENDIX C This sensor is an active part of the combustion control system and must be operational for accurate air fuel mixing control 2 10 3 SENSOR 02 amp 2 The O SENSOR O SENSOR terminals are used to connect an integrated oxygen sensor to the I O Box PCB The concentration is displayed in the operating menu of the C More Control system after a 60 second warm up period 2 10 4 SPARK SIGNAL FLW amp FLW The two SPARK SI
51. opening with a solid flat object such as a piece of thick plywood or a thick metal plate The unit should shut down and display AIRFLOW FAULT DURING RUN This step confirms proper operation of the Blocked Inlet Switch Remove the cover from the air inlet opening and reinstall the Combustion Air Duct or air filter Remove the jumper wires installed in step 2 and replace the black connector boot on the Flame Detector 10 Press the CLEAR button The unit should restart Page 80 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING AIR INLET Combustion Air Duct removed PRIMARY EXHAST WATER INLET MANIFOLD ANALYZER PORT Figure 6 4 Boiler Rear View Showing Air Inlet Location 6 9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6 1 contains the proof of closure switch The proof of closure switch circuit is checked as follows SSOV Proof of Closure Switch Set the unit s ON OFF switch to the OFF position Place the unit in Manual Mode and set the valve position between 25 and 30 Refer to Figure 6 1 and locate the SSOV Remove the cover from the SSOV by loosening the screw shown in Figure 6 5 Lift off the cover to access the terminal wiring connections Disconnect wire 148 from the SSOV to open the proof of closure switch circuit The unit sh
52. terminals and the selected output is available at the terminals labeled Analog Output 2 10 9 RS 485 Comm GND amp The 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 RS 485 communication 2 10 10 RS 232 Comm TxD amp RxD The RS 232 communication terminals permit a laptop computer or other suitable terminal to be connected to the boiler The RS 232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing fault and sensor log displays 2 10 11 VFD Blower 0 10 amp AGND These terminals 0 10 amp AGND send an analog signal to control the blower speed When any of the 4 20mA options is selected for the Analog Outputs Section 2 10 8 the output from the VFD Blower terminals is disabled 2 10 12 Interlocks The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or 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 12 Both interlocks described below are factory wired in the closed position using jumpers NOTE Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to fire 2 10 12 1 Remote Interlock In OUT amp IN
53. the unit will be in the Standby mode When there is a demand for heat the following events will occur 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 NOTE required conditions are not observed 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 3 for SSOV location Page 46 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION NATURAL GAS INLET HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH Figure 3 3 BMK 1500 2000 SSOV Location 3 With all required safety 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 position and closes purge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 47 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION c The VALVE POSITION bargraph
54. used to switch from space heating to domestic hot water However the ACS Relay Panel is required in combination with the ACS when there are up to two isolation valves boiler interlocks and or a Domestic Hot Water DHW pump in a Combination heating plant where AERCO boilers are being used for both Building Heat and Domestic Hot Water heating The following two options are available for using a combination system one that uses only the ACS and one that requires the optional ACS Relay Box e OPTION 1 This option is selected when the ACS controls a boiler plant containing up to eight combination boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers e OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler plant containing up to eight combination boilers that are divided up into Building Priority BLDG PRIORITY boilers and Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and using two hydronic isolation valves in the main header one between the BLDG HEAT and BLDG PRIORITY boilers and the other between the BLDG PRIORITY and the DHW PRIORITY boilers Page 68 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 00
55. will show 100 TO BLOWER PURGE VALVE POSITION DIAL AT 100 Figure 3 4 Air Fuel Valve In Purge Position 4 Next the blower proof switch on the Air Fuel Valve Figure 3 5 closes The display will show Purging and indicate the elapsed time of the purge cycle in seconds AIR FUEL VALVE OUTLET TO BLOWER BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR FUEL VALVE INLET FROM GAS TRAIN Figure 3 5 Blower Proof Switch 5 Upon completion of the purge cycle the Control Box 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 Figure 3 6 will read between 25 and 35 to indicate that the valve is in the low fire position Page 48 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION b c d The Spark Cycle Time item in the Factory menu can be set to either 0 Sec 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle This cycle turns on the spark transformer to produce a spark with no gas flowing to clean the spark element of moisture or carbon buildup For the duration of this cycle the C More will display the CLEANING IGNITER message Following the Spark Element Cleaning Cycle power is applied to the
56. 00 Boilers CHAPTER 9 RS232 COMMUNICATION Running a Command on a Remote Machine Using PuTTY Continued 5 You are now ready to execute this command on the remote machine simply click the Open button at the bottom of the dialog You will have to provide an account name and password in the terminal window to complete the 9 2 RS 232 COMMUNICATION SETUP Regardless of the terminal emulation utilized the following guidelines must be adhered to when setting up the RS 232 communication link e Baud Rate The baud rates which can be used with the C More Control Panel are o 2400 o 4800 o 9600 Default o 19 2K e Data Format The program must be set for o 8 data bits 1 stop bit o no parity o either Xon Xoff or No flow control 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS 232 communication is accomplished as follows Menu Processing Utilizing Rs 232 Communication Start the emulator software program and ensure that the specified baud rate and data formats have been entered Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS 232 password jaguar in lower case letters and press Enter Welcome to will appear in the laptop or dumb terminal display with a listing of the following available entry choices Display next Menu Display menu items Disp
57. 00 NIPPLE 3 4 NPT 10 1 124088 NIPPLE 1 4 C S 2 1 2 LG 34 1 124149 3 WIRE ASSY JUMPER O T SWITCHES 110 1 63109 GAS TRAIN HARNESS BMK 3000 350 1 124024 HARNESS WIRING IRI 120 1 124862 RESISTOR ASSY 36 2 95029 FLANGE SSOV 1 1 2 NPT 13 3 93035 ELBOW STREET 1 4 NPT 37 2 123533 NIPPLE CLOSE 1 8 14 1 9 420 TEE REDUCING 1 1 2 X 1 2 X 1 1 2 38 2 93445 COUPLING REDUCING 1 4 x 1 8 NPT BLK MI 15 1 94060 3 NIPPLE 1 1 2 NPT X 3 00 LG 39 1 93290 TEE MXFXF BLACK IRON 1 4 NPT 16 2 94060 6 NIPPLE 1 1 2 NPT X 6 00 LG 40 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 17 1 9 323 ELBOW 90 DEGREE 1 1 2 41 1 99017 SNUBBER PRESSURE 1 4 94060 18 2 50 NIPPLE 1 1 2 NPT X 2 50 LG 42 123536 BUSHING REDUCING 1 4 X 1 8 NPT 19 12607 8 NIPPLE 1 1 2 X 2 LG 43 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 94027 20 1 108 NIPPLE 2 NPT TBE X 27 LG 44 2 9 22 PIPE PLUG 1 4 NPT STEEL 21 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 45 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 22 1 93382 2 NPT CAP 46 1 124083 TEE 1 4 NPT 150 23 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 47 1 94061 22 NIPPLE 3 4 NPT X 22 00 LG 24 1 9 294 UNION 2 NPT 300 Notshown on drawing e A component of item 6 p n 64048 ACTUATOR SSOV W REGULATOR LEA DW IRES 2 iS m CAS TEAK warwess ROM VALVE m E Mie 150 REFERO Nil l 2 F EE JUMPER e P N 124024 TETT 3r t WN L L FROM GAS T
58. 02 108 25F 81 88 95 102 109 116 20F 84 92 100 108 116 124 15F 87 96 105 114 123 132 10F 90 100 110 120 130 140 SF 93 104 115 126 137 148 OF 96 108 120 132 144 156 5F 99 112 125 138 151 164 10 102 116 130 144 158 172 186 200 214 15F 105 120 135 150 165 180 195 210 20F 108 124 140 156 172 188 200 1 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 147 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS Table F 3 Header Temperature for a Building Reference Temperature of 65F Air Temp 65 65 65 65 6 6 65 65 65 65 6 60 68 69 70 71 72 73 74 75 76 7 55 71 73 75 77 79 81 83 85 87 89 50 74 77 80 83 86 89 92 95 98 101 45 77 81 85 89 93 97 101 105 109 113 40 80 85 90 95 100 105 110 115 120 125 35 83 89 95 101 107 113 119 125 131 137 30 86 93 100 107 114 121 128 135 142 149 25 89 97 105 113 121 129 137 145 153 161 20 92 101 110 119 128 137 146 155 164 173 15 95 105 115 125 135 145 155 165 175 185 10 98 109 120 1
59. 0713 LINY3Sd OL Q39Nvasv 38 GINOHS ISOH 31VSN30NOO ONY 3ATVA NIVHO T13HS 9 TWNOISNSWIG 33S H31V3H OL 5 33H10 ONY Nidid JO SNOLIVOO1 53215 71 2 JLVSNJQNO9 rx au a _ NYNA W31SAS ONILWSH 3ATvA TI3HS 310N MOlV1n93M SvS 34O1NHS SYD IWWNNYWN 1 330553 SVD XVN OM 0 v 3HnSS3Hd 5 9 W NWININ NIVLNIVIA YH NLE 1v AlddnS W31SAS 3ATVA Janay Drawing Number SD A 990 rev A GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Page 176 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS v 166 v as A33 1 31V0 5 NOLLVTIVISNI AYVONOO3S AMVMISd 0000 0051 EAS W3LSAS Add NS JAWA 7113 ONIONGSY 35055349 3O1V3Vd3S W31SAS ANVONOO3S ANVNOO3S W3LSAS ASNNVQ NOO3S cE SLI S3NIL S OL 38 5 H19N31 NOWWOO 1235 14 07 NVHL 5531 X04 03215 38 LSNW M3I3AVIO 3dld NOWWOO 31VSN3QNOO XNYL NOISNVdX3 JAYA IHS NYNLIY W3ISAS AYYONOO3S ig 8 310N 33S YOLVINDSY Sv9 33011 5 SVD lt OM VL 3YNSS3Yd SVD XV OM
60. 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS Appendix A BOILER MENU ITEM DESCRIPTIONS MENU LEVEL amp OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint Remote Setpoint or Outdoor Reset Mode When in the Constant Setpoint Mode this value is equal to the Internal Setpoint setting in the Configuration Menu When in the Remote Setpoint Mode this value is the setpoint equivalent to the remote analog signal supplied to the unit When in the Outdoor Reset Mode this is the derived value from the charts in Appendix F Inlet Water Temp Displays the inlet water temperature in F or C Default is F Air Temp Air Temp is the air temperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed Outdoor Temp Outdoor temperature is displayed in F default or C only if outdoor sensor is installed and enabled Valve Position In Desired input valve position This would normally be the same as the fire valve position shown on the bargraph valve position out when the boiler is operating Exhaust Temp Displays the exhaust temperature in F default or C Flame Strength Displays flame strength from 0 to 100 Oxygen Level Displays the real time combustion oxygen O gt level
61. 11 94 1 Acquiring the PuT LY Application ere eR o I Sa 111 9 1 2 Logging on to a Remote Machine Using PuTTY n u 111 9 1 3 Running a Command on a Remote Machine Using 112 9 2 RS 232 COMMUNICATION SETUP a a ranas na sana aan 113 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION esses 113 9 4 DATA LOGGING azu sad et eter eit or eh at d er tree ti ta un 114 QAM ure ente os nie n eene Suck nuo ee e 115 9 42 Operation TIME EO tiet rete RE SPERO asan T ERR 115 EEECET pIMK em 116 CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 117 101 NTRODUGTION citet ertt eer E ti ert cer nde eee 117 10 2 AERCO BST QUICK START GEAR T x eitis ecce odo eed er ane tei e aiite 118 10 3 BST IMPLEMENTATION 00 0 119 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor 119 10 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor 120 10 3 3 Option Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor 121 10 3 4 Option 4 Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor
62. 13 Page 77 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING IGNITER INUECTOR ASSEMBLY BLOWER PLENUM BLOWER A F VALVE PLENUM BLOWER HEAT PROOF EXCHANGER SWITCH AIR FUEL VALVE MANUAL SHUT OFF VALVE Sj SSOV BLOCKED NY NLET SWITCH mm AIR FILTER GAS TRAIN Figure 6 3 Bare Boiler Partial View BMK 1500 2000 Page 78 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6 3 6 8 1 Blower Proof Switch Test Blower Proof Switch Test Disable the blower output drive voltage as follows a Press the MENU key until CONFIGURATION MENU is displayed b Press the A arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the Y 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 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 Re enab
63. 140 150 160 170 180 190 200 210 220 230 240 250 RES OHMS 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 1364 2 1391 0 1418 2 1445 7 VOLTS 1 93 1 96 1 99 2 02 2 05 2 07 2 10 2 12 2 15 2 17 2 20 2 23 2 25 2 27 2 30 2 32 2 34 2 36 2 39 2 41 2 43 2 45 2 47 2 50 2 52 2 54 2 56 2 58 OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 141 of 188 Benchmark 1500 2000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART This Page Is Intentionally Blank Page 142 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX D BOILER DEFAULT SETTINGS Appendix D BOILER DEFAULT SETTINGS Appendix D Boiler Default Settings MENU amp OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type BMK Boiler LN Unit Size 1500 MBH or 2000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bldg Ref Temp
64. 15 4 9 38 5 GINOHS S3XO08 LINGNOD S3HOLIMS 321435 SNOLLO3NNOO 210193713 ONIdld SH3AOO ST3NVd YNO 30 32N3834331NI IN3A33d OL SONILLIJ WO233 9 JO WNWININ V 213 SMOST3 SNOIN 9 SONILLI4 131100 LIINI 331VM 31001 1N3AdIHS NI AT31vSvVd3S QIONTIONI 34v SNW3LI SHL 3AO8V 81 LHOISH V OL ATIVOLLM3A G3dld 38 GT0OHS J9YYH SIA JAYA 43M3Y JHL 318V1NAV SI ON N3HM NIVHG 80013 1S33V3N JHL OL Q3dld 38 GT0OHS 393VHOSIQ 3ATvA 331134 NIV3G 30014 V OL ALIAVYD AG A133H4 NIV3G OL SINMA LINYSd OL 38 GINOHS 3SOH 31 5 30 002 JAWA TI3HS TVNOISN3MIQ 33S Y3LVSH JHL OL SNOILO3NNOO 33H1O ONIdld JO SNOILV9O1 53215 WWALOV 304 3009 1 201 A8 GaYINOAY SSIINN TWNOLdO SI YOLVINDAY SVD V MOT38 YO OM vl 1V tb 3ATVA S310N 5 TI3HS W31SAS JAWA W114 SNIONGSY 34055349 XNVL NOISNYdX3 A1ddans dWNd W3LSAS 333308 35 W31SAS ANJA l33Nvd S Y a MOSN3S N30V3H SOV 6 310N 33S 1934 Sv9 3jJO1nHS SV9 OLLWNOLNY Nunl3H 7 7 W3lSAS 2 S vL 34nSS3ud SVD XVNW Ot lv 38055340 5 9 NIVLNIVIA YH NLE WRWIXVA 1v SAWA 323134 Draw
65. 2 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION CHAPTER 3 OPERATION 3 1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark Boiler using the Control Panel 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 Z WARNING A ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 120 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS N WARNING N 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 N CAUTION All of the installation procedures in Chapter 2 must be completed before attempting to start the unit 3 2 CONTROL PANEL DESCRIPTION All Benchmark boilers utilize the C More Control Panel shown in Figure 3 1 This panel contains all of the controls indicators and displays necessary to operate adjust and troubleshoot the boiler These operating controls indicators and displays are listed and described in Table 3 1 Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this
66. 232 COMMUNICATION 9 1 INTRODUCTION The RS 232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line Fault and Sensor log displays NOTE The information in this chapter does not apply when implementing BST The RS 232 port on the front panel of the C More Control Box Figure 3 1 can be interfaced to a laptop computer or other suitable terminal using a RS 232 adapter cable RS 232 communication can be accomplished using any Dumb Terminal emulation such as PuTTY which is not included with Microsoft Windows but can be downloaded for free on the internet Source and instructions for using Putty are provided below 9 1 1 Acquiring the PuTTY Application Download the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PUTTY does not need to be installed so just clicking the downloaded executable will start it 9 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote machine bring up the PuTTY application by double clicking its icon You will see the main window as shown in left image of Figure 9 1 SS PUTTY Configuration Lele Configuration Ac Category Cat
67. 3 5 1 INTRODUCTION ss hi pakuna donet Let bett EL Eus 63 5 2 INDOOR OUTDOOR RESET MODE uuu sesenta au nasa sana sa saa anna 63 5 2 1 Reset Cu 63 5 2 2 Building Reference 2 63 5 2 3 Outdoor Air Temperature Sensor 63 5 2 4 Indoor Outdoor Startup cccscccessscessccssscecssccssseecssecesseccssecesssecasecssseceaeecssseceasecesseeeasecesseeesaeceeseseaaeceseeeeseeeees 63 5 9 CONSTANT SETPOINT MODE Hii L oe ee nee ee ie eee 64 5 3 1 Setting tlie SetpOlnt uu Su 64 5 4 REMOTE SETPOINT MOBDPES a usu dne 65 5 4 1 Remote Setpoint Field T SUA u uye a us 65 5 4 2 Remote S tpboint Start uDu m l u nq Su SQ 66 5 5 BIRECTiDRIVEMODES uu es eder 66 5 54 Direct Drive Field Wiring aeree 67 5 5 2 Direct Drive 67 5 6 AERCO CONTROL SYSTEM ACS a aaraa 67 5 6 1 ACS External Field Wipi gu uuu TEE a 67 5 6 2 ACSSetu p and Startups i rrr ri ett ahua asd a Sus 68 5 7 COMBINATION CONTROL SYSTEM ann 68 5 7 1 Combination Control System Field Wiring
68. 3000 MBH 2000 MBH Type will be displayed 6000 MBH Fuel Type Natural Gas or Propane Natural Gas Constant Setpoint Remote Setpoint Constant Boiler Mode Direct Drive Setpoint Combination p Outdoor Reset Remote Signal If Mode Remote 2 ay 4 20 mA Setpoint Direct Drive or 1 5V Combination PWM Input Legacy BMS Network Outdoor Sensor Enabled or Disabled Disabled Bldg Ref Temp If Mode Outdoor 40 F 230 F 70 F Reset Reset Ratio If Mode Outdoor 0 1 9 9 12 Reset System Start Tmp If Outdoor Sensor 30 F 100 F 60 F Enabled Setpt Lo Limit 40 F Setpt Hi Limit 60 F Setpt Hi Limit Setpt Lo Limit 210 F 140 F Temp Hi Limit 40 F 210 F 160 F NOTE The Bldg Ref Temp and Reset Ratio Menu Items are only displayed when the Outdoor Sensor is set to Enabled OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 41 of 188 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Table 3 4 Configuration Menu Continued Menu Display Choices Default Minimum Maximum Max Valve Position 40 100 100 Pump Delay Timer 0 min 30 min 0 min Aux Start On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown Low Fire Timer 2 sec 600 sec 2 sec Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0 F 10 F 0 Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt
69. 31 142 153 164 175 186 197 5 101 113 125 137 149 161 173 185 197 209 oO 104 117 130 143 156 169 182 195 208 5 107 121 135 149 163 177 191 205 219 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 200 71 20 116 133 150 167 201 218 T Table F 4 Header Temperature for a Building Reference Temperature of 70F RESET RATIO nn 1 4 Temp 70 77 78 80 81 82 84 86 88 90 92 94 94 94 98 100 106 78 91 94 94 100 105 100 65F 60F 80 45F 40F 100 106 112 35F 119 30F 94 102 126 25F 97 106 115 124 133 20F 100 110 120 130 140 15F 103 114 125 136 147 10F 106 118 130 142 154 109 122 135 148 161 174 187 200 213 OF 112 126 140 154 168 182 196 23100 5F 115 130 145 160 175 190 25 10F 118 134 150 166 182 198 214 T 121 138 155 172 189 200 20F 124 142 160 178 196 214 2 Page 148 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0097 00 Ph 800 526 0288 142 Benchmark 1500 2000 Boilers APPENDIX F INDOOR OUTDOOR RESET RAT
70. 4 ott Weekly Operator See section 6 4 and alarm Perform a slow drain test in accordance with ASME Slow drain test Semi Annually Operator Boiler and Pressure Vessel Code Section High water temperature Annually Service Technician See section 6 5 safety control test Operating controls Annually Operator See section 3 2 Low air flow Monthly Operator See section 6 8 Fig I gas Monthly Operator See sections 6 2 and 6 3 pressure interlocks MA vale purge Annually Service Technician See section 6 10 position switch ignition Annually Service Technician See section 6 11 position switch Safety valves As required Operator Check per A S M E Boiler and Pressure Vessel Code Section IV Inspect burner Semi Annually Service Technician See section 7 6 components Semi Condensate Trap Operator See section 7 7 Annually 2 Oxygen Level Monthly Operator Verify oxygen level is between 3 and 8 during boiler operation OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 145 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING This Page Is Intentionally Blank Page 146 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX F INDOOR OUT
71. 500 2000 Boilers APPENDIX J PIPING DRAWINGS v lt 66 05 TIS180 31V0 AS NMG SNOILVOMdd 15008 3301V33JA31 834308 83108 M SNIdd MHQ SNUV3H NOILVNIBHWOO 31V 1d 14V WS MO 0000 0051 HVWHON38 vno vnan ODE 31108 ANYL 334308 8 3LON IWLSWNOW 8 3LON YONSN3S NHAI3M S Y LN3A 1 5 35 SOV TANVd SOV 1113 SNI9003s 1 435 Add NS 7 3002 1 201 A8 SSFINN TwNOWdO SI SVD V MOTHS HO HL lv 57130 00 011 SNOLLONYLSNI XNYI 31VSN3GNOO 33S 40014 JHL 3A08V NVHL Q31V A313 38 LSNW dV3l 31 5 30 02 OON3Y ONY 331108 YO V NI GITIVISNI 38 ISAW Y3ZNVYLNSN 39vNIVHQO 31VSN3qQNOO H3dOHd 804 YSZNVYLNAN 31 5 30 00 OON3V JHL ONISN N3HM ST3NVd 3015 9 38 5 GINOHS 53 S3HOLIMS 3OIAN3S SNOLLO3NNOO 214103713 ONIdid TIV SH3AOO ST3NVd N31l08 TVAOW3M 3ON3H34H3LNI 1N3A33d OL 9 331V3H WON3 9 30 WAWININ v 013 SNOIN Y9 SONLLLLY 131100 ONY I37NI N31YM 31V201 2N3 dIHS 5 GZONIONI 33v SW3LI TW STOMLNOD SNIQIInB AB Q3TIOMINOO YO AILNVLSNOO 0O31V33dO 38 TIVHS dnd W31SAS JHL 9NIdid AlddNS W3LSAS 1 3833308 NI IVISVNDV
72. 6 2 1 Check that the Air Fuel Valve is connected to the Control Box Inspect for loose connections between the Air Fuel Valve motor and the wiring harness Replace stepper motor Check DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Page 108 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097 0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8 2 to troubleshoot faults which may occur without a specific fault message being displayed TABLE 8 2 BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Clogged damaged Gas Injector 1 Disconnect the Staged Ignition Assembly solenoid from on Igniter Injector Figure 8 1 the Gas injector Tube of the Igniter Injector Figure 8 1 and inspect Gas Injector to ensure it is not clogged or damaged 2 Defective Staged Ignition 2 Close the 2 Manual Shutoff Valve Attempt to start the unit Solenoid Figure 8 1 and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged
73. 69 5 7 2 Combination Control System Setup and Startup 69 CHAPTER 6 SAFETY DEVICE 71 6 1 TESTING OF SAFETY DEVICES 2 tnit Ia h 71 6 2 LOW GAS PRESSURE FAUT TEST 72 6 3 HIGH GAS PRESSURE TEST eee 73 6 4 LOW WATER LEVEL FAULT TEST eR ee E REC 74 6 5 WATER TEMPERATURE FAULT a 75 66 INTERLOCK TES TS et opi n EIRMOD d 76 6 6 1 Remote I nterlock T8st eie 76 6 6 2 Delayed Interlock Test iie nun orna ba Ve Pe a 76 6 ELAME FAULT TESTS d iac ente ede teen e teta lue feet 77 6 8 AIRE EEOW FAUET TESTS u u eben 79 6 8 1 Blower Proof Switch D 79 Page 4 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers Installation Operation amp Maintenance Manual IOMM 6 8 2 Blocked InletSwitch Test te ON Sorel teens 79 6 9 SSOV PROOF OF CLOSURE 5 2 2 0 0 0 000000000000000000000000000000000000 81 6 10 PURGE SWITCH OPEN DURING PURGE esses 82 6 11 IGNITION SWITCH OPEN DURIN
74. 69151 PCB ASSY 700 1 38035 I O PANEL COVER CONTROLS 710 1 38036 POWER PANEL COVER 27 1 123966 SWITCH OVER TEMP AUTO RESET 28 1 123552 SWITCH OVER TEMP MANUAL RESET 29 1 60011 2 BLOWER SWITCH 30 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 31 1 181197 CONTROL BOX C MORE 32 1 65085 TRANSFORMER IGNITION 330 1 63108 SSOV RELAY JUMPER 34 1 93230 SNUBBER Not shown on drawing AERCO Benchmark 1500 2000 Part List 02 01 2014 International Inc Blauvelt NY 10913 Whole Boiler 29313 1 29337 1 Sheet 1 of 7 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 155 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Benchmark 1500 2000 Part List Continued Item Qty Part i Description Item Qty Part Description SHEET METAL PANEL ASSEMBLY OTHER ACCESSORIES amp PARTS SEE 72 1 37117 BACK PANEL LEFT 870 1 TABLEA PRESSURE TEMP GAUGE SEE 730 1 37118 BACK PANEL RIGHT 880 1 TABLEA PRESSSURE RELIEF VALVE 74 2 35029 TOP RAIL 89 0 1 123540 EXT MANUAL SHUT OFF VALVE 75 1 25078 ASSEMBLY FRONT PANEL 90 1 69126 LOW WATER CUTOFF CAPACITOR ASSY 76 1 25072 FRONT PANEL ASSY 91 1 123863 1 8 NTP BALL VALVE 77 1 72068 DOME LABEL 92 1 92094 3 4 DRAIN VALVE 78 2 5
75. 79 8 9 9 e o o Sk Zs z 5 5 14 oF 9 2 az A o 53 Y 146 o z T z H AIR FUEL VALVE 22 2 150 145 q SOLENOID Bo VALVE E 810 5 LI a _ a rane FLAME ROD C AMPLIFIER F fh hor CIS A 271 270 FUSE A 201 200 209_ di 19 136 A TO I O BOX 613 CANL 123456789 MANUAL RESET AUTO RESET 364 CANH 614 conROL_ OVER TEMPERATURE SWITCHES TO TEMP SENSOR 363 192 z 12V POWER I 2u L GND SUPPLY O V9 BOX 141 oz AGRD QN E 190 35 u 8 8 5 195 332 di PV 331 6 PIN CONNECTOR Vs A HH 190 gt 2 92 A 204 191 SN 203 3 A o 192 2 Es u js Im gt 2 0 POLE BREAKER M si ZI 193 209 A p gt 2 A BOARD oN gt 27 SEE SHT 2 m SS i L TOSEQUENCENG 321 VALVE HARNESS 206 P N 63155 SOLENOID S TO CONTROL BOX ENCLOSURE 350 GROUND TERMINALS 320 366 330 POWER BOX THIRD ANGLE PROJECTION owe omes CEVANS 12 3 13 AERC INTERNATIONAL INC D m 100 ORITANI DR BLAUVELT N Y TE 90 ADDED 24V POWER SUPPLY uzna CE NEN EOS D ALTARIS AE CE MEE XX 1 015 005 FRACTIONS 1 322 ANGLES 219 A 901 5 RELEASED FOR PRODUCTION 12 3 13 JC ARS ANA Golan see DIN REV ECO REVISIONS DATE BY CKD CRITICAL DIMENSION 68071 THESE DRAWINGS AND OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE ISSUED IN STRICT C
76. 8 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 2 LOW GAS PRESSURE FAULT TEST To simulate a low gas pressure fault refer to Figure 6 1a and perform the following steps V NATURAL GAS INLET MANUAL SHUT OFF VALVE LOW GAS PRESSURE HIGH GAS SWITCH PRESSURE SWITCH 1 4 NPT PLUG And Ball Valve install manometer here for LOW GAS PRESSURE FAULT TEST Figure 6 1a BMK 1500 2000 Low Gas Pressure Test LOW GAS BALL VALVE Low Gas Pressure Fault Test Close the leak detection ball valve located at the low gas pressure switch see Figure 6 1a Remove the 1 4 plug from the ball valve at the low gas pressure switch shown in the lower portion of Figure 6 1a Install a 0 16 W C manometer or a W C gauge where the 1 4 plug was removed Slowly open the ball valve near the low gas pressure switch Place the unit in Manual Mode and adjust the Air Fuel Valve position open between 25 and 30 6 While the unit is firing slowly close the external manual gas shut off valve 7 The unit should shut down and display a GAS PRESSURE fault message at approximately 3 6 W C for both BMK 1500 and BMK 2000 Fully open the external manual gas shut off valve and press the CLEAR button on the Control Box The fault message should clear and the FAULT indicator should go off The unit should restart Upon test completion close the ball valve and remove the manometer Replac
77. 9179 HANDLE CONCEALED 93 1 59043 CONDENSATE FLOAT 79 4 59133 LATCH 940 1 24060 COND TRAP ASSY 80 1 37119 FRONT TOP PANEL 95 1 59178 1 8 AIR VENT 81 1 37120 BACK TOP PANEL 96 1 90052 NIPPLE 1 8 X 1 50 LG 82 2 30117 SIDE PANEL 97 1 24386 1 0 POWER BOX ASSY 110 V 1 74031 BMK 1500 LOGO 83 MOTORIZED SEQUENCING VALVE 1 74033 BMK2000 LOS 100 1 92084 6 OPTIONAL 84 1 39164 AIR INLET ADAPTER Not shown on drawing TABLE A Benchmark 1500 TABLE A Benchmark 2000 Part No Description Item 88 Item 87 Part No Description Item 88 Item 87 58088 C30 30 PSI KIT CONBRACO 92023 1 69087 2 58087 1 30 PSI 123260 W30 69087 2 58088 C50 50 PSI KIT CONBRACO 92023 2 69087 2 58087 2 50 PSI 123260 W50 69087 2 58088 C60 60 PSI KIT CONBRACO 92023 3 69087 3 58087 3 75 PSI 123260 W75 69087 3 58088 C75 75 PSI KIT CONBRACO 92023 4 69087 3 58087 4 100 PSI 123260 W100 69087 3 58088 C100 100 PSI KIT CONBRACO 92023 5 69087 3 58087 5 150 PSI 123260 W150 69087 4 58088 C125 125 PSI KIT CONBRACO 92023 6 69087 3 58087 6 60 PSI 123260 W60 69087 3 58088 C150 150 PSI CONBRACO 92023 7 69087 4 58087 7 125 PSI 123260 W125 69087 3 58088 W30 30 PSI KIT WATTS 92023 8 69087 2 58087 8 160 PSI 123260 K160 69087 4 58088 W50 50 PSI KIT WATTS 92023 9 69087 2 58088 W60 60 PSI KIT WATTS 92023 10 69087 3 58088 W75 75 PSI KIT WATTS 92023 11 69087 3 58088 W100 100 PSI KIT WATTS 92023 12 69087 3 58088 W125 125 PSI KIT WATTS 92023 13
78. 97_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION In Option 2 when the space heating load is such that when all the space heating boilers are at the 100 valve position the ACS will then ask the ACS Relay Box for the domestic boilers to become space heating boilers Provided the domestic hot water load is satisfied the combo hot water boilers will then become space heating boilers If the domestic hot water load is not satisfied the combo boiler s remain on the domestic hot water load If the combo boilers switch over to space heating but there is a call for domestic hot water the ACS Relay Box switches the combo units back to the domestic load The ACS in combination with the ACS Relay Box will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand When the combo units are satisfying the domestic load they are in the constant setpoint mode of operation When the combo units switch over to space heating their mode of operation changes to follow the ACS command For more information concerning the operation of the ACS consult the ACS Operations Guide GF 131 For more information on the ACS Relay Box see section 2 14 in the same manual 5 7 1 Combination Control System Field Wiring Wiring for this system is between the ACS the ACS Relay Box and the terminals in the I O Box Wire the units usin
79. A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing Boiler in Service After Long Shutdown Review installation requirements included in Chapter 2 Inspect all piping and connections to the unit Inspect exhaust vent and air inlet duct work if applicable Perform initial startup per Chapter 4 Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of this manual Page 96 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE CHAPTER 8 TROUBLESHOOTING GUIDE 8 1 INTRODUCTION This troubleshooting guide is intended to aid service maintenance personnel in isolating the cause of a fault in a Benchmark 1500 MBH and 2000 MBH boilers The troubleshooting procedures contained herein are presented in tabular form on the following pages These tables are comprised of three columns labeled Fault Indication Probable Cause and Corrective Action The numbered items in the Probable Cause and Corrective Action columns correspond to each other For example Probable Cause No 1 corresponds to Corrective Action No 1 etc NOTE The front panel of the C More Control Box contains an RS 232 port which can be interfaced to a laptop computer or other suitable device This RS 232 communication feature permits service personnel to v
80. APTER 4 INITIAL START UP BMK 2000 Natural Gas Combustion Calibration Cont 15 If the oxygen level is not within the required tolerance 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 approximately 1 4 turn increments Allow the combustion analyzer to stabilize following each adjustment Clockwise rotation reduces the oxygen level while counterclockwise rotation increases the oxygen level Once the oxygen level is within the specified range at 10096 record the NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit Lower the valve position to 80 using the Y arrow key NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C More Control System The combustion calibration control functions will be used to adjust the oxygen level 96 at valve positions of 8096 5096 4096 3096 and 1496 as described in the following steps These steps assume that the inlet air temperature is within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O level up to 196 higher than the listed calibration range Record the increased value on the Combustion Calibration sheet 18 Press the MENU key on the front panel of the C MORE and access the Setup menu Enter password 6817 and then pre
81. BABLE CAUSES CORRECTIVE ACTION INTERLOCK 1 Interlock jumper not installed or 1 Check for a jumper properly installed across the interlock terminals OPEN removed in the I O box 2 Energy Management System 2 If there are two external wires on these terminals check any Energy does not have unit enabled Management system to see if they have the units disabled a jumper may be temporarily installed to see if the interlock circuit is functioning 3 Device proving switch hooked to 3 Check that proving switch for any device hooked to the interlock interlocks is not closed circuit is closing and that the device is operational LINE VOLTAGE 1 Line and Neutral switched in AC 1 Check hot and neutral in AC Power Box to ensure they are not OUT OF PHASE Power Box reversed 2 Incorrect power supply 2 Check transformer wiring in AC Power Box against the power box transformer wiring transformer wiring diagram to ensure it is wired correctly LOW GAS 1 Incorrect supply gas pressure 1 Measure gas pressure upstream of the SSOV Actuator s with the PRESSURE unit firing For FM gas trains ensure it is between 6 0 W C and 14 W C For DBB gas trains ensure it is between 6 5 W C and 14 W C see section 4 3 2 Defective Low Pressure Gas 2 Measure gas pressure at the low gas pressure switch If it is greater Switch than 4 7 W C for both BMK 1500 and BMK 2000 measure continuity across the switch and replace if necess
82. BMS amp BMS These terminals are only used to connect to legacy AERCO Boiler Management Systems BMS which utilize a 12 millisecond ON OFF duty cycle and is Pulse Width Modulated PWM to control valve position A 0 valve position a 5 ON pulse and a 100 valve position a 95 ON pulse Note that these connections cannot be used with the AERCO Control System ACS 2 10 7 Shield SHLD amp 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 10 8 Analog Output amp The ANALOG OUT terminals amp 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 Default setting in the C More controller is Valve Position 0 10v and settings behave as follows Page 28 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION e When 0 10VDC is selected the voltage output is used by the controller to modulate the combustion blower via the I O Box terminals labeled VFD Blower Section 2 10 11 On Board Boiler Sequencing Technology BST is enabled the Analog Output terminals are used to drive the isolation valve open and closed e When the 4 20mA is selected for the Analog Output the 0 10VDC is disabled at the VFD Blower
83. BST Setpt Lo Limit 40 F BST Setpt HI Limit 60 F BST Setpt HI Limit BST Setpt Lo Limit 220 F 195 F BST Prop Band 1 F 120 F 100 F BST Intgral Gain 0 00 2 00 0 50 BST Deriv Time 0 00 Min 2 00 Min 0 10 Min BST Deadband Hi 0 25 1 BST Deadband Lo 0 25 1 Deadband En Time 0 120 Sec 30 Sec BST FR Up Rate 1 120 20 BST Bldg Ref Tmp 40 F 230 F 70 F BST Reset Ratio 0 1 9 9 1 2 System Start Tmp 30 F 120 F 60 F BST COMM MENU Disabled Enabled Disabled Comm Address 0 127 0 BST Min Addr 1 128 1 BST Max Addr 1 128 8 SSD Address 0 250 247 SSD Poll Control 0 1000 0 OMM 0097_0D GF 142 Ph 800 526 0288 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 45 of 188 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Available Choices or Limits Menu Item Display Default Minimum Maximum Err Threshold 1 9 5 SSD Temp Format Degrees Points Degrees BST Upld Timer 0 9999 sec 0 3 10 START SEQUENCE When the Control Box ON OFF switch is set to the ON position it checks all pre purge safety switches to ensure they are closed These switches include e Safety Shut Off Valve SSOV Proof of Closure POC switch e Low Water Level switch e High Water Temperature switch e High Gas Pressure switch e Low Gas Pressure switch Blower Proof switch e Blocked Inlet switch If all of the above switches are closed the READY light above the ON OFF switch will light and
84. Benchmark 1500 2000 Boilers Installation Operation amp Maintenance Manual IOMM AERCO Natural Gas Modulating USER MANUAL amp Condensing Hot Water Installation Operation and Maintenance Boiler Models 1500 2000 1500 2000 Gas Fired Boilers Applicable to Serial Numbers G 14 0304 and Above Latest Update 03 20 2014 GAS FIRED CERTIFIED C Ee Commercial Boilers H LISTED AHRI Standard BTS 2000 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 1 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers Installation Operation amp Maintenance Manual IOMM Technical Support Mon Fri 8am 5pm EST 1 800 526 0288 www aerco com 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 Page 2 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers Installation Operation amp Maint
85. CONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER e SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF VALVE PROVIDED WITH THE UNIT e ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING Table 7 1 Maintenance Schedule Labor Time Igniter Injector iut Detector RES Sensor 74 Combustion 75 Testing of Safety See ASME CSD 1 45 mins Devices Chart 76 Bumer j A 7 7 Condensate soar Inspect Clean amp Inspect Clean amp SO mine Drain Trap P Replace Gaskets e Gaskets Air Filter 59138 Gem Clean Replace 15 mins mins Only MER after initial 6 month period after initial startup OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 85 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE 7 2 IGNITER INUECTOR The igniter injector part no 66026 is located on the burner plate at the top of the boiler In addition to providing the ignition spark required to light the burner the igniter injector also contains a gas injector tube which connects to the staged ignition assembly Figure 7 1 shows the complete burner assembly removed from the boiler and indicates the location of the igniter injector flame detector and other related components BLOWER BLOWER PLENUM A F VALVE PLENUM IGNITOR INJECTOR AE
86. CS Setup and Startup This mode of operation is factory preset and the ACS controls the firing rate air fuel valve open position There are no setup instructions for each individual unit To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the ACS mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 7 COMBINATION CONTROL SYSTEM CCS NOTE Only ACS can be utilized for the Combination Control System A Combination Control System CCS is one that uses multiple boilers to cover both space heating and domestic hot water needs The theory behind this type of system is that the maximum space heating load and the maximum domestic hot water load do not occur simultaneously Therefore boilers used for domestic hot water are capable of switching between constant setpoint and ACS control For a typical CCS an adequate number of boilers are installed to cover the space heating load on the design day However one or more units are used for the domestic hot water load as well These boilers are the combination units and are referred to as the combo boilers The combo boilers heat water to a constant setpoint temperature That water is then circulated through a heat exchanger in a domestic hot water storage tank Only the AERCO Control System ACS is necessary to configure this system if only a single valve is
87. DOOR RESET RATIO CHARTS Appendix F INDOOR OUTDOOR RESET RATIO CHARTS Table F 1 Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 40F 56 58 60 62 64 66 68 70 72 74 35F 59 62 65 68 71 74 77 83 86 30F 62 66 70 74 78 82 86 90 94 90 25F 65 70 75 80 85 90 95 100 105 110 20F 68 74 80 86 92 98 104 110 116 122 15F 71 78 85 92 99 106 113 120 127 134 10F 74 82 90 98 106 114 122 130 138 146 SF 77 86 95 104 113 122 131 140 149 158 OF 80 90 100 110 120 130 140 150 160 170 5F 83 94 105 116 127 138 149 160 171 482 10F 86 98 110 122 134 146 158 170 182 194 15F 89 102 115 128 141 154 167 180 193 206 20F 92 106 120 134 148 162 176 190 204 218 Table F 2 Header Temperature for a Building Reference Temperature of 60F RESET RATIO ws Du a ae Temp i 60F 60 60 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72 50F 66 68 70 72 74 76 78 80 82 84 45F 69 72 75 78 81 84 87 90 93 40F 72 76 80 84 88 92 96 100 104 108 35F 75 85 90 95 100 30F 78 84 90 96 1
88. EN 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 DO NOT CHANGE the Analog Output Menu Item from its Default Z CAUTION N setting Valve Position 0 10 3 7 TUNING MENU The Tuning Menu items in Table 3 5 are Factory set for each individual unit Do not change these menu entries unless specifically requested to do so by factory trained personnel Table 3 5 Tuning Menu Available Choices or Limits Menu Item Display WERE Tie Default Prop Band TF 120 F 8 F Integral Gain 0 00 2 00 1 6 Derivative Time 0 0 min 2 00 min 0 10 min Warmup Prop Band 0 F 120 F 95 F Warmup Int Gain 0 2 00 0 50 Warmup PID timer 0 sec 240 sec 20 sec Reset Defaults Yes No Are You Sure No Page 42 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION 3 8 COMBUSTION CAL MENU The Combustion Cal Calibration Menu is protected by the level 2 password 6817 which must be entered to view or change the menu items shown in Table 3 6 These menu items are used to vary the speed of the unit s blower motor based on air temperature and air density at prescribed Air Fuel Valve positions open This is accomplished by providing a DC drive voltage to the motor which adjusts the rotational speed of the blower to maximize combustion efficiency and ens
89. G IGNITION 006000000000 83 6 12 SAFETY PRESSURE RELIEF VALVE 84 CHAPTER 7 MAINTENANDGL irte cu scar anna o atro cade ca vica ska mp an cun acu sebo RC 85 T TMAINTENANCE SCHEDULE etie dre ee ee tierce e eee 85 EZ IGNLITER INJEGCTOR tete een ht teu ee 86 T 3 FEAME DETEGTOR iiie t tere ee eei e re Ee Leer nter 88 7 4 SENSOR89 To SAFETY DEVIGE TESTING uu u um io eite ere eed 89 7 6 BURNER ASSEMBLY INSPECTION 0 00 060000000008000000000000000000000000 nani sara sa saa aan 90 7 7 CONDENSATE DRAIN T RAP 1 ieiuno tte d dened bod ka 94 7 8 AIR FILTER CLEANING amp REPLACEMENT nnn nana nain 95 7 9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF 96 7 10 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWMNN 96 CHAPTER 8 TROUBLESHOOTING GUIDE 97 BA INTRODUC TO N au DR ES 97 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 109 CHAPTER 9 RS 232 2 2 1 11 U U u uu u 111 9 1 INTRODUCTION 1
90. GNAL terminals permit an external current sensor to be connected for ignition spark monitoring purposes If no spark is present during the ignition sequence the controller will shut down and display a fault message 2 10 5 Analog In amp The two ANALOG IN terminals 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 to 5 VDC or a 0 to 20 mA 0 to 5 VDC signal may be used to vary the set point or air fuel valve position The factory default setting is for 4 to 20 mA 1 to 5 VDC however this may be changed to 0 to 20 mA 0 to 5 VDC using the Configuration Menu described in Chapter 3 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 Control Box 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 PCB Figure 2 12 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 PCB Whether using voltage or current for the drive signal they are linearly mapped to a 40 F to 240 F setpoint or a 0 to 100 air fuel valve position No scaling for these signals is provided 2 10 6 B M S PWM In
91. IGN BOARD A communication fault has occurred between the PMC board COMM FAULT and Ignition board IGN SWTCH CLOSED IGN SWTCH OPEN DURING IGNITION The Ignition Position Limit switch on the Air Fuel Valve closed DURING PURGE during purge The Ignition Position Limit switch on the Air Fuel Valve opened during ignition INTERLOCK OPEN The Remote Interlock is open LINE VOLTAGE OUT OF PHASE The Line Hot and Neutral wires are reversed LOW GAS PRESSURE The Low Gas Pressure Limit Switch is open The Low Water Cutoff board is indicating low water level NETWORK COMM The RS 485 network information is not present or is FAULT corrupted O5 OUT OF RANGE The O has gone below 3 or above 8 Page 138 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 2 Fault Messages Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range OUTLET TEMP SENSOR FAULT The temperature measured by the Outlet Sensor is out of range e OUTLET TEMPERATURE display SHt sensor is shorted e OUTLET TEMPERATURE display Opn indicates sensor is open circuited Indicates PRG SWTCH CLOSED DURING IGNITION The Purge Position
92. IO CHARTS Table F 5 NIN Table F 6 N 11 E z 3 m ajma 0 e SNE Header Temperature for Building Reference Temperature of 75F RESET RATIO 100 105 110 115 120 125 130 135 140 145 150 155 160 165 1 2 75 81 87 93 99 105 111 117 123 129 135 141 147 153 159 165 171 177 183 75 5 7 82 83 84 8 86 87 97 99 75 82 89 91 93 95 97 96 99 102 105 108 111 166 179 192 205 218 173 187 201 215 J 180 195 210 187 208 219 194 214 pp j 201 219 Header Temperature for a Building Reference Temperature of 80F RESET RATIO 80 80 80 80 80 80 80 85 86 87 88 90 91 92 90 92 94 96 98 100 102 104 95 98 101 104 107 110 113 116 140 152 164 176 188 200 212 145 158 171 184 197 210 150 164 178 192 200 1 155 170 185 200 215 160 176 192 200 165 182 199 210 J L 170 188 206 OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 149 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX F INDOOR OUTDOOR RESET
93. Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 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 1 Set the unit s ON OFF switch to the OFF position Place the unit in Manual Mode and set the valve position between 25 and 30 Remove the Air Fuel Valve cover Figure 6 6 by rotating the cover counterclockwise to unlock and lift up to remove Remove one of the two wires 169 or 170 from the Ignition Switch Figure 6 7 Initiate a unit start sequence 6 The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION Replace the wire on the Ignition Switch and press the CLEAR button The unit should restart BLOWER PROOF SWITCH 75 AIR FUEL AIR FUEL VALVE COVER Rotate Counter Clock Wise VALVE to Remove BLOCKED INLET SWITCH Figure 6 6 Air Fuel Valve Cover Location OMM 0097_0D AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Page 83 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING TO BLOWER Ignition 1 Position Switch 170 VALVE POSITION AIR FUEL VALVE DIAL SWITCH WIRING BREAKOUT 1
94. International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 119 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor Step 1 MODbus Header Sensor Wiring 1 Using Shielded pair 18 22 AWG cable connect the Temperature Transmitter AERCO 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 the I O Box of any of the Boiler units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor AERCO PN 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 e Polarity must be observed for the RS485 connections e The ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e 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 Q GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter 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 BST Men
95. LD WIRING Figure 2 10 Power Box Cover Labels 120VAC Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A three 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 1 CSA C22 1 Electrical Code For electrical power wiring diagrams see the AERCO Benchmark Electrical Power Guide GF 2060 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 25 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 10 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 Control system used with all Benchmark units does allow for some additional control and monitoring features Wiring
96. Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE REMOTE SETPT SIGNAL FAULT The Purge Position Limit Switch on the Air Fuel Valve opened during purge The Remote Setpoint signal is not present or is out of range GF 142 RESIDUAL The Flame signal was seen for more than 60 seconds during FLAME standby SSOV SWITCH The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during purge SSOV FAULT T DURING IGN The SSOV switch closed or failed to open during ignition SSOV FAULT The SSOV switch closed for more than 15 seconds during DURING RUN run SSOV RELAY A failure has been detected in one of the relays that control FAILURE the SSOV STEPPER MOTOR The Stepper Motor failed to move the Air Fuel Valve to the FAILURE desired position OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 139 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES This Page Is Intentionally Blank Page 140 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Appendix C SENSOR RESISTANCE VOLTAGE CHART Temperature Sensor Resistance Voltage Chart Balco F 100 110 120 130
97. MBLY Once the combustion calibration adjustments are properly set the unit can be reassembled for service operation Reassembly Setthe ON OFF switch in the OFF position Disconnect AC power from the unit Shut off the gas supply to the unit Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound Remove the combustion analyzer probe from the 1 4 vent hole in the exhaust manifold Replace the 1 4 NPT plug in the manifold Replace all previously removed sheet metal enclosures on the unit This concludes reassembly of the unit after combustion calibration Page 60 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP 4 5 OVER TEMPERATURE LIMIT SWITCHES The unit contains three 3 types of over temperature limit switches These switches consist of a manual reset switch a rotary dial adjustable switch and a digital alarm switch These switches are mounted on a plate as shown in Figure 4 5 The switches can be accessed by opening the front panel door of the unit The manual reset switch is not adjustable and is permanently fixed at 210 F This switch will shut down and lock out the boiler if the water temperature exceeds 210 F Following an over temperature condition it must be manually reset by pressing the manual reset button shown in Figurer 4 5 be
98. MMON I O BOX PCB REMOTE INTL K COMBUSTION AIR E pcne B Refer to this image for PCB connection functions rather 2 SPARK SIGNAL than the silkscreen labels DELAYED INTL K IN O2 SENSOR on the PCB NOT USED NOT USED 12v OUT ANALOG IN ws Nc COM FAULT RELAY B M S PWM IN N O LI DIP1 MODBUS TERM u SHIELD a DIP2 RS232 ENABLE AUX RELAY ANALOG OUT NOT USED RS 485 Comm RELAY CONTACTS 120 VAC 30 VDC RS 232 Comm 5 ANPS RESISTIVE VFD BLOWER DANGER 120 VAC USED IN THIS BOX Figure 2 12 I O Box Terminal Strips 2 10 1 Outdoor Air In OUT amp Air Sensor Common COM The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor AERCO P N GM 123525 as required primarily 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 This feature 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 the Configuration Menu in Chapter 3 The outdoor sensor may be wired up to 200 feet from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O PCB Figure 2 12 Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG There is
99. ManualiGas Shutotf Valve scio Ettore ette e See et vede dede dedu 22 2 8 3 External Gas Supply Regulator eee Sama reo pe ere 23 2 9 AC ELECTRICAL POWER WIRING eronneita a a a a a 24 2 9 1 Electrical Power u la unan ua 25 2 10 FIEED CONTROE WIRING eee tete ce eate AA ol lee ee 26 2 10 1 Outdoor Air In OUT amp Air Sensor Common 27 2 10 2 COMBUSTION AIR Terminal y au rne ne redeo e Nae OSO 28 2 10 30 SENSOR Q2 F RO 2 i i Sus US Qa qua EIE eene reg h Tone Ra dra Tax eia eaae Tre gun 28 2 10 4 SPARK SIGNAL FLW amp FLW 28 210 5 fti amp 2 osy RC 28 2 10 6 B M S PWM In BMS amp BMS cccccesccscsccesscsesecsesecsrsesscsesscessnsusecsesecarsusececsssevansusecetsusavsesecessesesansnsaceeeesens 28 2 10 7 Shield SHLDO amp SALO LR 28 2 10 8 Analog O tp t 4 alpa y a u e e ea ee ie Ed IN u aya 28 2 10 9 RS 485 Comm GND a i t ce Ree e a e REESE Ex ce e Ead Pw 29 2 10 10 RS 232 Comm TXB SC RXD eo pia seen cette aeree eo pete cus ae ees pens ne sale Dre uba aa s 29 2 10 11 VFD Blower 0 10 re E Re Buster tri re er e eh eir 29 2 10 12 nterl ck a E 29 2 10 13 Fault Relay NC GOM a
100. N BLOCKED INLET SWITCH FLAME DETECTOR TOP PLATE FLAME OBSERVATION BURNER J PORT AIR FUEL VALVE Figure 7 1 Benchmark 1500 2000 Burner Assembly from Boiler The igniter injector may be hot therefore care should be exercised to avoid burns It is easier to remove the igniter injector from the unit after the unit has cooled to room temperature To inspect replace the Igniter Igniter Injector Maintenance Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Disconnect the cable from the igniter injector Figure 7 1 Page 86 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE Igniter Injector Maintenance Procedures Continued 4 Refer to the partial exploded view in Figure 7 2 Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly Disconnect the staged ignition assembly from the igniter injector Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Check the igniter injector for evidence of erosion or carbo
101. NECTOR 7 PIN Figure K 2 Benchmark Control Panel Rear View Page 182 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers APPENDIX L RECOMMENDED SPARES Appendix L RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix H for the locations of the recommended and optional spare parts listed in the following Tables Table L 1 Recommended Emergency Spare Parts DESCRIPTION PART NUMBER 120 VAC Blower 69078 SSOV Actuator Regulator Combo Used on e ALL FM gas train models 69005 Downstream SSOV of IRI gas train models SSOV Actuator Without Proof of Closure Switch Used on 69038 Upstream SSOV of IRI gas train models Temperature Switch Manual Reset 123552 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 13 NOTE Kits ending in xx were not available at the time this guide was printed Contact AERCO for availability Table L 3 Optional Spare Parts DESCRIPTION PART NUMBER C More Control Box 181197 BMK 1500 46042 BMK 2000 46044 Sensor 61026 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 183 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers
102. NG 1 4 20 X 1 00 LG 25 1 59104 OBSERVATION PORT 8 1 59138 FILTER AIR 6 26 1 81183 RELEASE GASKET 9 5 9 21 PLUG HEX HD 1 8 NPT 27 1 24277 STAGED IGNITION ASSY 10 2 123535 TEE 1 8 NPT 28 1 81184 GASKET BLOWER 11 1 124008 NIPPLE 1 8 NPT X 3 00 LG 29 2 123626 1 4 BOLT SIZE FLAT WASHER 12 1 61024 AIR INLET TEMPERATURE SENSOR 30 2 55026 BOLT HEX 1 4 20 X 1 25 LG 13 1 124979 1 8 C S STREET ELBOW 31 2 56005 NUT FLANGE NYLOCK 1 4 20 14 1 93230 SNUBBER 32 1 123533 NIPPLE CLOSE 1 8 15 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 33 1 81186 LOWER RELEASE GASKET BMK2000 16 1 60011 2 SWITCH ASSY BLOWER PROOF AERCO Benchmark 1500 2000 Burner Assembly 10 18 2013 International Inc Blauvelt NY 10913 24378 24388 rev A Sheet 1 of 2 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 165 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS AERCO Benchmark 1500 2000 Burner Assembly 10 18 2013 International Inc L Blauvelt NY 10913 24378 24388 rev A Sheet 2 of 1 Page 166 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Appendix 1 WIRING DIAGRAMS CONTROL BOX CONNECTIONS 7 CONNECTOR
103. NH 614 DIGITAL CONTROL OVER TEMPERATURE SWITCHES ee A 192 141 A AGRD 190 mg 195 332 AN AAA SNAN 6 PIN CONNECTOR A 190 gt 201 02 204 AN vane 191 gt 203 31 f 192 E 206 SINGLE POLE 28 BREAKER pS uu oa 206 TON I O BOARD gt gt J7 SEE SHT 2 195 gt TO SEQUENCEING VALVE HARNESS P N 63155 SOLENOID 350 TO CONTROL BOX ENCLOSURE GROUND TERMINALS 366 330 POWER BOX CEVANS 5 2613 200909 INTERNATIONAL INC C D PRIM Em 100 ORITANI DR BLAUVELT N Y WE 90 ADDED 24V POWER SUPPLY wi7na CE ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE n WIRING SCHEMATIC AS FOLLOWS UNLESS OTHERWISE SPECIFIED BMK 1500 2000 FM XX 015 XXX 005 FRACTIONS 1 32 ANGLES 21 901 5 RELEASED FOR PRODUCTION 12 3 19 DIAMETERS ON A COMMON AXIS 015 TOTAL MATL SPEC DWG NO Rev ECO REVISIONS DATE CRITICAL DIMENSION C 68050 THESE DRAWINGS AND OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE ISSUED IN STRICT CONFIDENCE AND PERPENDICULARITY PARALLELISM FLATNESS 015 TOTAL SHALL NOT BE REPRODUCED COPIED OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER DIMENSIONS ARE AFTER FINISH OR PLATING SHEET 1 OF 2 Drawing Number 68050 rev B page 1 of 2 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 167 of 188 GF
104. NOISN3WIG 33S OL SNOLL23NNOO 33H10 ONY 9Nldld JO SNOILYOOT ONY S3ZIS TWNLOV l S310N Drawing Number SD A 991 rev A Page 177 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS z66 v ds 15008 dW3l ONldld 831 LOH SLLSSNOG ONILW3H NOLLVTTVISNI 319NIS MOT 0002 0051 DHVAHON38 ONI NOLL viia iNi OO E 39 AlddnS d 3 vN W3lSAS MONSN3S 43Q0v3H SOV SAWA 77113 SNIOnQ33 340553349 35 N31SAS A009 7 201 Q33In038 SS31Nn TWNOlldO SI MO1v10934 SVO V MOT38 YO OM lv 8 571130 400 011 SNOLLONYLSN 31VSN3Q0NOO 335 740013 JHL 3AOB8V M3H9IH G31VA313 5 31VSN3QNOO OON3V 33108 SO V NI Q3TIVISNI 38 LSNW NVL Y3ZMVYLAIN SOVNIVYC 31VSN3Q0NO2 M3dOMd INVL YSZMVYLNSN 31VSN3Q0NO9 OON3V JHL ONISN N3HM 4 SS31 OM tl OL NMOG 330SS33d SVD JHL 8 OL SATIVA SSOLNHS JHL dO WV3HISNMOG 38 ISAW YOLVINDSY FILS 3201 HL N31v3H9 SI 34055344 SVD FIGVIIVAV N3HM 9 ST3NVd 3015 AVWW 9 38 5 GINOHS S3XO8 LINGNOD SSHOLIMS 39lAN3S SNOLLO3NNOO 21412313 SM43AOO ONY SI3NVd 831108 30 WWA
105. ONFIDENCE AND PERPENDICULARITY PARALLELISM FLATNESS 015 TOTAL SHALL NOT BE REPRODUCED COPIED OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER ALL DIMENSIONS ARE AFTER FINISH OR PLATING 1 2 Drawing Number 68071 rev page 1 of 2 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 171 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS This page intentionally blank Page 172 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS CONTROL BOX CONNECTORS 24 PIN CONNECTOR 1234567 8 910 11121314151617 18 19 20 21 222324 AN AN MS R R IR 8 8 18 18 JR 16 PIN CONNECTOR 16 15 14 13 12 11 10 9 87654321 N o _ OUTDOOR AIR SENSOR SENSOR COMMON IN AIR AUX SENSOR IN FLOW SENSOR IN 02 N C SENSOR 12 VDC m oppo 6 5 9 zog Z 0 o E o z 9 lt z 9 o 9 z z 8 2 lt lt mu z
106. OOR RESET MODE This mode of operation is based on outside air temperatures As the outside air temperature decreases the supply header temperature will increase and vice versa For this mode it is necessary to install an outside air sensor as well as select a building reference temperature and a reset ratio 5 2 1 Reset Ratio Reset ratio is an adjustable number from 0 1 to 9 9 Once adjusted the supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 5 2 2 Building Reference Temperature This is a temperature from 40 F to 230 F Once selected it is the temperature that the system references to begin increasing its temperature For instance if a reset ratio of 1 6 is used and we select a building reference temperature of 70 F then at an outside temperature of 69 F the supply header temperature will increase by 1 6 to 71 6 F 5 2 3 Outdoor Air Temperature Sensor Installation The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected The sensor must be shielded from the sun s direct rays as well as direct impingement by the elements If a cover or shield is used it must allow free air circulation The sensor may be mounted
107. OPEN VALVE CLOSED Figure 1 1 Manual Gas Shutoff Valve 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 6 of this manual be performed to verify all system operating parameters If there is an emergency turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit The installer must identify the emergency shut off device Page 12 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 1 SAFETY PRECAUTIONS IMPORTANT FOR MASSACHUSETTS INSTALLATIONS Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements e Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts e Prior to unit operation the complete gas train and all connections must be leak tested using a non corrosive soap e The vent termination must be located a minimum of 4 feet above grade level If side wall venting is used the installation must conform to the following requirements extracted from 248 CMR 5 08 2 a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by
108. OW3Y 30N3H33H31NI 1LN3A3 Hd OL SONLLLIJ M31V3H WONJ 9 WNWININ v 913 5 086813 SNOINn 9 5 131100 ONY LIINI XILYM 31V201 7831105 02 38 5 53000 1V201 SNIMVHO NOILVTIVLSNI Tv9IdAL V SI SIHL 4N3AdIHS NI 131 8 435 G3GMIONI 34V SWIL T 40014 JHL 3AO8V 81 L1HOI3H V OL ATIVOILYSA Q3dld 38 GINOHS 393vHOSIQ 33H13 JHL 318V1lIVAV SI NIVHO 0013 ON N3HM NIVYG NOOl4 1S3NY3N JHL OL Q3dld 38 MNOHS 394VHOSIQ 3JATVA 43134 NIVJO 3O014 V OL A8 AT33N4 NIV3G OL SAIMA LINYSd OL 38 GINOHS 3SOH 31VSN3QNOO 3 TVA TI3HS 2 IWNOISN3HIO 33S 331V3H JHL OL SNOILOSNNOD ONY 9NIdld JO 5 ONY S3ZIS WNLOY 303 L S310N E MN U31V3H 39 4015 N3lVM 1v1Svnov N30138 S SIULSSNO0 LOAYIGNI PEAS W3ISAS m 09 M31VM LOH S lt MOSN3S Sov 225 meen W3lISAS WOvHHdvia NOILVNIB OO S NG 31VSN30NOO 13 SOV t 9 bw BATA 33rn38 pe T VL 3YNSSAYd SVD XVN 8 310N S OH LY 340165344 SV9 MOlVI Q93M SVO WOWINIA NIVLNIVIA jJO1nHS YH NLE WOWIXVA SVD V nNVMW Drawing Number SD A 992 rev A GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Page 178 of 188 Ph 800 526 0288 Benchmark 1
109. PEN 2 Temp HI Limit setting is too low 2 Check Temp HI Limit setting IGN BOARD 1 Communication fault has occurred 1 Press CLEAR button and restart unit If fault persists contact COMM FAULT between the PMC board and qualified Service Personnel Ignition Stepper IGST board OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 103 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION IGN SWTCH CLOSED 1 Air Fuel Valve not rotating 1 Start the unit The Air Fuel Valve should rotate to the purge DURING PURGE open position If the valve does not rotate at all or does not rotate fully open check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Control Box Refer to qualified service personnel 2 Defective or shorted switch 2 If the Air Fuel Valve does rotate to purge check the ignition switch for continuity between the N O and COM terminals If the switch shows continuity when not in contact with the cam replace the switch 3 Switch wired incorrectly 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Defective Power Supply Board 4 Check DS1 amp DS2 LEDs
110. RAIN HARNESS PIN 63109 SKP15 01301 LOW PRESS SKP25 011U1 GAS SW ITCH N O WITH REGULATOR Ol li AERCO Benchmark 1500 2000 DBB Gas Train 10 31 2013 International Inc Blauvelt NY 10913 22199 rev A Sheet 1 of 2 OMM 0097 0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 163 of 188 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS QOZO TTO AERCO Benchmark 1500 2000 DBB Gas Train 10 31 2013 International Inc Blauvelt NY 10913 22199 rev A Sheet 2 of 2 Page 164 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Benchmark 1500 2000 Burner Assembly p n 24378 24388 rev Item Qty Part Description Item Qty Part Description 1 1 69078 BLOWER AMETEK 12 3 17 1 81100 GASKET BLOWER 12 3 2 1 43090 AIR FUEL VALVE PLENUM 18 6 55054 SCREW SOC HD CAP M8 x 1 25 x 22mm 1 24220 3 A F VALVE ASSY BMK 1500 19 1 81166 GASKET BURNER 3 1 24220 10 A F VALVE ASSY BMK2000 20 1 66026 IGNITOR INJECTOR 4 1 46042 BURNER BMK 1500 21 1 61026 SENSOR 1 46044 BURNER BMK 2000 22 2 122377 SCREW MACH 10 32 X 3 8 LG 5 1 81057 GASKET BLOWER 23 1 81048 GASKET FLAME ROD LOW NOX 6 1 43095 BLOWER PLENUM 24 1 66020 FLAME DETECTOR 7 10 55025 BOLT LOCKI
111. RATIO CHARTS Table F 7 Header Temperature for a Building Reference Temperature of 90F RESET RATIO s ve os Temp i 90F 90 90 90 90 9 90 85F 93 94 851868 9 100 101 102 80F 96 98 100 1021 104 16 108 100 12 14 75 99 102 105 108 1 14 m7 120 123 1 _ 106 Lo mp e Lm pus 19 65F 105 110 20 425 430 435 340 445 50 60 108 114 120 126 132 138 144 150 156 162 55 111 118 12 182 14 SOF 114 122 130 138 146 154 162 170 178 186 45F 117 126 135 144 153 162 171 180 189 198 40F 120 130 140 150 160 170 180 190 200 210 35 123 134 145 156 167 178 189 200 30F 126 138 i50 162 474 466 498 210 25F 129 142 L 155 1 168 181 194 200 S 20F 132 146 160 174 188 202 216 15 135 150 ies ieo es ao 1 0 10F 138 154 170 186 202 218 SF 141 158 175119212001 OF 144 162 1801198 216 Page 150 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS DIMENSIONAL AND CLEARANCE DRAWINGS Appendix G 31V A33 31 25
112. SSOV settles within the range of 3 6 0 1 W C Readjust the gas pressure if necessary With the valve position at 10096 insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer reading to stabilize Page 54 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP BMK 1500 Natural Gas Combustion Calibration Cont 13 Compare the oxygen readings on the combustion analyzer to the on board O sensor value displayed in the Operating Menu of the C More Control Panel 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 14 Compare the measured oxygen level to the oxygen range shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the values shown If you not NOx limited area and or do not have a NOx measurement your analyzer set the oxygen at 5 5 0 5 Combustion Calibration Readings 100 valve Position Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 100 5 0 6 0 20 ppm lt 100 ppm the oxygen level is not within the required tolerance the gas pressure on the downstream side of the SSOV must be adjusted usin
113. Sensor 123 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive 125 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive 126 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive 127 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive 129 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 131 APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES 137 APPENDIX C SENSOR RESISTANCE VOLTAGE CHART 141 APPENDIX D BOILER DEFAULT SETTINGS 143 APPENDIX E RECOMMENDED PERIODIC TESTING 145 APPENDIX INDOOR OUTDOOR RESET RATIO CHARTS 147 APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS 151 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 5 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers Installation Operation amp Maintenance Manual IOMM APPENDIX APPENDIX I APPENDIX J APPENDIX K APPENDIX L PART DRAWINGS I U
114. Sht Threshold Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature Span is 40 to 100 Default is 60 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 135 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature If the actual error is less than the proportional band setting 1 to 120 F the fire rate will be less than 100 If the error is equal to or greater than the proportional band setting the fire rate will be 100 Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 1 0 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output WARMUP The feature embodied in the next three menu items eliminates Temperature Overshoots during the Warmup period of a cold ignition cycle on all boilers by temporarily modifying the PID Gain parameter during warmup and for a period defined in the Tuning Menu
115. TER 10 BOILER SEQUENCING TECHNOLOGY 10 3 BST Implementation Instruction 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit Connect the Header Temperature Sensor AERCO PN 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 e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e 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 i TST Temp Sensor PN 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 BST Menu and set the BST Mode item to BST Slave for now On MASTER 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 BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0097_0D AERCO
116. Unit Size Sets unit size from 600 MBH to 6000 MBH depending on the Unit Type Fuel Type Allows selection of Natural Gas or Propane Boiler Mode It allows selection of Constant Setpoint Remote Setpoint If Unit Type Boiler Remote Signal Direct Drive Combination or Outdoor Reset Mode Default is Constant Setpoint Mode Used to set the type of external signal which will be used If Mode Remote Setpoint Direct Drive or Combination when operating in the Remote Setpoint Direct Drive or Combination Mode The factory default is 4 20 mA 1 5V Bldg Ref Temp If Boiler Mode Outdoor Reset Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode Default is 70 F Reset Ratio If Boiler Mode Outdoor Reset Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode Reset Ratio is adjustable from 0 1 to 9 9 Default is 1 2 Outdoor Sensor Allows outdoor sensor function to be enabled or disabled Default is disabled System Start Tmp If Outdoor Sensor is Enabled If outdoor sensor is enabled this menu item allows the system start temperature to be set from 30 to 100 F Default is 60 F Setpoint Lo Limit Used to set the minimum allowable setpoint 40 F to Setpoint Hi Limit Default is 60 F Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint Lo Limit to 210 F Default is 140 F Tem
117. VISNI Y j 28611 82 81 90 1 X X MAIA 4015 Drawing Number 898 rev Page 153 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS This Page Is Intentionally Blank Page 154 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX H PART DRAWINGS Appendix H PART DRAWINGS Benchmark 1500 2000 Part List Item Qty Part Description Item Qty Part Description EXHAUST MANIFOLD CONTROLS Continued 1 1 39187 MANIFOLD EXHAUST 35 1 64081 ECU 2 1 81165 MANIFOLD SEAL 36 1 65011 TRANSFORMER 115V 24V 100VA 3 6 9 22 PIPE PLUG 1 4 NPT STEEL 37 1 65109 12V POWER SUPLY 38 3 69141 DIN RAIL MOUNT END STOP GAS TRAIN 39 2 65120 TERMINAL BLOCK DIN MOUNTED BLK 4 1 22188 BMK 1500 STANDARD GAS TRAIN ASSY 40 2 65121 TERMINAL BLOCK DIN MOUNTED WHT 22199 BMK 1500 2000 DBB GAS TRAIN 41 3 65122 TERMINAL GROUND BLOCK DIN MOUNTED 42 2 65118 FUSE TERMINAL DIN MOUNTED LIMIT CONTROL TEMPERATURE
118. Wiring The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The signal must be floating ungrounded at the I O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG Polarity must be observed The source end of the shield must be connected at the source When driving multiple units each unit s wiring must conform to the above 5 5 2 Direct Drive Startup Since this mode of operation is factory preset and the valve position is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the signal is present To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Direct Drive mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 6 AERCO CONTROL SYSTEM ACS NOTE ACS is for installations with 9 or more boilers It utilizes only RS 485 signaling to the boiler Installations with 1 to 8 boilers can use BST see Chapter 10 The ACS mode of operation is used in conjunction with an AERCO Control System The ACS mode is used when it is des
119. Y 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP CHAPTER 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 installation Chapter 2 Set proper controls and limits Chapter 3 Perform combustion calibration Chapter 4 Test safety devices Chapter 6 All applicable installation procedures in Chapter 2 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 Chapter it will be necessary to perform the Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Benchmark must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at AERCO International Inc 100 Oritani Drive Blauvelt Ne
120. able 9 2 shows a sample Operation Time Log for a boiler The Operation Time Log can only be accessed through the RS 232 interface using a laptop or other terminal device Ten operation time records are displayed for each T command entry The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu Table 9 2 Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time Off Direct Drive 0 0 8 1 15 02 2 35pm Run Direct Drive 38 100 34 1 15 02 2 27pm Run Direct Drive 31 100 30 1 15 02 1 53am Run Direct Drive 35 100 2 1 15 02 1 23pm Run Direct Drive 29 100 0 1 15 02 1 21pm Ignition 0 0 0 1 15 02 1 20pm Off Switch 0 0 35 1 15 02 12 30pm Run Manual 40 100 0 1 15 02 11 55am Ignition 0 0 0 1 15 02 11 55am Power up 0 0 0 1 15 02 11 50am OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 115 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 9 RS232 COMMUNICATION NOTE The Sensor S Log can store up to 1200 records Therefore to view the most recently logged record enter S followed by 0 zero and then press Enter i e S0 lt Enter gt To view earlier records in reverse chronological order enter S and press Enter To go back 200 or 700 records enter S200 or S700 etc and press Enter 9 43 Sensor Log The sensor values can be logged at a different rate if n
121. ain is not available a condensate pump can be used to remove the condensate to drain The maximum condensate flow rate is 30 GPH The condensate drain trap associated fittings and drain line must be removable for routine maintenance N CAUTION N Use PVC stainless steel aluminum or polypropylene for condensate drain piping Figure 2 6 DO NOT use carbon or copper components TRAP INLET COMBUTION ADAPTOR AND ANALYZER THUMBSCREW PROBE PORT TOP FLUE STARTER COVER CONDENSATE SECTION THUMB TRAP P N 24060 SREWS BOILER des 3 47 NPT 58 NIPPLES HOSE MANIFOLD An d 5 1 DIAM HOSE NOTE 4 HOUSKEEPING papmustNot HOUSE 1 uMUM lt P Lm KEEPING s MAXIMUM EXHAUST io MANIFOLD CONDENSATE PAD DRAIN PORT SUPPORT DRAIN ASSEMBLY Figure 2 6 Sample Condensate Trap Installation Right Side View OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 21 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide GF 2030 must be consulted prior to designing or installing any gas supply piping Z WARNING A 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 w
122. aintaining the gas pressure at 6 inches W C for FM gas trains operating at maximum capacity 2 8 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 7 Maximum allowable gas pressure to the boiler is 14 W C Page 22 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 8 3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions see sections 2 8 3 1 and 2 8 3 2 below Regulators must conform to the following specifications e The external natural gas regulator must be capable of regulating 200 000 3 180 000 BTU HR of natural gas while maintaining a gas pressure of 8 0 W C minimum to the unit e A lock up style regulator MUST be used when gas supply pressure will exceed 14 W C 2 8 3 1 Massachusetts Installations Only For Massachusetts installations a mandatory external gas supply regulator must be positioned as shown in Figure 2 7 The gas supply regulator must be properly vented to outdoors Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator 2 8 3 2 All Installations Except Massachusetts For multi unit installations other than Massachusetts that EXCEED 7 W C gas pressure a mandatory e
123. alve position and return water temperature When installed and operated in accordance with this Instruction Manual these 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 the BMK 1500 and BMK 2000 offer the maximum venting flexibility with minimum installation space requirements These boilers are Category Il III and IV positive pressure appliances Single and or multiple breeched units capable of operation in the following vent configurations Conventional Vertical Conventional Sidewall Conventional Direct Vent Vertical Sealed Direct Vent Horizontal These 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 IMPORTANT Unless otherwise specified all descriptions and procedures provided in this Installation Operation amp Maintenance Manual apply to the Benchmark series of boiler OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 142 Ph 800 526 0288 Page 7 of 188 Benchmark 1500 2000 Boilers FORWARD Phrases Abbreviations and Acronyms Phrase Abbreviation or
124. ap inlet See the Condensate trap Installation instructions and Figure 2 6 on the next page AIR INLET EXHAST MANIFOLD PRIMARY WATER INLET 1 4 ANALYZER NPT PORT DRAIN VALVE i CONDENSATE DRAIN PORT Figure 2 5 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2 6 The following general guidelines must be observed to ensure proper condensate drainage e The condensate trap inlet Figure 2 6 must be level the exhaust manifold drain port e The base of the condensate trap must be supported to ensure that it is level horizontal e The trap must be removable for routine maintenance Page 20 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION While observing the above guidelines install the condensate trap as follows Condensate Trap Installation Connect the condensate trap inlet to the exhaust manifold drain connection by inserting the drain port directly into the trap adaptor inlet and then tightening the inlet thumbscrew as shown in Figure 2 6 The inlet features two integral O rings to prevent leakage 2 At the condensate trap outlet install a 3 4 NPT nipple Connect a length of 1 diameter polypropylene hose to the trap outlet and secure with a hose clamp Route the hose on the trap outlet to a nearby floor drain If a floor dr
125. ary LOW WATER 1 Insufficient water level in system 1 Check system for sufficient water level LEVEL 2 Defective water level circuitry 2 Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons Replace water level circuitry if it does not respond 3 Defective water level probe 3 Check continuity of probe end to the shell change probe if there is no continuity MODBUS Unit not seeing information from Check network connections If fault persists contact qualified COMMFAULT Modbus network Service Personnel PRG SWTCH CLOSED DURING IGNITION 1 A F Valve rotated open to purge and did not rotate to ignition position Start the unit The Air Fuel Valve should rotate to the purge open position then back to ignition position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Control Box Refer fault to qualified service personnel OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 105 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued Defective or shorted switch Switch
126. ator should also start flashing Reduce the gas pressure back to the value recorded in step 5 This pressure should be within the range of 3 6 0 2 W C for BMK 1500 and 3 9 0 2 W C for BMK 2000 Press the CLEAR button on the Control Box to clear the fault The fault message should clear and the FAULT indicator should go off The unit should restart Upon test completion close the ball valve and remove the manometer Replace the 1 4 plug removed in step 1 OMM 0097_0D AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Page 73 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault proceed as follows Low Water Level Fault 1 Setthe 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 Continue draining the unit until a LOW WATER LEVEL fault message is displayed and the FAULT indicator flashes 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
127. connect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Page 88 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE Flame Detector Maintenance Continued Disconnect the flame detector lead wire Remove the two 2 screws securing the flame detector to the plate Figure 7 2 The flame detector is secured to the burner plate with one 10 32 screw and one 8 32 screw Remove the flame detector and gasket from the burner plate 6 Thoroughly inspect the flame detector If eroded the detector should be replaced Otherwise clean the detector with a fine emery cloth Reinstall the flame detector and flame detector gasket Reconnect the flame detector lead wire Reinstall the shroud on the unit 7 4 O2 SENSOR The sensor part no 61026 is located on the burner plate at the top of the unit see Figures 7 1 and 7 2 The sensor may be hot Allow the unit to cool sufficiently before removing or replacing the O sensor O Sensor Maintenance Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the sh
128. connections for these features are made on the Input Output I O board located behind the removable front panel assembly of the unit The I O board is located in the upper left portion on the front of the unit as shown in Figure 2 11 The I O board terminal strip connections are shown in Figure 2 12 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 board Refer to the wiring diagram provided below the I O Box Figure 2 12 when making all wiring connections TERMINAL STRIPS imm imini tme Umm ime mm mu em U us Im lp me Dmm Bioooclooosolooodooodooocoooc k Figure 2 11 Input Output 1 0 Box Location NOTE Use Figure 2 12 to determine the functions of the I O PCB connections Do not use the silkscreened labels on the PCB itself as these may not match the function names There is a diagram of the connection functions on the cover of the I O Box as well CAUTION N DO NOT make any connections to the I O Box terminals labeled NOT USED Attempting to do so may cause equipment damage Page 26 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION OUTDOORAIRIN 5 AIR SENSOR CO
129. ct Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation End of Extracted Information From 248 CMR 5 08 2 Page 14 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION CHAPTER 2 INSTALLATION 2 1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack inspect and install the AERCO Benchmark Boiler Model BMK 1500 and BMK 2000 2 2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit The shipping weight for these BMK models is approximately 1800 pounds 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 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 during shipment If the Tip N Tell indicator is tripped do not sign for the shipment Note the information on the carriers paperwork and request a freight cla
130. cues u uuu uu 155 WIRING DIAGRAMS Q 167 PIPING DRAWINGS I 175 C MORE CONTROL PANEL VIEWS 181 RECOMMENDED SPARES U U u 183 Page 6 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers FORWARD FOREWORD The AERCO Benchmark BMK 1500 and 2000 MBH 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 the Benchmark s modulating capability relates energy input directly to fluctuating system loads The turn down ratios for these boilers is 20 1 These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature as well as conventional heating systems The Benchmark Model BMK 1500 and BMK 2000 boilers operate within the following input and output ranges Benchmark Model Input Range BTU hr Output Range BTU hr Minimum Maximum Minimum Maximum BMK 1500 75 000 1 500 000 64 500 1 395 000 BMK 2000 100 000 2 000 000 86 000 1 860 000 The output of the boiler is a function of the unit s firing rate v
131. d Blocked Inlet Switch Test instructions section 6 8 2 PIR 1005 Changed Maintenance Kit part numbers Curtis Harvey amp Chris Blair AERCO International Inc AERCO International Inc 2014 Page 188 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142
132. dures in Chapter 4 4 Debris on burner 4 Remove the burner and inspect for any carbon build up or debris Clean and reinstall 5 Blocked condensate drain 5 Remove blockage in condensate drain HEAT DEMAND 1 The Heat Demand Relays on the 1 Press CLEAR button and restart the unit If the fault FAILURE Ignition Stepper IGST board persists replace Ignition Stepper IGST Board failed to activate when commanded 2 Relay is activated when not in 2 Defective relay Replace IGST Board Demand HIGH EXHAUST 1 Poor combustion calibration 1 Check combustion calibration using procedures in TEMPERATURE Chapter 4 2 Carboned heat exchanger due to 2 If exhaust temperature is greater than 200 F check incorrect combustion calibration combustion calibration Calibrate or repair as necessary Page 102 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS 1 Incorrect supply gas pressure 1 Check to ensure gas pressure at inlet of SSOV does not PRESSURE exceed 14 W C 2 Defective SSOV Actuator 2 If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range of 3 6 0 2 W C for BMK1500 or 3 9 0 2 W C for BMK2000 using the gas pressure adjustment screw
133. during the initial warm up only OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 137 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 2 Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge or air inlet is blocked AIRFLOW FAULT The Blower Proof Switch opened during ignition DURING IGN AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run DELAYED INTERLOCK OPEN The Delayed Interlock is open DIRECT DRIVE SIGNAL FAULT The direct drive signal is not present or is out of range FFWD TEMP The temperature measured by the Feed Forward FFWD SENSOR FAULT Sensor is out of range FLAME LOSS The Flame signal was not seen during ignition or lost within 5 DURING IGN seconds after ignition FLAME LOSS 2 DURING RUN The Flame signal was lost during run HEAT DEMAND The Heat Demand Relays on the Ignition board failed to FAILURE activate when commanded HIGH EXHAUST o TEMPERATURE The Exhaust Temperature has exceeded 200 F HIGH GAS aum PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER The temperature measured by the Outlet Sensor exceeded TEMPERATURE the Temp Hi Limit setting HIGH WATER TEMP es SWITCH OPEN The High Water Temperature Limit Switch is open
134. e 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 if 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 C More unit is defined as the MASTER unit and all other C More units on the BST Modbus Network are defined as SLAVE units The Master unit will monitor the system Header Temperature monitor all Slave units status information and efficiently control all units in order to achieve and maintain the required BST Setpoint Temperature When there is a demand the Master unit 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 units reach the Next On VP valve position the BST master will light off the next available unit A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9 1 below Note Use either FFWD Header sensor or Modbus Header Sensor Modbus FFWD Header Header Sensor Sensor OUTLET Optional H a ret Controled D Note Modbus Header sensor A A Sequencing be connected to any Vake boiler on the Modbu
135. e observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 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 BST Menu and set the BST Mode item to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the BST Remote Signal and select either Network 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 14 000 When ALL C More units have been configured 10 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 129 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY This Page Is Intentionally Blank Page 130 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_
136. e specified range at 8096 press the ENTER key to store the selected blower output voltage for the 8096 valve position Record all readings on the Combustion Calibration Sheets provided Repeat steps 20 through 27 for valve positions of 8096 5096 4096 30 and 1496 The oxygen O2 nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table NOTE If NOx readings exceed the target values shown 20 ppm increase the O level up to 196 higher than the listed calibration range shown in the table Record the increased O value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 60 6 0 0 5 lt 20 ppm lt 100 ppm 45 6 3 0 5 lt 20 ppm lt 100 ppm 30 6 3 0 5 lt 20 ppm lt 100 ppm 16 6 0 0 5 lt 20 ppm lt 100 ppm If the oxygen level at the 14 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 4 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the to the specified level Recalibration MUST be performed again from 6096 down to 16 after making a change to the idle screw TAC valve 30 This completes the BMK 2000 Natural Gas combustion calibration procedures 4 4 REASSE
137. e the 1 4 plug removed in step 1 Page 72 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 3 HIGH GAS PRESSURE TEST To simulate a high gas pressure fault refer to Figure 6 1b and perform the following steps NATURAL GAS INLET af SSOV HIGH GAS EMIL OPE PRESSURE 2 SWITCH VALVE AIR FUEL VALVE LOW GAS PRESSURE SWITCH 1 4 NPT PLUG and Ball Valve HIGH GAS install manometer here for BALL VALVE HIGH GAS PRESSURE FAULT TEST Figure 6 1b BMK 1500 2000 High Gas Pressure Fault Test High Gas Pressure Test Close the leak detection ball valve located at the high gas pressure switch see Figure 6 1b Remove the 1 4 plug from the leak detection ball valve shown in Figure 6 1b Install a 0 16 W C manometer or W C gauge where the 1 4 plug was removed Slowly open the leak detection ball valve Start the unit in Manual mode at a valve position firing rate between 25 and 30 With the unit running monitor the gas pressure the manometer installed in step 2 and record the gas pressure reading Slowly increase the gas pressure using the adjustment screw on the SSOV see Figure 4 3 The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 4 7 W C for both BMK 1500 and BMK 2000 The FAULT indic
138. ea for the BMK 2000 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 2 12 2 Combustion Air from Inside the Building When combustion air is provided from within the building it must be supplied through two permanent openings in an interior wall Each opening must have a free area of not less than one square inch per 1000 BTUH of total input or 3000 square inches of free area The free area must take into account any restrictions such as louvers 2 13 DUCTED COMBUSTION AIR For ducted combustion air installations the air ductwork must then be attached directly to the air inlet connection on the sheet metal enclosure 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 See the AERCO Benchmark Venting and Combustion Air Guide GF 2050 When using the unit in a ducted combustion air configuration each unit must have a minimum 8 inch diameter connection at the unit 2 14 SEQUENCING VALVE INSTALLATION All Benchmark units are shipped with a connection for an optional motorized external sequencing valve p n 92084 TAB included in the shipping container This valve is an integral component of the AERCO s on board Boiler Sequencing Technology BST solution BST allows sites with multiple boile
139. ect against bodily injury and property damage The owner or user of an automatic boiler system should set up a formal system of periodic preventive maintenance and testing Tests should be conducted on a regular basis and the results recorded in a log book Item Frequency Accomplished By Remarks Refer to indicated sections of this manual for detailed procedures Gauges monitors and indicators Daily Operator Visual inspection and record readings in operator log Instrument and Visual check against factory recommended Daily Operator equipment settings specifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Technician Verify factory settings Check with combustion calibration test equipment Annually Service Technician See sections 43 and 7 4 Flue vent stack or Visually inspection condition and check for Monthly Operator intake air duct obstructions Spark Igniter Injector Weekly Operator See section 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial section 3 11 SSOV Leakage test Annually Service Technician sere m ix manufacturer s Siemens recommendations Close manual gas shutoff valve and check safety Flame failure Weekly Operator shutdown See section 67 Check flame strength using the Control Panel Flame signal strength Weekly Operator Operating Menu See section 3
140. eeded by setting the Sensor Log Interval in the Diagnostics Menu The log interval can vary from once every minute to once every day Table 9 3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 16pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 11pm 130 180 OPEN OPEN OPEN OPEN OPEN O0 0 0 1 15 02 5 06pm Page 116 of 188 AERCO International Inc 100 Oritani Dr e Blauvelt NY 10913 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 1 INTRODUCTION The C More on board Boiler Sequencing Technology system is an integrated 8 boiler control system designed into the C More controller The BST has its own sophisticated PID control system designed to simultaneously control th
141. egory Basic options for your Pu T T Y session E Session Options controlling local serial lines Legging Specify the destination you want to connect to i Logging Select a serial line B Terminal a Terminal T Serial line A _ Speed i Keyboard Serial line to connect to COM1 i COMI 9600 i Uber Bell ies Configure the serial l Features Connection type Features ebd aci ne B Window Telnet Rogn SSH 9 Serial E Window Speed baud 9600 To de i Appearance 1 f Peer Load save or delete a stored session 3 Data bits 8 Translation Saved Sessions i Translation Stop bits 1 Selection fe Selection E Paty Colours Default Settings Load Colours Connection B Connection Flow control XON XOFF Y Data Save i Data see i Telnet Delete i Rlogin SSH 5 Close window on exit Aways Never Only on clean ext m Figure 9 1 GUI Basic Serial Session L Serial Options R In Serial mode text typed into the PuTTY window will be sent straight out of your computer s serial port and data received through that port will be displayed in the PuTTY window To create a Serial connection click the radio button labeled Serial The Serial line and Speed fields will then be automatically filled in as shown in left image of Figure 9 1 but will allow you to specify the serial line to use if your computer has more t
142. em within the item list OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 142 Ph 800 526 0288 Page 43 of 188 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION The Items contained in group 1 BST Monitor Items are ALWAYS displayed within the menu as these items are critical for proper system operation Therefore the BST Monitor Items Header itself is NOT displayed The Items contained in groups 2 5 are NOT DISPLAYED unless that particular item group has been enabled from the C More keypad Table 3 7 BST Menu Available Choices or Limits Menu Item Display Default Minimum Maximum BST Mode Off BST Slave BST Master Off BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130 F Header Temp NA Header Temp CF BST Fire Rate 0 100 Fire rate BST Ave Fire Rate 0 100 Avg Fire Rate BST Outdoor Temp NA ae emp Units Available 0 8 Units Present Units Ignited 0 8 Units firing BST Valve State 0 CLOSED 1 OPEN 0 1 Comm Errors 8 0 9 0 1 BST Units 8 0 see table 0 see table 0 BST SETUP MENU Disabled Enabled Disabled BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr 0 255 240 Header Temp Point 0 255 14 BST Outdoor Sens Disabled Enabled Disabled Outdr Tmp Source Ou
143. enance Manual IOMM TABLE OF CONTENTS FOREWORD 7 CHAPTER 1 SAFETY PRECAUTIONS U U U U U U u u uu uuu 11 1 1 WARNINGS amp CAUTIONS uuu uuu suqu attt chest 11 1 2 EMERGENCY SHUTDOWN naaa ee eden d rt edet 12 1 3 PROLONGED SHUTDOWN ere eere etes ese e Pr ERE e Ta EN e Re PE 12 CHAPTER 2 INSTALLATION Z u I oe error antem uoi a ass 15 24 INTRODUGTIQN itte ulna ha ect a teas dam 15 2 2 RECEIVING THE UNIT iet d e eie ehe etie 15 2 9 UNPAGCHKING tiae eie eedem eee sen D 15 24 SITE PREPARATIGNIN docete a avete eade 15 2 4 1 Installation Clearances d Up reo SSC uqu RUNE ERREUR ee ERU 16 2 42 Setting the u TY eene nlite oe ed ve set Y Gene ved en sted e ex vente y e neue bee er dete u 17 2 5 SUPPLY AND aan un nne enne enirn asa aa Bayas sa 19 2 6 PRESSURE RELIEF VALVE INSTALLATION 19 2T CONDENSATE DRAIN amp PIPINQ 2 2 iiio veto cere ia dut t nto discs bri seta sa dice apa dt 20 2 9 GAS SUPPLY PIPING ioc tette ede Ced eee e e etti 22 2 8 1 Gas Supply Specificatioris ettet hee et haee eth 22 2 8 2
144. enu categories Figure 3 2 pressing this key will select the displayed menu category If Y DOWN Arrow the CHANGE key was pressed and the menu item is flashing pressing the Y arrow key will decrement the selected setting Permits a setting to be changed edited When the CHANGE key is pressed the displayed menu item will CHANGE begin to flash Pressing the A or Y arrow key when the item is flashing will increment or decrement the displayed setting Saves the modified menu settings in memory The display ENTER will stop flashing This switch toggles the boiler between the Automatic and Manual modes of operation When in the Manual MAN mode the front panel controls are enabled and the 11 AUTO MAN Switch MANUAL status LED lights Manual operation is for service only When in the Automatic AUTO mode the MANUAL status LED will be off and the front panel controls disabled 12 VALVE POSITION 20 segment red LED bargraph continuously shows the Bargraph Air Fuel Valve position in 5 increments from 0 to 100 Page 36 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION 3 3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up and configure the unit The menu structure consists of five major menu categories which are app
145. er Manual OMM 0080 GF 129 for more information Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit Connect the Header Temperature Sensor AERCO PN 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 e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e 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 xs ST Temp Sensor PN 61040 Header Temp Sensor Box Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF 129 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 BST Menu and set the BST Mode item to BST Slave for now On Master only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint Goto the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the Head Temp Source item and select FFWD Temp Goto the BST Remote Signal item and select Network Of When ALL units have been configured 8 Go to the BST Menu of t
146. ess 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 Chapter 3 2 10 13 Fault Relay NC COM amp 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 12 2 10 14 Auxiliary Relay Contacts NC COM amp 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 12 to locate the AUXILLIARY RELAY terminals for wiring connections 2 11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide GF 2050 must be consulted before any flue or combustion air venting is designed or installed Suitable U L approved positive pressure watertight vent ma
147. etting 5 The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature 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 HIGH WATER TEMP SWITCH OPEN fault message should be displayed It should not be possible to restart the unit Reset the adjustable over temperature switch to its original setting 8 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 6 2 Temperature Limit Switch Location OMM 0097_0D AERCO International Inc e 100 Oritani e Blauvelt NY 10913 Page 75 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 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 13 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
148. fore the boiler can be restarted The rotary dial over temperature switch is manually adjustable from xxx to yyy F This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this over temperature switch to the desired setting The digital alarm switch shown in Figures 4 5 and 4 6 is preset at the factory to 210 F 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 over temperature alarm switch settings can be checked or adjusted using the procedure in section 4 5 1 DIGITAL OVER TEMPERATURE ALARM SWITCH ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4 5 Over Temperature Limit Switch Locations 4 5 1 Digital Alarm Switch Checks and Adjustments The digital 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 6 and Table 4 1 Alarm E III ela I d LI 7 Limit Control Figure 4 6 Digital Over Temperature Alarm Switch Front Panel OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 61 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP Table 4
149. forms to the values shown in the tabular listing provided in Appendix C 8 Defective temperature sensor 8 Refer to CORRECTIVE ACTION 7 and verify that the voltage conforms to the values shown in Appendix C 9 Loose wire connection between the 0 9 Check wire connection from I O Box 0 10V signal to the 10V signal from I O box to the Blower Blower Motor input 10 Measure voltage at the I O box 0 10V output A voltage of 10 Defective I O Box 10V equates to a 100 open valve position 11 Check the Analog Out option on the C More Configuration 11 Wrong 0 10V output selection on the Menu Valve Position 0 10V should be selected control box 12 Check Air Fuel Valve position at 096 5096 and 10096 open 12 Defective Air Fuel Valve potentiometer positions The positions on the VALVE POSITION bargraph should match the readings on the Air Fuel Valve dial 13 Hard light 13 Check igniter injector for soot or erosion of electrode Check injector solenoid valve to insure proper open close operation OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 99 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING PURGE Blower not running or running too slow Defective Blocked Inlet switch Blockage in air filte
150. g a shielded twisted pair of 18 to 22 AWG wire When wiring multiple units each unit s wiring must conform to the above 5 7 2 Combination Control System Setup and Startup Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode remote signal type and setpoint The setpoint is adjustable from 40 F to 190 F Enter the following settings in the Configuration Menu Menu Option Setting Boiler Mode Combination Remote Signal Network Internal Setpt 40 F to 190 F Refer to section 3 3 for instructions on changing menu options While it is possible to change other temperature related functions for combination mode these functions are preset to their factory default values These default settings work well in most applications It is suggested that AERCO be contacted prior to changing settings other than the unit s setpoint For a complete listing of temperature related function defaults see Appendix D To set the unit to the manual mode press the AUTO MAN switch The MANUAL LED will light To set the unit back to the auto mode press the AUTO MAN switch The MANUAL LED will go off and the REMOTE LED will light When the boiler is switched to ACS control the ACS controls the valve position There are no setup requirements to the boiler s in this mode OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 69 of 188 GF 142 Ph 800 526 0288 Benchmar
151. g the gas pressure adjustment screw on the SSOV Figure 4 3 Slowly rotate the gas pressure adjustment approximately 1 4 turn increments Allow the combustion analyzer to stabilize following each adjustment Clockwise rotation reduces the oxygen level while counterclockwise rotation increases the oxygen level Once the oxygen level is within the specified range at 10096 record the NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit Lower the valve position to 80 using the Y arrow key NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C More Control System The combustion calibration control functions will be used to adjust the oxygen level 96 at valve positions of 8096 6096 4596 3096 and 16 as described in the following steps These steps assume that the inlet air temperature is within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O level up to 196 higher than the listed calibration range Record the increased value on the Combustion Calibration sheet Press the MENU key on the front panel of the C MORE and access the Setup menu Enter password 6817 and then press the ENTER key Press the MENU key on the front panel of the C MORE until Combustion Cal Menu appears on the display Press the A arrow key until SET Valve Position appears on the display Press the CHANGE key
152. g 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 from the boiler OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 123 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 4 Continued e 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 TYPE aad GND 12VDC Power Supply Temp Sensor PN 61043 Modbus Transmitter 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 BST Menu and set the BST Mode item to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Outdoor Reset 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 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 Addres
153. gle Phase 60 Hz 20 Amps e Access to Natural Gas line at a minimum pressure of 8 inches W C at gas flow for 1 500 000 BTU hr energy input for the 1500 OR 2 000 000 BTU hr energy input for the BMK 2000 2 4 1 Installation Clearances The Benchmark Model 1500 and 2000 are packaged in an enclosure having identical exterior dimensions The unit must be installed with the prescribed clearances for service as shown in Figure 2 1a 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 as follows Sides 24 inches e Front 24 inches e Rear 24 inches e Top 18 inches 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 56 1448 SIDE VIEW Ensure that condensate assembly is not located over the housekeeping Da WE T Figure 2 1a Benchmark Boiler Model 1500 2000 Clearances N WARNING N KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS Page 16 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION CAUTION N While pac
154. han one and what speed baud rate to use when transferring data For further configuration options data bits stop bits parity OMM 0097_0D Page 111 of 188 GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 9 RS232 COMMUNICATION flow control you can use the Serial Configuration panel right image in Figure 9 1 by selecting Serial in the left navigation pane Now to connect to the remote server simply click the Open button at the bottom of the dialog box A new terminal window will pop up and ask you to log in So that you don t have to enter this information every time you wish to connect to your server you can save this configuration by typing an appropriate name in the Saved Sessions text box in the PuTTY Basic Options window left image of Figure 9 1 and then clicking the Save button In the future you can select the name you chose in the list box and click the Load button to initialize this particular configuration 9 1 3 Running a Command on a Remote Machine Using PuTTY PuTTY may also be used to run some command residing on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open depending on how you configure the se
155. he Configuration Menu Menu Option Setting Boiler Mode Constant Setpoint Internal Setpt Select desired setpoint using A and Y arrow keys 40 F to 240 F Refer to section 3 3 for detailed instructions on changing menu options Page 64 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION 5 4 REMOTE SETPOINT MODES The unit s setpoint can be remotely controlled by an Energy Management System EMS or Building Automation System BAS The Remote Setpoint can be driven by a current or voltage signal within the following ranges e 4 20 mA 1 5 Vdc e 0 20 mA 0 5 Vdc The factory default setting for the Remote Setpoint mode is 4 20 mA 1 5 Vdc With this setting a 4 to 20 mA 1 to 5 Vdc signal sent by EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F setpoint while a 20 mA 5V signal is equal to a 240 F setpoint When a 0 to 20 to 5 signal is used 0 mA is equal to a 40 F setpoint In addition to the current and voltage signals described above the Remote Setpoint mode can also driven by a RS 485 Modbus Network signal from an EMS or BAS The Remote Setpoint modes of operation can be used to drive single as well as multiple units NOTE If a voltage rather than current signal is used to control the remote setpoint a DIP switch adjustment must be made
156. he desired Master unit and set the BST Mode item to BST MASTER Page 126 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive 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 AERCO P N 65169 terminal Pin to the RS485 terminal on the I O Box of any of the Boiler units and Pin 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 AERCO PN 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 e Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the s
157. heat 3 Digit 7 Segment LED display continuously displays the outlet OUTLET water temperature The or C LED next to the display lights to TEMPERATURE indicate whether the displayed temperature is in degrees 2 Displ Fahrenheit or degrees Celsius The F or C blinks when operating ispay in the Deadband Mode On a BST Master display flashes amp shows header temperature Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes VED Disol e Startup Messages 3 isp ay e Faul Messages e Operating Status Messages e Menu Selection BST Messages Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel AERCO offers for purchase the RS232 Adaptor Cable P N 124675 which is designed to 4 RS 232 Port work with this port This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports 5 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm condition occurs An alarm message will appear in the VFD Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid Lockout type alarms will be latched and 6 cannot be cleared by simply pressing this key Troubleshooting may be required to clear these types of alarms 7 READY Indicator Lights ON OFF switch is set to ON a
158. hield must be left free and ungrounded 9 GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 Direct Wired 0 20ma or 4 20ma Wirin 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master NOTES e Units I O Box Shielded pair 18 22 AWG cable is recommended for this connection Polarity must be observed e The ground for the shield is at the driver signal source Remote Signal ms a i Remote Signal 0097 00 AERCO International Inc e 100 Oritani Dr e Blauvelt 10913 Page 127 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 7 Continued 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 BST Menu and set the BST Mode item to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the BST Remote Signal and select either 4 20ma or 0 20ma 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 O O
159. ided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 13 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 1 SAFETY PRECAUTIONS 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the B
160. ief valve must be specified on the sales order Available pressure ratings range from 30 psi to 160 psi The relief valve is installed on the hot water outlet of the boiler as shown in Figure 2 4 A suitable pipe joint compound should 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 of the floor to prevent injury in the event of a discharge are allowed in the discharge line In multiple unit installations the discharge lines must not be manifolded together Each must be individually run to a suitable discharge location OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 19 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION PRESSURE RELIEF VALVE 4 HOT BOILER WATER OUTLET Figure 2 4 P amp T Relief Valve Location 2 7 CONDENSATE DRAIN amp 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 located on the exhaust manifold Figure 2 5 must be connected to the condensate trap P N 24060 which is packed separately within the unit s shipping container The condensate trap inlet features two integral O rings and a thumbscrew to allow direct connection of the drain port into the tr
161. iew menu items and data logs which can be useful in isolating faults Refer to Chapter 9 of this manual for detailed RS 232 communication set up and procedures When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Correction Observe the fault messages displayed in the Control Box display Refer to the Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best describes the existing conditions Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication Perform the checks and procedures listed in the Corrective Action column for the first Probable Cause candidate Continue checking each additional Probable Cause for the existing fault until the fault is corrected Section 8 2 and Table 8 2 contain additional troubleshooting information which may apply when a no fault message is displayed If the fault cannot be corrected using the information provided in the Troubleshooting Tables contact your local AERCO Representative OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 97 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE This page left intentionally blank Page 98 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER
162. im 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 Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials After unpacking a close inspection of the unit should be made to ensure that there is no evidence of damage not indicated by the Tip N Tell indicator 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 e ASME Pressure Relief Valve e Condensate Drain Trap part no 24060 e 2 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 2 4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark 1500 2000 Boiler includes OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 15 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION Access to AC Input Power at 120 VAC Sin
163. ing Number SD A 994 rev A GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Page 180 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX K C MORE CONTROL PANEL VIEWS Appendix K C MORE CONTROL PANEL VIEWS CONNECTOR BOARD P N 124366 LOW WATER CUTOFF BOARD 124363 PMC BOARD P N 124364 DISPLAY BOARD Z P N 124365 TUT 7 AS Se E X Q GREEN LED 9 124948 9 ENCLOSURE SOCKER P N 124951 S 2 SWITCH on ZA P N 124947 i NY waf POWER SUPPLY BOARD s V F D oe P N 124362 R s PIN 124527 IGNITION STEPPER BOARD i FISH PAPER FIN 124961 INSULATOR PIN 124960 k FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 PUSH BUTTON SWITCHES P N 124954 Figure K 1 Benchmark Control Panel Exploded View OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 181 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX K C MORE CONTROL PANEL VIEWS INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX SENSOR HARNESS CON
164. ional Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 107 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV SWITCH OPEN Actuator not allowing for full closure of gas valve SSOV powered when it should not be Defective Switch or Actuator Incorrectly wired switch 1 Observe operation of the Safety Shut Off Valve SSOV through indicator on the Valve actuator and ensure that the valve is fully and not partially closing If the SSOV never closes it may be powered continuously Close the gas supply and remove power from the unit Refer fault to qualified service personnel Remove the electrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE 4 5 6 Air Fuel Valve out of calibration Air Fuel Valve unplugged Loose wiring connection to the stepper motor Defective Air Fuel Valve stepper motor Defective Power Supply Board or fuse Defective IGST Board 5 6 Refer to GF 112 C More O amp M and perform the Stepper Feedback Calibration procedure in Section 6 section
165. ired to operate multiple units in the most efficient manner possible For this mode of operation an ACS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant s supply water header The ACS can control up to 40 boilers Up to 32 via Modbus RS 485 network communication For ACS programming operation and Header Sensor installation details see ACS Operations Guide GF 131 For operation via an RS 485 Modbus network refer to Modbus Communication Manual GF 114 To enable the ACS Mode the following menu settings must be made in the Configuration Menu Menu Option Setting Boiler Mode Direct Drive Remote Signal Network RS 485 Refer to section 3 3 for instructions on changing menu options 5 6 1 ACS External Field Wiring Wiring connections for RS 485 Modbus control are made between the 485 A and 485 B terminals on the ACS boilers 9 through 40 and the RS 485 COMM terminals in the I O Box on the front of the boilers OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 67 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION Wire the units using shielded twisted pair wire between 18 and 22 AWG Observe the proper polarity for the ACS RS 485 COMM wiring connections Shields should be terminated only at the ACS and the boiler end must be left floating Each unit s wiring must conform to the above 5 6 2 A
166. is procedure as shown in Figure 7 5 even if there is only one existing gasket being replaced Note that the LOWER RELEASE GASKET has tabs which the others do not NOTE During reassembly apply a light coating of high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is properly positioned as indicated in Figure 7 3 Torque the igniter injector to 170 180 in Ibs Beginning with the burner assembly reinstall all the components in the reverse order that they were removed When reinstalling the blower plenum removed in step 11 tighten the 3 8 16 nuts using a typical torque pattern for example loosely tighten one nut then loosely tighten a second nut on the opposite side a third at 90 degrees to the first two and a fourth opposite the third and then repeat this pattern with the remaining four nuts Repeat the entire pattern a second time to partially tighten all eight nuts and then repeat a third time until all eight nuts are fully torqued to 22 ft Ibs Ensure that the igniter injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 91 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE Burner Assembly Inspection and Maintenance Procedure Cont BLOWER PLENUM
167. items shown with an asterisk in Table 3 2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu Table 3 4 3 5 SETUP MENU The Setup Menu Table 3 3 permits the operator to enter the unit password 159 which is required to change the menu options To prevent unauthorized use the password will time out after 1 hour Therefore the correct password must be reentered when required In addition to permitting password entries the Setup Menu is also used to enter date and time units of temperature measurements and entries required for external communication and control of the unit via the RS 232 port A view only software version display is also provided to indicate the current Control Box software version OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 39 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Table 3 3 Setup Menu Available Choices or Limits Menu Item Display e Default Minimum Maximum Passsword 0 9999 0 Language English English Time 12 00 am 11 59 pm Date 01 01 00 12 31 99 Unit of Temp Fahrenheit or Celsius Fahrenheit Comm Address 0 127 0 Baud Rate 2400 4800 9600 19 2K 9600 Upload Timer 0 0 Unit Alpha A 2 Unit Serial 0000 9999 0000 Unit Year 0 99 00 C More Year 0 99 11 C More Serial 0 9999 0000 C More Alpha A 2 Software
168. ith 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 1500 MBH and 2000 MBH units contain a 2 inch NPT gas inlet connection on the top of the unit as shown in Figure 2 2 and 2 3 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 the unit must be isolated from the gas supply piping At no time should the gas pressure applied to the unit exceed 14 W C A thorough leak test of all external piping must be performed using a soap and water solution or suitable equivalent The gas piping used must meet all applicable codes 2 8 1 Gas Supply Specifications The gas supply input specifications to the unit for Natural Gas are as follows e The maximum static pressure to the unit must not exceed 14 W C e The gas supply piping and pressure to the unit must be of sufficient capacity to provide 2000 cfh while m
169. its 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 boilers and ANSI NFPASB for LP gas fired 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 See pages 13 and 14 for important information regarding installation of units within the Commonwealth of Massachusetts IMPORTANT This Instruction Manual 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 Z WARNING N DO NOT USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS Z WARNING A 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 N WARNING BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE UNIT SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT N WARNING N THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THEREFORE MUST BE
170. k 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION This Page Is Intentionally Blank Page 70 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING CHAPTER 6 SAFETY DEVICE TESTING 6 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 combustion related safety devices before during and after the start sequence The following 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 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Chapter 3 NOTE It will be necessary to remove the front door and side panels from the unit to perform the following tests N WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 208 230 OR 460 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 71 of 18
171. kaged in the shipping container the unit must be moved by pallet jack or forklift from the FRONT ONLY FOR MASSACHUSSETTS ONLY For Massachusetts installations the unit must be installed by a plumber or gas fitter licensed within the Commonwealth of Massachusetts In addition the installation must comply with all requirements specified in Chapter 1 Safety Precautions pages 11 and 12 2 4 2 Setting the Unit The unit must be installed on a 4 inch to 8 inch thick housekeeping pad to ensure proper condensate drainage If anchoring the unit refer to Figure 2 1b for anchor locations je M 1 2 1046 5 9 2 235 24 610 4X 60 75 619 27 585 e 24 610 FRONT REAR ME o Figure 2 1b Benchmark 1500 2000 Anchor Bolt Locations A total of 3 lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2 2 Remove the front top panel from the unit to provide access to the lifting tabs Remove the four 4 lag screws securing the unit to the shipping skid Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad required in the desired location N WARNING WHEN LIFTING OR MOVING THE BOILER DO NOT ATTEMPT TO MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 17
172. lay next menu items Change item xx Fault log display Sensor log display Time line display Log off X r do0omozo lI H Hog qoa OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 113 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 9 RS232 COMMUNICATION MENU PROCESSING UTILIZING RS 232 COMMUNICATION Continued NOTE The Level 1 password 159 must be entered to change options in the Setup Configuration and Tuning Menus The Level 2 password 6817 must be entered to view or change options in the Calibration and Diagnostics Menus With the exception of the password entry all other keyboard entries can be made using either upper or lower case To view the available menus in the top down sequence shown in Figure 3 2 enter M lt Rtn gt The Menu title and first 10 options will be displayed When viewing menus containing more than 10 options enter lt Rtn gt to display the remaining options Menu Processing Utilizing Rs 232 Communication Shortcut keys are also available to go directly to a specific menu These shortcut keys are m1 m2 m3 m4 m5 Default Operating Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu Tochange a value or setting for a displayed menu option proceed as follows d Enter C followed by the number to the right of the displayed option to be changed and then press lt
173. le the blower output drive voltage by performing the following steps a Press the MENU key until CONFIGURATION MENU is displayed b Press the A arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the A arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key d Press the CLEAR button to clear the airflow fault Once the unit has proved flame turn off the blower again by going to the Configuration Menu Analog Output menu item and select OFF The Blower Proof Switch will open and the blower should stop The unit should shut down and display AIRFLOW FAULT DURING RUN Go to the Configuration Menu Analog Output item and select VALVE POSITION 0 10 6 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 Turn off the main ON OFF switch on the front of the Control Panel For units that get combustion air from a Combustion Air Duct remove that duct located on the rear panel of the boiler see Figure 6 4 below For units that have an air filter in place of a Combustion Air Duct not shown remove the air filter OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 79 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING Blocked Iniet Switch Test C
174. lers CHAPTER 7 MAINTENANCE 7 7 CONDENSATE DRAIN TRAP Benchmark boilers contain a condensate trap as shown in Chapter 2 Figure 2 6 The trap is located external to the unit and attached to the drain pipe from the exhaust manifold This trap should be inspected and cleaned in accordance with the maintenance schedule shown in Table 7 1 to ensure proper operation To inspect and clean the trap proceed as follows Condensate Drain Trap Maintenance Procedure Disconnect the external condensate trap by loosening the union pipe connection between the trap and the exhaust manifold drain pipe Remove the connections on the inlet and outlet sides of the condensate trap shown in Figure 7 6 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover Remove the float from the condensate trap Remove the O ring and orifice gaskets from the trap AERCO recommends that these items be replaced annually Thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thoroughly cleaned replace the trap After the above items have been inspected and thoroughly cleaned replace the O ring 84017 and orifice gasket 81092 with new parts Reassemble all piping and hose connections to the condensate trap inlet and outlet Reconnect trap to exhaust manifold drain NOTE There are two slightly different types of condensate traps that may be used in your configuratio
175. licable to this manual These categories are shown in Figure 3 2 Each of the menus shown contain options which permit operating parameters to be viewed or changed The menus are protected by a password levels to prevent unauthorized use Prior to entering the correct password the options contained in the Operation Setup Configuration and Tuning Menu categories can be viewed However with the exception of Internal Setpoint Temperature Configuration Menu none of the viewable menu options can be changed Once the valid level 1 password 159 is entered the options listed in the Setup Configuration and Tuning Menus can be viewed and changed if desired The Combustion Cal Menu is protected by the level 2 password 6817 which is used in Chapter 4 to perform combustion calibration prior to service use 3 3 1 Menu Processing Procedure Accessing and initiating each menu and option is accomplished using the Menu Keys shown in Figure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures Menu Processing Procedure The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status Pressing the or Y arrow key will display the other available data items in the Operating Menu Press the MENU key The display will show the Setup Menu which is the next menu category shown in Figure 3 2 This menu contains the
176. mp NO uma 30 2 10 14 Auxiliary Relay Contacts NC COM amp NO 30 2 11 FLUE GAS VENT 30 212 COMBUSTION AIR ul a pen 31 2 12 1 Combustion From Outside the Building 31 2 12 2 Combustion Air from Inside the Building 31 2 13 0 yun a E aun aY aaa 31 2 14 SEQUENCING VALVE INSTAELATIQON uu u uu uuu usan 9 22 31 CHAPTER 3 OPERATION 33 SAINTRODUCTION 33 3 2 CONTROL PANEL DESGRIPTION a u a aS Su Y a uka 33 3 9 CONTROL PANEL MENUS iiic ct et etx 37 3 3 1 Menu Processing Procedure oorr nere ee 37 2 4 2 c eie era a itor 39 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 3 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers Installation Operation amp Maintenance Manual IOMM SS SETUPIMENU 224 5 Josten tu 39 3 6 CONFIGURATION MENU tet
177. n an older style with a separate inlet adapter and a newer style with a built in adapter Maintenance is the same except that the newer style does not need an orifice gasket Step 5 THUMB SCREWS EBD lt cove Thum d m 2 2484 GASKET 3 4 NPT Port FLOAT GUIDE Condensate Trap O Ring Float Guide Float Adapter i CONDENSATE Opening TRAP P N 24060 Figure 7 6 External Condensate Trap Cutaway and Exploded Views Page 94 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE 7 8 AIR FILTER CLEANING amp REPLACEMENT The Benchmark boiler is equipped with an air filter part no 88014 which should be cleaned and re oiled every 12 months and replaced every 24 months The air filter is located at the inlet of the air fuel valve at the top of the boiler as shown in Figure 7 7 To inspect replace the air filter proceed as follows Air Filter Cleaning amp Replacement Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Refer to Figure 7 7 and locate the air filter attached to the air fuel valve inlet Using flat tip screwdriver or 5 16 nut driver loosen the clamp securing
178. n build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present clean the component using fine emery cloth Repeated carbon build up is an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion calibration procedures FLEX GAS COMPRESSION FITTING amp ELBOW IGNITION SOLENOID BLOWER INJECTOR S 2 PLENUM IGNITOR ASSY WITH INDEXING CLOCKING WASHERS 0 3 as t i ls needed 3 i 2 SENSOR 4 amp WASHER gt NS gt 4 FLAME BURNER PLATE M DETECTOR amp FLANGE n EE GASKET Figure 7 2 Igniter Injector amp Flame Detector Mounting Details Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present clean the component using fine emery cloth Repeated carbon build up is an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion calibration procedures Prior to reinstalling the igniter injector a high temperature conductive anti seize com pound must be applied to the threads OMM 0097_0D AERCO International Inc e 100 Oritani D
179. n step 3 to restore the interlock Press the CLEAR button to reset the fault 7 Theunit should start Page 76 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 7 FLAME FAULT TESTS 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 Tests 1 Setthe ON OFF switch to the OFF position 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 see Figure 6 3 4 Setthe ON OFF switch to the ON position to start the unit 5 The unit should purge and light the Pilot Flame then it should shut down after reaching the main burner ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve previously closed in step 3 and press the CLEAR button Restart the unit and allow it to prove flame Once flame is proven close the manual gas valve located between the SSOV Figure 6 3 and the Air Fuel Valve 9 The unit should shut down and Lockout flashing FLDR in the display 10 Open the valve previously closed in step 8 11 Press the CLEAR button The unit should restart and fire OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 109
180. nd all Pre Purge conditions have been satisfied 8 ON OFF Switch Enables and disables boiler operation Allows operator to test operation of the water level monitor LOW WATER LEVEL Pressing TEST opens the water level probe circuit and simulates a 9 TEST RESET Switch Low Water Level alarm Pressing RESET resets the water level monitor circuit Pressing the CLEAR key item 6 resets the display OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 35 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Table 3 1 Operating Controls Indicators and Displays Continued CONTROL a INDICATOR OR FUNCTION i DISPLAY MENU Keypad Six 6 keys which provide the following functions for the Control Panel Menus MENU Steps through the main menu categories shown in Figure 3 2 The Menu categories wrap around in the order shown Allows you to go back to the previous menu level without changing any information Continuously pressing this key BACK will bring you back to the default status display in the VFD Also this key allows you to go back to the top of a main menu category When in one of the main menu categories Figure 3 2 pressing the A arrow key will select the displayed menu A UP Arrow category If the CHANGE key was pressed and the menu 10 item is flashing pressing the A arrow key will increment the selected setting When in one of the main m
181. nded at the I O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG Polarity must be observed The source end of the shield must be connected at the source When driving multiple units each unit s wiring must conform to the above OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 65 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION 5 4 2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the external signal is present To operate the unit in the Manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Remote Setpoint mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 5 DIRECT DRIVE MODES The unit s air fuel valve position open be changed by a remote signal which is typically sent from an Energy Management System EMS or from a Building Automation System BAS The Direct Drive mode can be driven by a current or voltage signal within the following ranges e 4 20 mA 1 5 Vdc e 0 20 mA 0 5 Vdc The factory default setting for the Direct Drive mode is 4 20 mA 1 5 Vdc With this setting a 4 to 20 mA signal sent by an EMS or BAS is used to change the unit
182. nstalled to test the interlock DIRECT DRIVE 1 Direct drive signal is not present Check I O Box to ensure signal is hooked up SIGNAL FAULT Not yet installed Wrong polarity Signal defective at source Broken or loose wiring Signal is not isolated floating Control Box signal type selection switches not set for correct signal type voltage or current Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Check signal at source to ensure it is isolated Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration Menu FLAME LOSS DURING IGN Worn Flame Detector No spark from Spark Igniter Defective Ignition Transformer Defective Ignition Stepper IGST Board Defective SSOV Remove and inspect the Flame Detector for signs of wear Replace if necessary Close the internal gas valve in the unit Install and arc a spark igniter outside the unit If there is no spark check for 120VAC at the primary side to the ignition transformer during the ignition cycle If 120VAC is not present the IGST Board in the Control Box may be defective Refer fault to qualified service personnel While externally arcing the spark igniter observe the open close indicator in the Safety Shut
183. oard OUTDOOR TEMP SENSOR FAULT Loose or broken wiring Defective Sensor Incorrect Sensor e Inspect Outdoor Temperature sensor for loose or broken wiring Check resistance of sensor to determine if it is within specification Ensure that the correct sensor is installed O2 OUT OF RANGE Combustion Calibration incorrect Blocked inlet air duct or louver Check Combustion Analyzer and recalibrate the boiler Page 106 of 188 2 Unblock air inlet and measure open area for combustion air to the room AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION RECIRC PUMP FAILURE 1 Internal recirculation pump failed 1 Replace recirculation pump REMOTE SETPT SIGNAL FAULT 1 Remote setpoint signal not present Not yet installed Wrong polarity Signal defective at source Broken or loose wiring 2 Signal is not isolated floating if 4 to 20 mA 3 Control Box signal type selection switches not set for correct signal type voltage or current Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check continuity of wiring between so
184. oard and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design 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 installation of the venting system design or the venting system components and 2 Acomplete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e copy of all installation instructions for all Produ
185. of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION LIFTING LUGS 3 POSITIONS Figure 2 2 Boiler Lifting Provisions 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 If installing a Combination Control Panel CCP system it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location Refer to Chapter 5 for information on Combination Mode Boilers Page 18 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 5 SUPPLY AND RETURN PIPING The Benchmark Boiler utilizes 4 150 flanges for the water system supply and return piping connections The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2 3 2 GAS INLET BOILER HOT WATER OUTLET SUPPLY AIR INLET PRIMARY WATER INLET RETURN EXHAUST MANIFOLD CONDENSATE DRAIN PORT DRAIN VALVE Figure 2 3 Supply and Return Locations 2 6 PRESSURE RELIEF VALVE INSTALLATION An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler The pressure rating for the rel
186. of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES e Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e 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 GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 Modbus Outdoor Sensor Wirin 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 Box of any of the Boiler units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor AERCO PN 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 e Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box e When mounting the Outdoor sensor it must be located on the North side of the buildin
187. on Power Supply Board If they or fuse are not steady ON replace Power Supply Board 5 Defective IGST Board 5 Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board IGN SWTCH OPEN 1 Air Fuel Valve not rotating to 1 Start the unit The Air Fuel Valve should rotate to the purge DURING IGNITION ignition position open position then back to ignition position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Control Box Refer fault to qualified service personnel 2 Defective ignition switch 2 If the Air Fuel Valve does rotate to the ignition position check the ignition position switch for continuity between the N O and COM terminals when in contact with the cam 3 Defective Power Supply Board 3 Check DS1 amp DS2 LEDs on Power Supply Board If they or fuse are not steady ON replace Power Supply Board 4 Defective IGST Board 4 Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Page 104 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097 0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PRO
188. on the PMC Board located in the Control Panel Assembly Contact your local AERCO representative for details In order to enable the Remote Setpoint Mode the following menu setting must be made in the Configuration Menu Menu Option Setting Boiler Mode Remote Setpoint Remote Signal 4 20mA 1 5V 0 20mA 0 5V or Network Refer to section 3 3 for detailed instructions on changing menu options If the Network setting is selected for RS 485 Modbus operation a valid Comm Address must be entered in the Setup Menu Refer to Modbus Communication Manual GF 114 for additional information While it is possible to change the settings of temperature related functions the unit is factory preset with settings that work well in most applications It is suggested that an AERCO representative be contacted prior to changing any temperature related function settings For descriptions of temperature related functions and their factory defaults refer to Appendices A and E 5 4 1 Remote Setpoint Field Wiring The only wiring connections necessary for the Remote Setpoint mode are connection of the remote signal leads from the source to the units I O Box The I O Box is located on the front panel of the boiler For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The signal must be floating ungrou
189. ontinued WARNING THE BLOWER SUCTION IS VERY STRONG AND CAN PULL NEARBY OBJECTS INTO THE BLOWER S FAN BLADES DO ALLOW ANYTHING TO BE PULLED INTO THE BLOWER DO NOT WEAR ANYTHING THAT COULD GET CAUGHT AND PULL YOU INTO THE BLOWER 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 a Flame Detector i Connector Boot TO WIRE HARNESS Flame Signal Generator Figure 6 3a Connecting the Flame Signal Generator d Keep the alligator clip away from bare metal parts until step 4c Complete the following with the boiler operating in Manual mode a Ramp the boiler up to 100 fire rate and then turn on the main ON OFF switch on the front of the Control Panel Push the BACK button three 3 times to return to the upper level menu When the Controller gets into the ignition phase the Control Panel will show IGNITION TRIAL At that point attach the alligator clip see Figure 6 3a to any bare metal surface or ground The C More display 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 Wait for the boiler to ramp up to at least 90 before continuing Cover the combustion air inlet
190. ould fault and display SSOV SWITCH OPEN Replace wire 148 and press the CLEAR button Setthe ON OFF switch to the ON position to start the unit Remove the wire again when the unit reaches the purge cycle and PURGING is displayed 10 The unit should shut down and display SSOV FAULT DURING PURGE 11 Replace the wire on the SSOV and press the CLEAR button The unit should restart OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 81 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING SSOV ACTUATOR COVER ACTUATOR COVER SCREW l 5 7 Figure 6 5 5507 Actuator Cover Location 6 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 Set the unit s ON OFF switch to the OFF position Place the unit in manual mode and set the valve position between 25 and 30 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 6 6 Remove one of the two wires 171 or 172 from the Purge Switch Figure 6 6 Initiate a unit start sequence 5 The unit should begin its start sequence then shut down and display PRG SWITCH OPEN DURING PURGE Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart Page 82 of 188 AERCO International
191. p Hi Limit This is the maximum allowable outlet temperature 40 to 210 F Any temperature above this setting will turn off the unit The temperature must then drop 5 below this setting to allow the unit to run Default Hi Limit is 160 F Max Valve Position Sets the maximum allowable valve position for the unit 40 to 100 Default is 100 Pump Delay Timer Specifies the amount of time 0 to 30 min to keep the pump running after the unit turns off Default is zero OMM 0097_0D GF 142 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 133 of 188 Ph 800 526 0288 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION CONFIGURATION MENU Cont Aux Start On Dly Specifies the amount of time to wait 0 to 120 sec between activating the Aux Relay due to a demand and checking the pre purge string to start the boiler Default is 0 sec Failsafe Mode Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown Default is Shutdown Analog Output Must be set to Valve Pos 0 10V for BMK 1500 amp 2000 Lo Fire Timer Specifies how long 2 to 600 sec to remain in the low fire position after ignition before going to the desired output Default is 2 sec Setpt Limiting Setpoint Limiting can be Enables or Disablled The default setting i
192. pload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The COMM LED will light during the upload Unit Alpha Mandatory for AERCO OnAER Remote Data Collection This value must match the first alpha digit on the Code Plate e g G 12 1234 Unit Year Mandatory for AERCO OnAER Remote Data Collection This value must match the 2 digit year on the Code Plate e g G 12 1234 Unit Serial Mandatory for AERCO OnAER Remote Data Collection This value must match the 4 digit serial on the Code Plate e g G 12 1234 Software Version Internal Setpoint Identifies the current software version of the control box Ver 0 0 to Ver 9 9 Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of KC Boiler KC Boiler LN BMK Boiler Std BMK Blr Std Dual BMK Boiler LN BMK Blr LN Dual KC Water Heater KC Wtr Heater LN Innovation WH Page 132 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set 40 F to 240 F Default is 130 F
193. r Blauvelt NY 10913 Page 87 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE IGNITER INJ ECTOR MAINTENANCE PROCEDURES Continued NOTE If a replacement igniter injector part no 66026 is being installed a compression nut containing a built in ferrule will be included with the replacement part If needed 3 indexing washers are also included These washers may be needed to properly position the gas injector tube of the igniter injector within the 120 angle range shown in Figure 7 3 BLOWER PLENUM IGNITER INJECTOR ANGLE OF GASINJECTOR 120 TUBE O2 SENSOR OBSERVATION PORT Figure 7 3 Igniter Injector Orientation Viewed Looking Down from Above 10 Reinstall the igniter injector in the burner plate Torque to 170 180 in Ibs DO NOT over tighten 11 Connect the staged ignition assembly to the gas injector tube of the igniter injector by securing the compression nut to the elbow of the staged ignition assembly 12 Reconnect the igniter injector cable 13 Reinstall the shroud on the unit 7 3 FLAME DETECTOR The flame detector part no 66020 is located on the burner plate at the top of the unit see Figures 7 1 and 7 2 The flame detector may be hot Allow the unit to cool sufficiently before removing the flame detector Inspect or replace the flame detector as follows Flame Detector Maintenance Set the control panel ON OFF switch to the OFF position Dis
194. r 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 C ST Temp Sensor PN 61040 Header Temp Sensor Box Step 2 Direct Wired Outdoor Sensor 1 On the MASTER Unit Connect the Outdoor Temperature Sensor AERCO PN 123525 to the OUT and terminals in the I O Box NOTES e 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 e 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 from the boiler Temp Sensor PN 123525 OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 121 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 3 Continued 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 BST Menu and set the BST Mode i
195. r or Blocked Inlet switch Blocked blower inlet or inlet ductwork No voltage to Blocked Inlet switch from C More Control Box PROBABLE CAUSES from 3 to 12 for AIRFLOW FAULT DURING IGNITION apply for this fault 1 Start the unit If the blower does not run check the blower solid state relay for input and output voltage If the relay is OK check the blower Start the unit If the blower runs turn off unit and check the Blocked Inlet switch for continuity Replace the switch if continuity does not exist Remove the air filter and Blocked Inlet switch and inspect for signs of blockage Clean or replace as necessary Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN Blower stopped running due to thermal or current overload Blocked Blower inlet or inlet ductwork Blockage in air filter or Blocked Inlet switch Defective Blocked Inlet switch Combustion oscillations Probable causes from 3 to 16 for AIRFLOW FAULT DURING IGNITION applies for this fault Check combustion blower for signs of excessi
196. re 3 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Appendix B for listings and descriptions of displayed startup status and error messages Page 38 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097 0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION 3 4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3 2 This menu is Read Only and does not allow personnel to change or adjust any displayed items Since this menu is Read Only it can be viewed at any time without entering a password Pressing the A arrow key to display the menu items in the order listed Top Down Pressing the Y arrow key will display the menu items in reverse order Bottom Up Table 3 2 Operating Menu Menu Item Display ELSE Choices or miis Default Minimum Maximum Status Message Active Setpoint 40 F 240 F Inlet Temp 40 F 140 F Air Temp 70 F 245 F Outdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Out 0 100 Exhaust Temp F F Flame Strength 0 100 Oxygen Level 0 21 Run Cycles 0 999 999 999 Run Hours 0 999 999 999 Fault Log 0 19 0 NOTE The Outdoor Temp and Valve Position Out display
197. ream side of the SSOV during the Combustion Calibration procedures described in section 4 3 The gas supply manometer is installed at the upstream and or downstream location shown in Figure 4 1 NATURAL GAS INLET MANUAL SHUT OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH LEAK DETECTION 1 4 NPT PLUG BALE VALNE Install manometer here for Combustion Calibration Figure 4 1 BMK 1500 2000 1 4 Inch Gas Plug Location for Combustion Calibration Page 52 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP Install the 16 W C manometer s as described in the following steps Installing Gas Supply Manometer 1 Turn off the main gas supply upstream of the unit Remove the top panel and front panel from the boiler to access the gas train components To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration section 4 3 remove the 1 4 NPT plug from the leak detection ball valve on the downstream side of the SSOV as shown in Figure 4 1 Install a NPT to barbed fitting into the tapped plug port Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C 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
198. rformance Instructions for natural gas combustion calibration follow with the BMK 1500 instructions first followed by the BMK 2000 instructions BMK 1500 Natural Gas Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running Open the natural gas supply valve to the unit Set the control panel ON OFF switch to the OFF position 4 Turn on external ac power to the unit The display will show loss of power and the time and date 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 Also the MANUAL LED will light Adjust the air fuel valve position to 0 by pressing the Y arrow key Ensure that the leak detection ball valve downstream of the SSOV is open Set the ON OFF switch to the ON position Change the valve position to 30 using the A arrow key The unit should begin its start sequence and fire Next verify that the gas pressure downstream of the SSOV is set to 3 6 0 2 W C 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 approximately 3 6 W C 0 2 W C Using the A arrow key increase the valve open position to 100 Verify that the gas pressure on the downstream side of the
199. roud from the four 4 pins in the side panels Disconnect the O gt sensor lead wire by pushing in on the release tab and pulling apart the connector Next loosen and remove the sensor and crush washer from the burner plate using a 15 16 open end wrench Thoroughly inspect the sensor If eroded the sensor should be replaced Otherwise clean the sensor with a fine emery cloth Reinstall the O sensor and crush washer on the burner plate Reconnect the sensor lead wire Reinstall the shroud on the unit 7 5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed Certain code requirements such as ASME CSD 1 require that these tests be performed on a scheduled basis Test schedules must conform to local jurisdictions The results of the tests should be recorded in a log book See Chapter 6 Safety Device Testing Procedures OMM 0097_0D AERCO International Inc e 100 Oritani Blauvelt NY 10913 Page 89 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE 7 6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top of the unit s heat exchanger The burner assembly may be hot Therefore allow the unit to cool sufficiently before removing the burner assembly NOTE In order to do this procedure most efficiently with a minimum of steps a simple support rig
200. rs to have one boiler acting as a master to manage the other boilers at the site in such a way that the efficiency of the entire boiler array is maximized The implementation of BST and the installation and use of this valve is optional The boiler IS pre wired to accept the sequencing valve Installation consists of installing the sequencing valve in the hot water outlet pipe and then connecting it into the shell harness as described below OMM 0097_0D AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Page 31 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 1 Install the sequencing valve in the boiler s hot water outlet pipe SEQUENCING VALVE HOT WATER OUTLET Figure 2 13 Sequencing Valve Installed 2 The boiler s shell harness has one unused cable One end of this cable is connected to the DELAYED INTERLOCK IN terminals in the I O board see Figure 2 14 while the other end contains a Molex connector with a jumper wire inserted in it this jumper wire allows units that do not have a sequencing valve to operate normally Find the free end of this cable inside the unit s enclosure as Figure 2 14 Sequencing Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing valve s connector Page 32 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 14
201. s 240 12 Go to the Outdoor Temp Point item and enter the Modbus Point 15 OND oF When ALL C More units have been configured 13 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 124 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive 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 MASTER Unit Connect the Header Temperature Sensor AERCO PN 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 e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler 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 xs ST Temp Sensor PN 61040 Header Temp Sensor I O Box Step 2 Direct Wired 0 20ma or 4 20ma Wiring 1 Connec
202. s Enabled Setpt Limit Band The Setpoint Limit Band can be set from 0 to 10 The default setting is 5 Network Timeout Specifies the timeout value seconds before a Modbus fault is declared Available settings range from 5 to 999 seconds Default is 30 seconds Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temperature value the Outlet Temperature is permitted to rise above setpoint before being shut down Span is 0 to 25 Default is 10 Demand Offset This entry will reduce excessive ON OFF cycling in AUTO mode When this entry is a non zero value the unit will not turn on again until Valve Position In reaches the Start Level value AND the Outlet Temperature goes below the Active Setpoint Demand Offset In addition the boiler will fire at the 29 Valve Position level or below for a period of one minute When this entry is set to zero the unit will turn on again as soon as the Valve Position in reaches the Start Level value There will not be a one minute delay when firing at the 29 Valve Position level Setting range is 0 to 25 Default is 10 Page 134 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION
203. s Network Boiler Boiler Boiler 1 2 8 Note FFWD Header Sensor Slave must connected to Master INLET Figure 10 1 Simplified BST Block Diagram OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 117 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 2 AERCO BST Quick Start Chart Select the single option that suites your installation and then complete the instructions in the corresponding sub sections of section 10 3 BST Implementation Instructions Constant Setpoint choose option 1 or 2 Option 1 Direct Wired Header Complete section 10 3 1 OR Option 2 Modbus Header Complete section 10 3 2 Outdoor Reset choose option 3 or 4 Option Direct Wired Header AND Direct Wired Outdoor Air Complete section 10 3 3 OR Option 4 Modbus Header AND Modbus Outdoor Air Complete section 10 3 4 Remote Setpoint choose option 5 through 8 Option 5 4 20ma Drive AND Direct Wired Header Complete section 10 3 5 OR Option 6 Modbus Drive AND Direct Wired Header Complete section 10 3 6 OR Option 7 4 20ma Drive AND Modbus Header Complete section 10 3 7 OR Option 8 Modbus Drive AND Modbus Header Complete section 10 3 8 Page 118 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAP
204. s of 6096 4596 30 and 1696 The oxygen O5 nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table NOTE If NOx readings exceed the target values shown 20 ppm increase the O level up to 196 higher than the listed calibration range shown in the table Record the increased O value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 6096 6 0 0 5 20 ppm 100 ppm 45 6 3 0 5 lt 20 ppm lt 100 ppm 30 6 3 0 5 lt 20 ppm lt 100 ppm 16 6 0 0 5 lt 20 ppm lt 100 ppm If the oxygen level at the 16 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 4 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the to the specified level Recalibration MUST be performed again from 60 down to 16 after making a change to the idle screw TAC valve 30 This completes the BMK 1500 Natural Gas combustion calibration procedures AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 56 of 188 OMM 0097 0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP BRASS HEX HEAD
205. ss the ENTER key 19 Press the MENU key on the front panel of the C MORE until Combustion Cal Menu appears on the display 20 Press the A arrow key until SET Valve Position appears on the display 21 Press the CHANGE key SET Valve Position will begin to flash 22 Press the A arrow key until the SET Valve Position reads 80 Press the ENTER key 23 Next press the down Y arrow key until CAL Voltage 8096 is displayed 24 Press the CHANGE key and observe that CAL Voltage 80 is flashing 25 The oxygen level at the 80 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the following values Combustion Calibration Readings 2 8096 Valve Position Valve Position Oxygen 02 Nitrogen Oxide NOx Carbon Monoxide CO 80 5 9 0 5 lt 20 ppm 100 ppm If the oxygen level is not within the specified range adjust the level using the A and Y arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the A arrow key increases the oxygen level and pressing the down Y arrow key decreases the oxygen level OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 59 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP BMK 2000 Natural Gas Combustion Calibration Cont 27 Once the oxygen level is within th
206. ssion Here are the steps Running a Command on a Remote Machine Using PuTTY 1 Bring up the PuTTY application and select the server you wish to connect to 2 Atthe bottom of the Basic Options dialog box left image of Figure 9 1 the section titled Close window on exit select the Never radio button This will keep the window open after the command has finished executing so that you can see any results in the terminal window In the menu bar along the left side of the dialog box click the SSH menu near the bottom The following screen will be presented Category Session Options controlling SSH connections i Logging Terminal Data to send to the server Remote command Protocol options Dont start shell or command at all Enable compression Preferred SSH protocol version Olony 1 2 2 only Encryption options Encryption cipher selection policy AES SSH 2 only Blowfish 3DES wam below here Arcfour SSH 2 only DES Enable legacy use of single DES in SSH 2 Figure 9 2 GUI Basic SSH Options for Running Remote 4 Into the textbox titled Remote command type the full command line you wish to have executed on the remote machine Page 112 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 20
207. 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 1500 BMK 2000 Start Level 24 24 Stop Level 16 16 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 Refer to Table 3 8 for the relationship between the energy input and Air Fuel Valve position for a BMK 1500 MBH boiler running on natural gas Table 3 8a 1500 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas due Energy Input Boiler Energy Input Open BTU Hr of Full Capacity 16 Stop Level 76 000 5 0 20 127 000 8 5 30 366 000 24 4 40 629 000 41 9 50 822 000 54 7 60 977 000 65 0 70 1 119 000 74 5 80 1 255 000 83 5 90 1 396 000 92 9 100 1 502 000 100 Table 3 8b BMK 2000 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas S s Energy Input Boiler Energy Input Open BTU Hr of Full Capacity 16 Stop Level 100 000 6 7 20 143 000 11 30 388 000 23 40 759 000 37 50 1 069 000 51 60 1 283 000 61 70 1 476 000 74 80 1 675 000 83 90 1 833 000 93 100 2 000 000 100 Page 50 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt N
208. t panel display or via the RS 232 port The Fault Log cannot be cleared If the Fault Log already contains 10 faults the earliest fault is overwritten when a new fault occurs A sample Fault Log display is shown in Table 9 1 Table 9 1 Sample Fault Log Display No Fault Message Cycle Date Time 0 Direct Drive Signal Fault 609 1 10 02 8 42am 1 Low Gas Pressure 366 7 04 01 5 29pm 2 Loss of Power 0 1 01 01 11 50 Operation Time Log store thousands of records Therefore to view the most recently logged record enter followed by 0 zero and press Enter i e T0 lt Enter gt To view earlier records in reverse chronological order enter T and press Enter To go back 200 or 1000 records enter T200 or T1000 etc and press Enter 9 4 2 Operation Time Log The Operation Time Log consists of a string of ASCII records stored in non volatile memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate or flame strength must change by more than 5 or the run mode must change At steady state the run length is allowed to reach a maximum of 30 minutes before the record is logged This means that no more than 30 minutes of data can be lost if the unit loses power T
209. t the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master Unit s I O Box NOTE e 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 Remote Signal i sarai 2 2 maia a A e amsaca a Remote Signal 1 0 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 BST Menu and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the Head Temp Source item and select FFWD Temp Go to the BST Remote Signal and select either 4 20ma or 0 20ma NO Of When ALL C More units have been configured 8 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 125 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive NOTE Both Header Sensor AND the ProtoNode SSD Device must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode Us
210. tdoor Temp Network Outdoor Temp Outdoor Tmp Addr 0 255 240 Outdoor Tmp Pnt 0 255 215 BST Remote Signal 4 20 mA 1 5 Vdc Network Network Yes BST Auto Mstr No NOTE A Modbus temperature No transmitter must be installed in conjunction with this feature BST Auto Timer 10 sec 120 sec 30 sec Remote Intlk Use Boiler Shutdown System Shutdown Sm Shutdown One Boiler Mode Off On Avg Temp Off Temp 1 Bir Threshold 10 35 25 Setpoint Setback Disable Enable Disable Page 44 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Available Choices or Limits Menu Item Display Default Minimum Maximum Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130 F Setback Start 12 00am 11 59pm 12 00am Setback End 12 00am 11 59pm 12 00am Rate Threshold 1 F 30 F 15 F Disabled Enabled Disabled BST Next On VP 16 100 50 BST Max Boilers 1 8 8 BST On Delay 30 sec 300 sec 60 sec BST On Timeout 15 sec 300 sec 60 Sec Valve Override Off Closed Open Off Valve Off Delay 0 15 min 1 min BST Sequencing Run Hours Unit Size Select Lead Run Hours Select Lead Unit 0 127 0 Select Lag Unit 0 127 0 Lead Lag Hours 25 hours 225 hours 72 hours U Disabled Enabled Disabled BST Temp Hi Limit 40 F 210 F 210 F
211. tem to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Outdoor Reset Go to the Head Temp Source item and select FFWD Temp Go to the BST Outdoor Sens item and select Enabled Go to the Outdoor Temp Source item and select Outdoor Temp OND When ALL units have been configured 9 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 122 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 4 Option 4 Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor 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 AERCO 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 AERCO PN 24410 to pins 2 and 3
212. terials 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 to avoid any condensate pooling and to allow for proper drainage 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 or 0 8 W C 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 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 For Massachusetts installations the following companies provide vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts Contact information is as follows Selkirk Corporation Heatfab Division Watertown Supply 130 Industrial Blvd 33Grove St Turners Falls MA 01376 Watertown MA 02472 Phone 1 800 772 0739 Phone 617 924 2840 www heat fab com http www watertownsupply com M A Peacard Glover Sheet Metal Inc 1250 Massachusetts Ave 44 Riverdale Ave Boston MA 02125 1689 Newton MA 02485 Phone 617 288 0629 Phone 617 527 8178 www mapeacard com www gloversheetmetal com Page 30 of 188 AERCO International Inc e 100
213. ternational Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers FORWARD Phrases Abbreviations and Acronyms Continued ug or Meaning IGST Board Ignition Stepper Board contained in C More Control Box INTLK INTL K Interlock Input Output I O Box Input Output I O Box currently used on Benchmark Innovation and KC1000 Series products IP Internet Protocol IRI Industrial Risk Insurers now discontinued code used to define gas trains containing two SSOVs and a solenoid operated vent valve ISO Isolated LED Light Emitting Diode LN Low NOx MA mA Milliampere 0 001 Amp one thousandth of an amp MAX Max Maximum MIN Min Minimum Modbus om half duplex data transmission protocol developed by AEG NC N C Normally Closed NO N O Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen O D Outside Diameter PUC Boa oe PPM Parts Per Million PTP Point to Point usually over RS 232 networks PWM Pulse Width Modulation REF Ref Reference RES Resistive RS 232 A standard for serial full duplex FDX transmission of data based on the or EIA 232 RS 232 Standard RS 422 A standard for serial full duplex FDX transmission of data based on the or EIA 422 RS 422 Standard RS 485 A standard for serial half duplex HDX
214. the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed 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 alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements prov
215. 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 After the shell is full press the LOW WATER LEVEL RESET button to reset the low water cutoff 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 Page 74 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 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 6 2 Water Temperature Fault Test Start the unit in the normal operating mode Allow the unit to stabilize at its setpoint Lower the adjustable over temperature switch setting to match the displayed OUTLET TEMPERATURE 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 HIGH WATER TEMP SWITCH fault message should be displayed It should not be possible to restart the unit Reset the adjustable over temperature switch to its original s
216. the filter to the inlet flange of the air fuel valve Remove the filter and clamp The filter may be cleaned hot soapy water to remove oil and dirt The filter should be thoroughly dried and then sprayed with a light coating of oil such as WD 40 prior to reinstallation Each replacement air filter is equipped with its own clamp Therefore simply install the replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat tip screwdriver or 5 16 nut driver Replace the top shroud on the unit and return boiler to service use AIR FUEL VALVE AIR FILTER HOSE CLAMP AIR FILTER TT vw gt mS Figure 7 7 Air Filter Location OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 95 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 7 MAINTENANCE 7 9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time one year or more the following instructions must be followed Shutting Boiler Down for Extended Period Set ON OFF switch on the front panel to the OFF position to shut down the boiler s operating controls Disconnect AC power from the unit Close the water supply and return valves to isolate boiler Close external gas supply valve Open relief valve to vent water pressure 7 10 PLACING THE BOILER BACK IN SERVICE AFTER
217. the port for the combustion analyzer probe as follows Accessing the Analyzer Probe Port 1 Refer to Figure 4 2 and remove the 1 4 NPT plug from the exhaust manifold 2 If necessary adjust the stop on the combustion analyzer probe so it will extend mid way into the flue gas flow DO NOT install the probe at this time AIR INLET PRIMARY HOT WATER INLET DRAIN VALVE EXHAST MANIFOLD ANALYZER PORT CONDENSATE DRAIN Figure 4 2 Analyzer Probe Port Location Right Side Partial View OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 53 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP 4 3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated at the factory prior to shipping This gas pressure must be within the following ranges for each model of boiler at full fire BMK Boiler Model Nominal Gas Pressure BMK 1500 3 6 W C 0 2 W C BMK 2000 3 9 W C 0 2 W C 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 following procedure as outlined This will keep readjustments to a minimum and provide optimum pe
218. ti cett Q 40 3 7 TUNING MEN Ue nai uet ime ieu deest 42 3 8 COMBUSTION CAL MENU uu uuu a ias esae demi sede sisse e 43 3 9 BST BOILER SEQUENCING TECHNOLOGY MENU a 43 3 1T0 START SEQUENCE 2 iniit ed iot Io eC e eb 46 3 AT START STOP EEMEES iet Dd Ie md edad 50 CHAPTER 4 INITIAL START UP U U UU U ramus amarae kan ao u 51 4 1 INITIAL START UP 51 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION 51 4 2 1 Required Tools amp Instrumentation 52 4 2 2 Installing Gas Supply 52 4 2 3 Accessing the Analyzer Probe Port 53 4 3 NATURAL GAS COMBUSTION CALIBRATION a aa 54 44 REASSENMBILIY eie tee tette d tede 60 4 5 OVER TEMPERATURE LIMIT SWITCHES 61 4 5 1 Digital Alarm Switch Checks and entra nnns sensn 61 CHAPTER 5 MODE OF OPERATION 6
219. tion 3 3 for detailed instructions on menu changing Press the CHANGE key The display will begin to flash Use the A and Y arrow keys to select the desired Building Reference Temperature Press ENTER to save any changes Next scroll through the Configuration Menu until the display shows Reset Ratio Press the CHANGE key The display will begin to flash Use the A and Y arrow keys to select the Reset Ratio determined in step 5 Press ENTER to save the change This completes 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired Common uses of this mode of operation include water source heat pump loops and indirect heat exchangers for potable hot water systems or processes No external sensors are required to operate in this mode While it is necessary to set the desired setpoint temperature it is not necessary to change any other temperature related functions The unit is factory preset with settings that work well in most applications Prior to changing any temperature related parameters other than the setpoint it is suggested that an AERCO representative be contacted For descriptions of temperature related functions and their factory defaults see Appendices A and E 5 3 1 Setting the Setpoint The setpoint temperature of the unit is adjustable from 40 F to 240 F To set the unit for operation in the Constant Setpoint Mode the following menu settings must be made in t
220. u and set the BST Mode item to BST Slave for now On MASTER only 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 CONDOR When ALL C More units have been configured 9 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 120 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 3 Option 3 Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor 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 MASTER Unit connect the Header Temperature Sensor AERCO PN 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 downstream of the LAST boiler in the plant s supply water header Shielded pai
221. up to two hundred feet from the unit Sensor connections are made at the Input Output I O Box on the front of the boiler Connections are made at the terminals labeled OUTDOOR AIR IN and AIR SENSOR COM inside the I O Box Use shielded 18 to 22 AWG wire for connections A wiring diagram is provided on the cover of the I O Box Refer to Chapter 2 section 2 9 1 for additional wiring information 5 2 4 Indoor Outdoor Startup Startup in the Indoor Outdoor Reset Mode is accomplished as follows NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 63 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION Indoor Outdoor Startup Refer to the Indoor Outdoor reset ratio charts in Appendix F Choose the chart corresponding to the desired Building Reference Temperature Go down the left column of the chart to the coldest design outdoor air temperature expected in your area Once the design outdoor air temperature is chosen go across the chart to the desired supply header temperature for the design temperature chosen in step 3 Next go up that column to the Reset Ratio row to find the corresponding reset ratio 6 Access the Configuration Menu and scroll through it until the display shows Bldg Ref Temp Building Reference Temperature If necessary refer to sec
222. urce and unit Check signal at source to ensure it is isolated Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration Menu RESIDUAL FLAME 1 Defective Flame Detector 2 SSOV not fully closed Replace Flame Detector Check open close indicator window of Safety Shut Off Valve SSOV and ensure that the SSOV is fully closed If not fully closed replace the valve and or actuator Close the 2 Gas Shut Off Valve downstream of SSOV Figure 2 7 Install a manometer or gauge at the leak detection port between the SSOV and Gas Shut Off Valve If a gas pressure reading is observed replace the SSOV Valve and or Actuator SSOV FAULT DURING PURGE See SSOV SWITCH OPEN SSOV FAULT SSOV switch closed for 15 seconds 1 Replace or adjust micro switch in SSOV actuator If fault persists DURING RUN during run replace actuator SSOV RELAY 1 SSOV relay failed on IGST board 1 Press CLEAR button and restart unit If fault persists replace FAILURE Ignition Stepper IGST Board 2 Floating Neutral 3 Hot and Neutral reversed at SSOV The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two Normally this measurement should be near zero or no more than a few millivolts Check SSOV power wiring OMM 0097 0D GF 142 AERCO Internat
223. ure the unit conforms to the Nitrogen Oxide NOx and Carbon Monoxide CO emissions specified in Chapter 4 The valve positions and default drive voltages are listed in Table 3 6 Table 3 6 Combustion Cal Menu Menu Item Display BMK 1500 BMK 2000 CAL Voltage 16 CAL Voltage 14 CAL Voltage 30 CAL Voltage 30 CAL Voltage 45 CAL Voltage 45 CAL Voltage 60 CAL Voltage 60 CAL Voltage 80 CAL Voltage 80 CAL Voltage 100 CAL Voltage 100 SET Valve Position SET Valve Position Blower Output Set Stdby Volt Oxygen Level Blower Output Set Stdby Volt Oxygen Level 3 9 BST Boiler Sequencing Technology Menu The BST Menu must be Enabled in order to be displayed and accessed The BST Enable item is located at the end of the Configuration Menu The Boiler Sequencing Technology BST Menu contains all of the items required to Configure Operate and Monitor the functionality of the BST System There are over 50 items in this menu and selecting any particular item from the list for inspection or modification could be time consuming As a result the BST Menu has been segmented into FIVE logical groups based on functionality The five Item groups are BST Monitor Items BST SETUP MENU OPERATE MENU TEMP CTRL MENU BST COMM MENU E oh These displayed item groups are displayed in UPPER CASE letters and are bounded by an asterisk in order to readily identify th
224. using a flat tip screwdriver to obtain a gas pressure within the range of 3 9 W C 0 2 W C Using the A arrow key increase the valve open position to 10096 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 3 9 0 2 W C Readjust the gas pressure if necessary 12 With the valve position at 100 insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer reading to stabilize 13 Compare the oxygen readings on the combustion analyzer to the on board O sensor value displayed in the Operating Menu of the C More Control Panel 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 14 Compare the measured oxygen level to the oxygen range shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the values shown If you are not in a NOx limited area and or do not have a NOx measurement your analyzer set the oxygen O2 at 5 5 0 5 Combustion Calibration Readings 100 6 valve Position Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 10096 5 0 6 0 lt 20 ppm lt 100 ppm Page 58 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CH
225. ve heat or high current draw that may trip thermal or current overload devices Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage Remove the air filter and Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary Verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present at both sides replace switch Run unit to full fire If the unit rumbles or runs rough perform combustion calibration See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION Page 100 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0097_0D GF 142 Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED 1 Delayed Interlock Jumper not Check to insure jumper is properly installed across the delayed INTERLOCK OPEN properly installed or missing interlock terminals in the Box 2 Device proving switch hooked to If there 2 external wires on these terminals check to see if interlocks is not closed an end switch for a proving device such as a pump louver etc is tied these interlocks Ensure that the device and or its end switch is functional A jumper may be temporarily i
226. ver Closed N WARNING N THE POWER BREAKER SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS WIRE CONDUITS POWER BREAKER TRANSFORMER 24V POWER SUPPLY ooooooooo 12V POWER SUPPLY FUSE BLOCKS 2 TERMINAL BLOCKS Figure 2 9 Power Box Internal Components With the exception of the transformer shown in Figure 2 9 all of the components in the Power Box are mounted on a DIN rail Page 24 of 188 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 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 2 9 1 Electrical Power Requirements The Benchmark 1500 and Benchmark 2000 models are available in one voltage configuration e 120 VAC Single Phase 60 Hz 20 Amps The Power Box contains terminal blocks as shown in Figure 2 9 In addition a label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2 10 AERCO INTERNATIONAL INC POWER BOX DANGER HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING INPUT POWER Li NEU 120 VAC GND 050 50 60 HZ NEU O O 20 AMP L1 USE COPPER CONDUCTORS ONLY FOR FIE
227. w York 10913 FAX 845 580 8090 N WARNING N 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 CHAPTER 2 MUST BE COMPLETED BEFORE ATTEMPTING TO START THE UNIT 4 2 TOOLS AND INSTRUMENTATION 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 OMM 0097 0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 51 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 4 INITIAL START UP 4 2 1 Required Tools amp Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit Digital Combustion Analyzer Oxygen accuracy to 0 496 Carbon Monoxide CO and Nitrogen Oxide NOx resolution to 1PPM e 16 inch W C manometer or equivalent gauge and plastic tubing e 1 4 inch NPT to barbed fittings for use with gas supply manometer or gauge e Small and large flat blade screwdrivers e 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 downst
228. wired incorrectly Defective Power Supply Board or fuse Defective IGST Board 2 e If the Air Fuel Valve does rotate to the ignition position check the purge switch for continuity between the N O and COM terminals If the switch shows continuity when not in contact with the cam check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch Check DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED 051 and verify it is blinking ON amp OFF every second If not replace IGST Board PRG SWTCH OPEN DURING PURGE 4 Defective purge switch No voltage present at switch Switch wired incorrectly Defective Power Supply Board or fuse Defective IGST Board If the air fuel valve does rotate check purge switch for continuity when closing Replace switch if continuity does not exist Measure for 24 VAC from each side of the switch to ground If 24VAC is not present refer fault to qualified service personnel Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals Check 051 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST B
229. xternal gas supply regulator as shown in Figure 2 7 is highly recommended No regulator is required for gas pressures below 7 W C of pressure Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator GAS PRESSURE REGULATOR NATURAL GAS SUPPLY NATURAL GAS INLET 2 MANUAL SHUT OFF VALVE Figure 2 7 Manual Gas Shut Off Valve Location 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 AERCO for more information OMM 0097_0D AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 23 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION 2 9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide GF 2060 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 8 Loosen the two upper screws of the Power Box cover and remove cover to access the internal connections shown in Figure 2 9 Figure 2 8 Power Box Location with Co

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