Home

01-Airco BMK 750 IOM

1. 23 2 8 3 1 Massachusetts Installations Only 23 2 8 3 2 All Installations Except 15 23 2 9 AC ELECTRICAL POWER WIRING l eene enne nnne sten 24 2 9 1 Electrical Power Requirements 25 2 10 FIELD CONTROL WIRING u 26 2 10 1 OUTDOOR AIR IN Terminals eese sees eene ener sternere innen seen 28 2 10 2 COMBUSTION AIR Terminal 29 2 10 3 0 SENSOR eue ae be Ue ee Cu 29 2 10 4 SPARK SIGNAL Terminals l s y ss ene enne nein A 29 2 10 5 ANALOG IN te o deese venen eee 29 2 10 6 B M S PWM IN Terminals seen ener enne nnne 29 2 10 7 SHIELD Tebmitials reet m EH ERE asss 29 2 10 8 ANALOG OUT Termiinals eerte eere rie netten eae o rae n Eod nob ERE e e 30 2 10 9 RS485 Comim Terminals 30 2 10 10 RS 232 Comm Terminals atv eleg
2. 75 CHAPTER 6 SAFETY DEVICE TESTING J 77 6 LTESTING OF SAFETY DEV GES e acts dee e eg uade 77 6 2 LOW GAS PRESSURE FAULT 5 78 6 3 HIGH GAS PRESSURE TEST 79 6 4 LOW WATER LEVEL FAULT 80 6 5 WATER TEMPERATURE FAULT 5 81 6 6 petet ee e ere de te ed ua u dn 82 6 6 1 Remote Interlock Test eor E i er ern dco Re diva ne e i Rh adeo 82 6 6 2 Delayed Interlock Test nre et T sees 82 6 7 FEAMERFAULT TESTS ce cese cente e Gere eme de ee area ce Gens amena e ea Nan a wa 83 6 8 AIR FLOW FAULT TESTS ee etc tee 84 6 8 1 Blower Proof Switch Testi uuu k een ee cin oe een eh ca Re diva 84 6 8 2 Blocked Inlet SWitch Test cec ener ete ee oh need he epe aaa aa aS 84 6 9 SSOV PROOF OF CLOSURE 5 86 6 10 PURGE SWITCH OPEN en nennen a e 87 6 11 IGNITION SWITCH OPEN 87 6 12 SAFETY PRESSURE RELIEF VALVE 5 entes sten 88 CHAPTER 7 MAINTENANCE
3. 56 4 2 2 Installing Gas Supply Manometer 56 4 2 3 Accessing the Analyzer Probe Port 57 4 3 NATURAL GAS COMBUSTION 2 2 00 00000 0 000001 1000000000000000000000000000 00 58 4 4 PROPANE COMBUSTION 61 4 5 REASSEMBLY AFTER COMBUSTION 64 4 6 OVER TEMPERATURE LIMIT 5 5 1 2020 0 2 0 0 080 enne 65 4 6 1 Digital Alarm Switch Checks and Adjustments 66 CHAPTER 5 MODE OF OPERATIONN J J 69 5S LINTRODUCTION l uD ua a 69 5 2 INDOOR OUTDOOR RESET 69 5 2 V E GS 69 5 2 2 Building Reference Temperature uu uu Run 69 5 2 3 Outdoor Air Temperature Sensor Installation 69 5 2 4 Indoor OutdoOr Start p ttr tee ie tee a E o Pa ah usasqa 70 5 3 CONSTANT S
4. u 117 CLER 117 9 1 1 Aquiring the PUTTY Application 117 9 1 2 Logging on to a Remote Machine Using PuTTY 117 9 1 3 Running a Command on a Remote Machine Using PuTTY 118 9 2 RS 232 COMMUNICATION 5 nnne 119 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 5 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 9 3 MENU PROCESSING UTILIZING RS 232 10 0000000001 00 100000000 119 S apr uw scc icem 120 PEUT 120 9 4 2 Operation Time dea aee e dee ave uu ain des 121 9 24 3 Sensor LOB ee ra aped ea ape cre pasu n 122 CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 123 TO T INTRODUCTION coton ee edo t rete tree d e coat re alien tet tele ea ede R d eee dena 123 10 2 AERCO BST Quick Start Chart 6 rentrer tree eva dead cvs de ee eine 124 10
5. Lo Moua _ SSVdAH Q 3715 3NH Alddns E dau SS3ud dri 3XvW W3l1SAS SIN3NOdWOO NOISNVdX3 dO NOILVOO WOIdAL 3ATVA 38019 Q3ZIHOLON WALSAS ONILV3H Nana 3OIVH3N39 015 OILS3AWOQG WOMJ NANOJ SN iN N 1100 NOlVH3N39 39vsOlS OlIS3AOd OL AlddNS 3ATVA 33134 Drawing Number SD A 874 rev C AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 174 of 192 05 21 2014 Ph 800 526 0288 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX C MORE WIRING DIAGRAMS APPENDIX I C MORE WIRING DIAGRAMS CONTROL BOX CONNECTIONS 9 PIN CONNECTOR 16 PIN CONNECTOR 19 PIN CONNECTOR 7 PIN CONNECTOR 16 15 14 131211109 8 7 6 5 4 17 16 15 14 13 12 11 10 9 EXHAUST HEADER INLET OUTLET TEMP TEMP TEMP TEMP SENSOR SENSOR SENSOR SENSOR CIRCULATOR BLOWER PROOF SWITCH WATER LEVEL PROBE LOW GAS PRESS SW HIGH GAS PRESS SW SAFETY SHUTOFF VALVE PROOF OF CLOSURE SWITCH IGNITOR JUMPER WIRE 18 AERCO P N 63145 POWER BOX GROUND TERMINALS HOT WATER TEMP T C SENSOR BLOCKED AIR INLET SW FLAME ROD 136 R TO VO BOARD TO SEQUENCEING S7PIN2 VALVE HARNESS 63155 x 123456789 04 613 CANL DIGITAL TEMP CONTROL MANU PEST ARE MES _514 i OV
6. Meaning or Acronym INTLK INTL K Interlock Input Output Box Input Output VO Box currently used on Benchmark Innovation and KC1000 Series products IP Internet Protocol IBI Industrial Risk Insurers A 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 1 thousand of an ampere MAX Max Maximum MIN Min Minimum A serial half duplex data transmission protocol developed by AEG Modbus amp enfe P P Normally Closed NO N O Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O D Outside Diameter Board A Primary Micro Controller PMC board is contained in the C More Control Box used on all Benchmark units 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 or EIA 232 the RS 232 Standard RS 422 A standard for serial full duplex FDX transmission of data based on or EIA 422 the RS 422 Standard RS 485 A standard for serial half duplex HDX transmission of data based on or EIA 485 the RS 485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield SSOV Safety Shut Off Valve TEMP Temp Temperature OMM 0082_0J AE
7. OUT OF RANGE The O gt has gone below 3 or above 8 Page 146 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 PRG SWTCH CLOSED DURING IGNITION The temperature measured by the Outlet Sensor is out of range e OUTLET TEMPERATURE display SHt Indicates sensor is shorted OUTLET TEMPERATURE display Opn indicates sensor is open circuited The Purge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL The Flame signal was seen for more than 60 seconds during FLAME standby SSOV SWITCH OPEN The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during purge SSOV FAULT wm DURING IGN The SSOV switch closed or failed to open during ignition SSOV FAULT The SSOV switch closed for more than 15 sec
8. 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 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 O 1 15 02 5 21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 O 1 15 02 5 16pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 O 1 15 02 5 11pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 06pm Page 122 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 1 INTRODUCTION The C More on board Boiler Sequencing Technology system BST 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 the 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 boiler
9. during boiler operation Page 180 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX K C MORE CONTROL PANEL VIEWS APPENDIX K C MORE CONTROL PANEL VIEWS CONNECTOR BOARD P N 124366 LOW WATER CUTOFF BOARD P N 124363 PMC BOARD P N 124364 DISPLAY BOARD P N 124365 2 T W f lt q NS Za AA EN s e A M N 42 e O A n 5 L3 GREEN LED q S X P N 124948 3 X Sk DI ROCKER lt OS cx WES DISPLAY POWER SUPPLY BOARD Qr MODULE P N 124362 s P N 124527 IGNITIONSTEPPER BOARD eI FISH PAPER PN 12496 INSULATOR P N 124960 9 s 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 181 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX K C MORE CONTROL PANEL VIEWS INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX SHELL HARNESS CONNECTOR 19 PIN
10. 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 5 of 6 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 165 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS AERCO International Benchmark 750 1000 Part List 03 07 2014 Inc Blauvelt NY 10913 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 6 of 6 Page 166 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS Benchmark 750 1000 FM Gas Train 22140 1 rev E Item Qty Part Description Item Oty Part Description 1 1 95026 1 25 NPT 125 THREADED FLANGE 17 1 92006 5 VALVE BALL 1 NPT 2 1 93046 ELBOW 45 MOD DEG 1 B I 1508 18 1 94028 5 00 NIPPLE 1 NPT TBE X 5 00 LG 3 1 92036 VALVE SSOV 1 NPT 19 1 94028 3 50 NIPPLE 1 NPT TBE X 3 50 LG 4 1 69005 ACTUATOR SSOV W REGULATOR 20 1 12609 10 8 1 1 4 x 1 HEX RED BUSHING 5 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 21 3 9 222 ELBOW 90 lt MOD DEG gt 1 M I 6 2 12951 2 BUSHING CONTROL BOX 22 1 93364 TEE1X1X 1 2 NPT 7 1 61002 1 PRESSURE SWITCH 2 6 W C FALL 23 1 123311 BUSHING REDUCING 1 2 NPT X 1
11. Item Qty Part Description Item Qty Parts Description SHEET METAL PANEL ASSEMBLY OTHER ACCESSORIES PARTS SEE TABLE 70 1 37110 PANEL LEFT 85 1 A 3 4 CLOSE NIPPLE SEE TABLE 71 1 37111 PANEL RIGHT 860 1 A PRESS TEMP GAUGE SEE TABLE 72 1 37114 COVER ASSY 870 1 A PRESSURE RELIEF VALVE KIT 73 1 25068 ASSEMBLY FRONT PANEL 880 1 92006 5 VALVE BALL 1 NPT 74 1 25078 ASSEMBLY FRONT PANEL 89 1 122843 LOW WATER CUTOFF 75 1 72068 LABEL DOME 90 1 123863 VALVE BALL 1 8 NPT 76 2 59179 HANDLE CONCEALED PULL 91 1 92094 VALVE 3 4 BOILER DRAIN MNPT x GHT 77 2 59133 LATCH COMPRESSION 920 1 59043 CONDENSATE FLOAT 78 1 50010 LATCH DRAW 930 1 24060 COND TRAP ASSEMBLY 79 1 50011 KEEPER DRAW LATCH 94 1 59178 VENT AIR 1 8 NPT 1 74023 LOGO LABEL BMK 1000 95 1 124008 NIPPLE 1 8 NPT X 3 00 LG 80 MOTORIZED SEQUENCING ISOLATION 74026 LOGO LABEL BMK 750 100 0 1 92084 6 VALVE OPTIONAL 81 4 123621 BOLT HEX HD 1 4 20 X 50 LG 1010 1 63150 HARNESS FLAME ROD 82 1 39125 ADAPTER AIR INLET 6 PVC NOTES NOT SHOWN ON DRAWINGS BELOW TABLE A Available in Item 85 Item 86 Item 87 Kit Number Description 9 234 69087 2 92015 1 58037 1 30 PSI Kit Apollo NOT REQUIRED 69087 2 92014 58037 2 50 PSI Kit Conbraco 9 234 69087 3 92015 20 58037 3 75 PSI Kit Apollo 9 234 69087 3 92015 15 58037 4 100 PSI Kit Watts 9 234 69087 4 123659 58037 5 150 PSI Kit Watts 9 234 69087 3 92015 13 58037 6 60 PSI Kit Watts 9 234 69087 3 92015 16 58037 7
12. OUTDOOR TEMP SENSOR FAULT 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 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 6 OUT OF RANGE 1 Combustion Calibration incorrect 2 Blocked inlet air duct or louver Check Combustion Analyzer and recalibrate Boiler Unblock air inlet and measure open area for combustion air to the room Page 110 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 RESIDUAL FLAME 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 1 Defective Flame Detector 2 SSOV not fully closed 1 Check I O Box to ensure signal is hooked up Hook up if not
13. SVD LVN LdN l NNOO 131100 Y3LVM LOH BSONVI4 OSL 8 MO vo cc vs 1331S NOBNVO 1 113 8 SS6tv 6vZ VS 560 X 0 0 91 6 19315 5531 15 53801 5566 0 0 513315 SS3INVIS t l 133HS38nl 83 01 556 0 0 513315 SS3TNIVIS 9 1 133 538 1 5566 0 2 513315 SS3INIVIS 1 NOISNVdX3 047749 915 513315 1 0 3 556 0 0 5 13316 SS3INIVIS v L M3NNI TI3HS NOILSQBWOO 8 49 S VS 1331S NO8MVO v 1 M31n0 TI3HS NOILONYLSNOD 30 SIVIH31VN 3OLLON HOlMd LNOHLIM SNOISN3WIQ 431108 AJIQOW OL 1H9lM JHL S3AM3S3H OOMN3V 9v 1 AV 1dSIGQ T3NVd OMINOO NOLLO3NNOO gt 19313 v 64 ez rz9 oe vz 2481 131nO 1SnvHX3 9 Drawing Number AP A 891 rev F AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 157 of 192 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS LL8 v QS M ME 110160 Ud A8 12 LINN d ONIS 1 Gauls SVO 0001 OSZ oHVWHON38 Twnouwneain 8 2 831 3OLLON YOld SNOISN3WIG X31108 AJIQOW OL 1HOlM AHL S3AH3S3H OOV SIIVI3O 04 v400 GlL SNOLLONYLSNI ANVL 3IVSN3QNOO 33S 40014 JHL 3AO8V NVHL M3H9IH G3IVA313 38 LS
14. 31VSN3QNOO 33dOMd YOA NAZMVALNAN 31VSN3GNOO OONSV ONISN N3HM 4 NOLIVTIVISNI LINN 319NIS 5521 MO O M OL NMOQ 3BnSS3Nd SVO ONIN OL INTIVA JJOLNHS NDNVA JO WW3HISNMOQ Qld SVO XON MOT 38 5 MOlvin93H 31415 d 4001 V vL NVHL M3lVdM9 SI 34055384 SVO 318V VAV N3HM 9 HE 0006 OL OG MNVAHON3H 1105 02 GINOHS 53000 7 201 NIMVYA NOLLVTIVISNI TVOIdAL V SI SIHL 6 STANVd 3015 WOMJ 9 36 qTnOHS S3XO8 LINGNOD S3HOlIMS 3014435 SNOLLOSNNOO OlMIO3T3 mM qorpa 35 ANY SN3AOO ST3NVd 331IO8 3ON3N3JM3INI IN3A3Md OL SONILLIJ ONI IVNOLLVNHSINI 9 jO WNWININ v 913 SMOHT3 SNOINN 9 SONILLIS 137100 LIINI H31VM 31V901 F AMOLOVS IN3AdIHS NI AT31vaivd3S IHY SW3l 53002 1 201 AdWOO ISNW 331135 ONldld 30014 IN3IN3ANOO V OL ALIAVHO AG ATIY OL SANNA llNM3d OL Q39NvHV 5 dVHL NIVMO 31VSN3QNOO TIBHS Z ONIMVMQ TWNOISNAWIG 33S 43108 OL SNOLLO3NNOO 33HIO QNY 9Nldid jO SNOILVOO1 53215 1 SALON W31SAS ONILVAH NNOO ze dn errs dvMlL Adds wea a 05 21 2014 Page 171 of 192 Benchmark 750 1000 Boiler Installat
15. BST Setpt HI Limit 609 BST Setpt Limit BST Setpt Lo Limit 2209 1959 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 BST Reset Ratio 0 1 9 9 1 2 System Start Tmp 30 F 120 F 60 F BST COMM MENU Disabled Enabled Disabled OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 49 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION Menu Display Available Choices or Limits 3 10 START SEQUENCE Minimum Maximum 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 Err Threshold 1 9 5 SSD Temp Format Degrees Points Degrees BST Upld Timer 0 9999 sec 0 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 Safety Shut Off Valve SSOV Proof of Closure POC switch Low Water Level switch e High Water Temperature switch e High Gas Pressure switch e Low Gas Pressure switch e Blower Proof switch e Blocked Inlet switch If all of the above switches are closed the READY light above the ON OFF switch will
16. above the floor See Condensate Tank instructions in TID 0074 for details After unpacking and inspecting the boiler remove the four 4 lag screws securing the boiler to the shipping pallet The boiler can be lifted and moved by inserting forklift tines in the front slots provided in the base of the unit or it can be lifted by attaching a lifting bar to the unit s heat exchanger A lifting bar 59174 with attaching hardware is supplied with each unit When shipped this bar is attached to the rear of the unit as shown in Figure 2 2 View A One 1 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 17 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION lifting tab is provided at the top of the unit s heat exchanger as shown This tab is used to attach the lifting bar to the unit as follows Z WARNING Z WHEN LIFTING OR MOVING THE BOILER e DO ATTEMPT TO MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER e WHEN USING THE LIFTING TAB AND BAR ENSURE THERE IS NO LOAD PLACED ON THE GAS TRAIN OR BLOWER Attachment of Lifting Bar Remove the lifting bar from its shipping location at the rear of the unit Figure 2 2 View A Retain the attaching hardware consisting of two 2 hex head cap screws hex nuts and flat washers Remove the top shroud from the boiler by grasping the handle on the top of t
17. 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 header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header 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 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 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
18. Contact Relay Terminals Supplied by Others N POWER PUMP S FROM H INDEPENDENT FUSED CIRCUITS Heating Pump USE COPPER CONDUCTORS ONLY FOR FIELD WIRING iu BMK PUMP mud RELAY PUMP RELAY WIRE CONNECTIONS CONTACT DRY SPDT CO Tan RES 277VAC 28VDC WHT BLK WIREs182 H 9120240VAC WHT YEL WIRE 184 N 489V A PLOT DUTY 77 VAS ORANGE N O IYELLOW COMMON BLUE N BMK PUMP RELAY LABEL Figure 2 15 Identifying the Presence of Pump Relay Option 69102 2 15 SEQUENCING ISOLATION VALVE INSTALLATION All Benchmark units are shipped with a connection for an optional motorized external sequencing isolation 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 boilers 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 When operated with the BST system the Master controls its own isolation valve and sends signals to the slave units to open or close their isolation valves After the boiler load is satisfied Page 34 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Insta
19. s 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 System Shutdown Page 48 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION Available Choices or Limits GF 130 Ph 800 526 0288 Menu Item Display TES WE Default One Boiler Mode Off OR oue Onaga Temp Off Temp 1 Threshold 10 35 25 Setpoint Setback Disable Enable Disable 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 15 F ao 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 Disabled Enabled Disabled BST Temp Hi Limit 40 2109 2109 BST Setpt Lo Limit 40
20. OPERATION 6 Up to 7 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 7 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 8 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 3 11 START STOP LEVELS The 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 Start Level 2296 Stop Level 1896 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 750 MBH or BMK 1000 MBH boiler running on natural gas Table 3 8 Relationship Between Air Fuel Valve Position and Energy Input For 750 MBH amp 1000 MBH Units Running On NATURAL GAS En
21. Table 3 6 Combustion Cal Menu Available Choices or Limits Menu Item Display ver p Default Minimum Maximum CAL Voltage 16 1 70 2 20 1 80 CAL Voltage 30 1 90 3 50 3 20 CAL Voltage 45 2 60 4 40 3 70 CAL Voltage 60 2 70 4 50 3 80 CAL Voltage 80 3 60 4 40 4 60 CAL Voltage 100 4 80 6 20 6 00 SET Valve Position 0 100 Variable Blower Output Monitor Blower Output Voltage Set Stdby Volt 0 4 00 V 0 2 00 V Oxygen Level 0 25 Variable 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 1 BST Monitor Items BST SETUP MENU OPERATE MENU TEMP CTRL MENU BST COMM MENU eoe pr N These displayed item groups are displayed in UPPER CASE letters and are bounded by an asterisk in order to readily identify them within the item list OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 47 of 192 GF 130 Ph 800 526 0288
22. 145 158 171 184 197 210 150 164 178 192 206 155 170 185 200 2s JT teo 17e 192 208 j t 148 165 189 t2 1 18 92 100 104 108 112 116 120 124 128 132 136 140 144 cO 00 e 992164 Co NJN 9l 3 nim 5 C AR OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 153 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX D INDOOR OUTDOOR RATIO CHARTS Table D 7 Header Temperature for a Building Reference Temperature of 90F 90F 90 90 90 90 90 90 90 90 90 85F 93 94 95 96 97 98 99 100 101 102 80F 96 98 100 102 104 106 108 110 112 114 75F 99 102 105 108 111 114 117 120 123 126 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126 132 138 144 150 156 162 55F 111 118 125 132 139 146 153 160 167 174 50F 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
23. 5 53002 7 201 SNIMVHO NOLVTIVISNI IVOIdAL V SI SIHL S STANVd 3015 WOM 9 35 TInOHS S3XOB8 SSHOLIMS 39IAM3S SNOLLO3NNOO JALOTA CNV ONidid SN3A00 STSNVd N3108 TVAOW3H 3ON3N34H31N IN3A3Bd OL SONILLI WONJ 9 JO WNWININ 513 SMOGT3 SNOINN 791 SONILUA 1570 LIINI 33IVM AMOlOvd WON IN3AdIHS NI ATilvavdis 34v SA3L Tv 53002 7 201 AdWOO ISAW 3ATVA J3IT3H 40 ONldld 3O014 V OL A8 AT3384 OL 501114 OL 38 5 31VSN30NOO 3ATVA NIVA TT3HS Z ONIMVHO TWNOISNAWIG 335 3108 OL SNOLLOSNNOO 33H10 9Nidid JO SNOILVOO1 53715 TVniOv 1 SALON E ous LdN 3A AlddNS WALSAS lV 34 SSdHd SVO WDMWINIA NIVLNIVA SNLLV3H YH NLE WRWIXVA LV Drawing Number SD A 869 rev B AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J Page 173 of 192 05 21 2014 Ph 800 526 0288 GF 130 v400 GlL SNOLLONYLSNI 1 3IVSN3QNOO 33S 740014 SHL 3AO8V NVHL O3l1VAdT3 38 ISNA 31VSN3QNOO OOM3V ANY X31104 AHL MO V NI Q3TIVISNI 38 LSNW 1 YAZMVYLNAN JHL 3OVNIVMO 31VSN3QNOO 33dOMd 3O4 NVL N3ZIIVHIRN 31VSN30NOO OOM3V ONISN
24. Each must be individually run to a suitable discharge location OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 19 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION PRESSURE RELIEF VALVE 3 HOT BOILER WATER OUTLET P amp T GAUGE COUPLING Figure2 4 Pressure 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 part no 24060 which is packed separately within the unit s shipping container The condensate trap inlet and outlet connections contain tapped 3 4 NPT ports PRIMARY INTLET DRAIN VALVE EXHAUST MANIFOLD CONDENSATE DRAIN ANALYZER PROBE PARTIAL REAR VIEW Figure2 5 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2 6 However the actual installation details for the trap will vary depending on the available clearances housekeeping pad height dimensions and other prevailing conditions at the site The following general guidelines must be observed to ensure proper condensate drainage e The condensate trap inlet Figure 2 6 must be level
25. 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 609 Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint Lo Limit to 210 F Default is 140 F Temp Hi Limit Max Valve Position 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 Sets the maximum allowable valve position for the unit 4096 to 10096 Default is 10096 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 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 141 of 192 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION CONFIGURA
26. 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 Box and locate the REMOTE INTL K IN terminals 2 Start the unit in the Manual Mode and set the valve position between 25 and 30 If there is a jumper across the REMOTE INTL K IN terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock 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 5 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 Box and locate the DELAYED INTL K IN terminals 2 Start the unit in the Manual Mode at a valve position between 25 and 3096 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 in step 3 to restore the interlock Press the CLEAR button to reset the fault 7 The unit sh
27. e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual LIMITED WARRANTY BENCHMARK 750 6000 GAS FIRED BOILERS LIMITED WARRANTY BENCHMARK 750 6000 GAS FIRED BOILERS PRESSURE VESSEL HEAT EXCHANGER 10 YEAR NON PRORATED FROM SHIPMENT The pressure vessel heat exchanger shall carry a 10 year non prorated limited warranty from date of shipment against any condensate corrosion thermal stress failure mechanical defects or workmanship Operation of the boiler using contaminated air will void the warranty The pressure vessel heat exchanger shall not be warranted from failure due to scaling liming corrosion or erosion due to water or installation conditions AERCO will repair rebuild or exchange at its option the pressure vessel heat exchanger C MORE CONTROL PANEL 2 YEARS FROM SHIPMENT AERCO labeled control panels are conditionally warranted against failure for 2 two years from shipment OTHER COMPONENTS 18 MONTHS FROM SHIPMENT All other components with the exception of the igniter and flame detector are conditionally guaranteed against any failure for 18 months from shipment The warranty as set forth on the back page of the Operations amp Maintenance Manual is in lieu of and not in addition to any other express or implied warranties in any documents or under any law No salesman or other representative of AERCO
28. e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 750 MBH or 1000 MBH boiler 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 view 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 Troubleshooting Instructions 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 condi
29. new Propane combustion calibration section 4 4 modified sections 6 2 amp 6 3 added Propane gas train 22140 3 drawings to Appendix G PIR 934 65 Added explanatory paragraph amp note to section 2 15 Sequencing Isolation Valve Installation Chris Blair AERCO International Inc AERCO International Inc 2014 Page 192 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130
30. or W C gauge where the 1 4 plug was removed Slowly open the leak detection ball valve near the High Gas Pressure switch Start the unit in Manual mode at a valve position firing rate between 25 and 30 With the unit running monitor the gas pressure on 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 in Chapter 4 The unit should shut down and display a GAS PRESSURE fault message and the FAULT indicator should also start flashing at the following approximate pressures BMK 750 amp 1000 NATURAL GAS gas trains 4 7 W C BMK 750 PROPANE gas train 4 7 W C 1000 PROPANE gas train 10 5 W C Reduce the gas pressure back to the value recorded in step 5 This pressure should be within the range of BMK 750 amp 1000 NATURAL GAS gas trains 2 0 W C 0 4 W C e BMK 750 PROPANE gas train 3 9 W C 0 2 W C 1000 PROPANE gas train 7 4 W C 0 2 W C 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 MANUAL SHUT OFF VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH IJ gt SSOV GAS INLET ap 1
31. osos ndun suae rua acce ode aae s 89 7 1 MAINTENANCE SCHEDULE IILI 89 7 2 IGNITER INJECTOR REPLACEMENT eene enne nennen 90 7 3 FLAME DETECTOR REPLACEMENT ccccssscccessecceceeseececeeseneeceeseeeecesseeeeceseeeeecseeeeecseeeeaeeseeeaaeesseenaees 92 TAO SENSOR REPLACEMENT ener eo e Roe eek a ee Rae eere d A 93 7 5 COMBUSTION CALIBRATION cccssccccesssececeesnececeeseeeeceseeeeecsseeeeececeeeeeceseeeeecseeeeaecsseeeaecseseaaeesseeaaees 93 7 6 SAFETY DEVICE TESTING u L u eee etae eaa deese eu eaaet eek a ae eoe De emen 93 7 7 BURNER ASSEMBLY 5 22 4 0 001 eene S 93 7 8 CONDENSATE DRAIN TRAP MAINTENANCE nennen 96 7 9 AIR FILTER CLEANING amp 4 441 0000 00026000000000000000000000000050005050500 98 7 10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME 99 7 11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED 99 CHAPTER 8 TROUBLESHOOTING 101 S LIINTRODUCTION Poe 101 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT 55 6 5 113 CHAPTER 9 RS 232 COMMUNICATION
32. 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 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 Box Use shielded 18 to 22 AWG wire for connections A wiring diagram is provided on the cover of the Box Refer to Chapter 2 section 2 9 1 for additio
33. 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER OPERATION Table 3 1 Operating Controls Indicators and Displays VFD Display ITEM FEATURE FUNCTION LED Status Indicators Four 4 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 1 MANUAL using 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 REMOTE from an Energy Management System DEMAND Lights when there is a demand for heat 3 Digit 7 Segment LED display continuously displays the OUTLET outlet water temperature The F or C LED next to the display TEMPERATURE lights to indicate whether the displayed temperature is in 2 Display degrees Fahrenheit or degrees Celsius The or blinks when operating 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 e Startup Messages e Fault Messages e Operating Status Messages e Menu Selection e BST Messages RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the units Control Panel AERCO offers for purchase the
34. 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 M Displ Defaul Maximum BST Mode Off BST Slave BST Master Off BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130 F Header Temp NA ia BST Fire Rate 0 10096 Fire rate 96 BST Ave Fire Rate 0 100 Avg Po in BST Outdoor Temp NA 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 Constant Remote Outdoor BST Setpoint Mode Setpoint Setpoint 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 Outdoor 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
35. 149 APPENDIX D INDOOR OUTDOOR RESET RATIO 5 151 APPENDIX BOILER DEFAULT 5 65 enne 155 APPENDIX F DIMENSIONAL 5 00 enne ener nter entere 157 APPENDIX G PART LIST 5 8 nns 161 APPENDIX PIPING 65 71 2 21 2 0 000 080 000 0 0000000000000000000000 N 171 APPENDIX C MORE WIRING DIAGRAMS esee enne nnne nnne sten nnns sternere nnns 175 APPENDIX J RECOMMENDED PERIODIC 5 0 nennen enne nns 179 APPENDIX K C MORE CONTROL PANEL 5 1 0020 1 10 enne nennen nns 181 APPENDIX L RECOMMENDED 5 5 183 APPENDIX M ULTRA LOW NOx 2 185 LIMITED WARRANTY l RL l etn eee Eae 189 Page 6 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual FOREWORD The AERCO Benchmark BMK 750 and 1000 MBH Boilers are modulating and condensing units They are a true industry advancement that meets the needs of today s energy and environmental concerns Designed for
36. 2 0 0 4 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 of 2 0 W C 0 4 W C Page 58 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP NATURAL GAS Combustion Calibration Continued BRASS HEAD CAP Remove to access Gas Pressure Adjustment Screw Figure 4 3 Gas Pressure Adjustment Screw Location 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 2 0 W C 0 4 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 Compare the oxygen readings on the combustion analyzer to the on board 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 Os sensor may be defective and need to be replaced Compare the measured oxygen level to the oxygen range shown below Also
37. 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 INTL K Terminals The remote interlock circuit is provided to remotely start enable and stop disable the unit if desired The is 24 VAC and comes factory pre wired closed jumped 2 10 12 2 DELAYED INTL K Terminals OUT amp IN 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 Page 30 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION NOTE Both the Delaye
38. 3 BST Implementation Instruction 125 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header 125 10 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor 126 10 3 3 Option 3 Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor x r n 127 10 3 4 Option 4 Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor 129 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive eter eA A ste EURO oe vue nee ve naa Eu E E E 131 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive i ae Ve Yee e RU 133 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive 134 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive 136 APPENDIX A BOILER MENU ITEM 5 44 0044 0 enne nnns 139 APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES 145 APPENDIX C SENSOR RESISTANCE VOLTAGE CHART eren nnn nnn nnn nennen
39. 4 NTP PLUG 5 Install HIGH GAS PRESSURE LEAK F p for i Gas DETECTION BALL VALVE ressure Test Figure 6 1B High Gas Pressure Test Natural Gas gas train shown OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 79 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 Test 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 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 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
40. 7 lt 9 lt 100 Valve Position Oxygen O If the oxygen level is not within the specified range adjust the level using the A and V 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 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 60 45 30 and 1896 see NOTE below The oxygen O nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table NOTE Set the Valve Position at 1896 but make adjustments to the Combustion Calibration value designated as 16 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 187 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX M ULTRA LOW NOx CALIBRATION Ultra Low NOx Natural Gas Combustion Calibration Continued NOTE If NOx readings exceed the target values shown 9 ppm increase the level up to 1 higher than the listed calibration range shown in the table Record the in
41. Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP PROPANE Combustion Calibration Continued 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 above 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 100 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 80 60 45 30 and 18 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 level up to 196 higher than the listed calibration range Record the increased value on the Combus
42. CHAPTER 4 INITIAL START UP PROPANE Combustion Calibration Continued 27 Once the oxygen level is within the 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 28 Repeat steps 20 through 27 for valve positions of 6096 45 30 and 18 see below The oxygen Oz nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table NOTE Set the Valve Position at 18 but make adjustments to the Combustion Calibration value designated as 16 NOTE If NOx readings exceed the target values shown 30 ppm increase the level up to 196 higher than the listed calibration range shown in the table Record the increased O value on the Combustion Calibration sheet Propane Combustion Calibration Readings a Nitrogen Oxide Carbon Monoxide Valve Position Oxygen 02 NOx CO 60 5 6 lt 30 ppm lt 100 ppm 45 5 6 lt 30 ppm lt 100 ppm 30 5 8 6 8 lt 30 ppm lt 100 ppm 18 5 6 lt 30 ppm lt 100 ppm 29 If the oxygen level at the 18 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 Appendix G Rotate the screw 1 2 turn clockwise CW to add fue
43. Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Quiput CAUTION DO NOT Ch ange Lo Fire Timer 2 sec OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 155 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX E BOILER DEFAULT SETTINGS BOILER DEFAULT SETTINGS Continued MENU amp OPTION FACTORY DEFAULT Configuration Menu Cont Setpt Limit Band If Setpt Limiting BT Enabled 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 156 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS APPENDIX F DIMENSIONAL DRAWINGS 110150 YOT A8 IVNOISN3NIG 431l08 03415 SVD XON 0001 05 NVWHON38 6160 AN ONI IVNOLLVNH3LLNI 2 lt 96 9 sz9 lt 9 2 sev LONG 9 dW3l 2 NNOO M31VM JONVI4 091 WNOILdO 331VM 0709 39Nv1j OSL 60611 os ic NNOO 13 NI 3NvdONd LdN 2 1
44. Features Connection type Features Configure the serial line B Window Tenet Rlogin SSH Serial Window Speed baud 9600 i Appearance i i Load save or delete a stored session Poi Data bits 8 Translation Saved Sessions Translation Stop bits 1 Party i Colours Default Settings Load amp Connection B Connection Flow control XON XOFF gt Data Save Data Proxy Proxy i Telnet Delete Telnet Rlogin Rlogin SSH SSH H BI Serial sag Close window on exit Aways Never Only on clean exit Figure 9 1 PuTTY 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 eft image of Figure 9 1 but will allow you to specify the serial line to use if your computer has more than one and what speed baud rate to use when transferring data For further configuration options data bits stop bits parity flow control you can use the Serial Configuration panel right image in Figure 9 1 by selecting Serial in the left navigation pane OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauve
45. GAS TRAIN HARNESS CONNECTOR 9 PIN AIF VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX SENSOR HARNESS CONNECTOR 7 PIN Figure K 2 Benchmark Control Panel Rear View Page 182 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 05 21 2014 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX L RECOMMENDED SPARES APPENDIX L RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix G 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 Single Phase Blower 58061 SSOV Actuator Regulator Combo Used on 64048 e ALL FM gas train models Downstream SSOV of IRI gas train models SSOV Actuator Without Proof of Closure Switch Used 69038 on e Upstream SSOV of IRI gas train models Temperature Switch Manual Reset 123552 Staged Ignition Assembly 24277 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 08 Table L 3 Optional Spare Parts DESCRIPTION PART NUMBER C More Control Box 181197 Burner 46023 Lean Oxygen Sensor 61026 Temperature Sw
46. ISNW dvML 31VSN3Q0NOO OOM3V 33708 AHL YO V NI Q3TIVISNI 38 1SQA INVL YSZMVULNAN 3OVNIVMO 3IVSN30NOO N3dOMd YAZMVYLNAN 31VSN30NOO ONISN NAHM 4 5541 OL NMOG 34055144 SVD JHL OL SATIVA JJOlnHS TWANVW 3Hl 20 Q3TIVISNI 38 5 NOIVIhO3N 31415 d 4001 V FL NVHL MilV3NO SI 3unsS3Hd SVD 318VjJNAV N3HM 9 3 1 5 02 38 5 5 ANY 53002 1 201 STANVd 3015 WOMJ 9 38 3 lt 100 6 S3XO8 LINGNOO SAHOLIMS 39IAM3S SNOLLO3NNOO 21419313 ONIMVHO NOILVTIVISNI WOIdAL V SI SIHL S ONidid TIY 553 00 STANVd 831108 430 VAOW3H HUM SONSYSSYSLNI IN3A3Hd OL SONILLIJ WONJ 9 JO WnWINIA v 013 SMOHT3 SNOINN e SONILLIA 131100 INI YSLVM 31V901 AMOLOV IN3AdIHS NI ATALVEVdSS GSGNIONI 38v SW3ll 513402 WOOT HLM AdWOO ISNW 3AA 43134 JO ONidid NiVMO YOO IN3INJANOO V OL ALIAVMO AT3384 OL SAINTA liWH3d OL GASNVYYVY 3H GInOHS NIVHO 31VSN3QNO2 JAYA TT3HS 2 ONIMYMQ IVNOISN3AIQ 33S 44108 OL SNOLLO3NNOO M3HIO ONIdid 40 5 01 201 53215 TWNLOW S310N T E LdN AlddNS WALSAS ONILVAH CdAL 3ATVA 33133 Drawing Number SD A 868 rev B GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 O
47. N3HM 9 831115 02 38 5 5 53002 1v901 ONIMVYC NOLLVTIVISNI TVOIdAL V SI SIHL S SHNvd 3015 WOMJ 9 38 3SIM3MIT qinoHs 53 08 LINAGNOD SAHOLIMS 3OIAW3S SNOLLO3NNOO OhIOTT3 ONIdid SH3AOOD NV STANVd 431008 40 IVAOW3M 3ON3334831INI INd3Ad8d OL SONILLI amog WO4 9 JO WNWININ v 013 SMOHT3 SNOINN 791 SONILUS 131100 LAINI S31VM 31V201 AMOlOV4 LNANdIHS NI AT3IVMNVd3S QJANIONI 33V SWALI x TY 3AO8V LHOISH V V OL ATIVOLIM3A Cadid 38 Q1n0HS SIAYA 431144 NIVHO MOO14 IN3INJANOO V OL ALIAVHO AB AT3334 OL Sairri4 JHL llAM3d Ol GAONVYNV GINOHS 31VSN30NOO 3ATVA TT3HS 2 ONIMVHO NNOISN3AIQ 33S 431108 OL SNOLLO3NNOO YSHIO ANY JO SNOILVOO1 ANY S3ZIS 1 304 S310N 2 728 05 A38 1 001 3198 lNVId OILS3WOQ SNILV3H NOLNVNIBAOO 304 LNOAV 44108 AAAI Sv9 HEN 000 0 064 MYVNHONAG our roD VARIA 2247 7 V W3lSAS SNILVSH OL AlddNS 3NTVA YOLVEVdAS GF 130 OMM 0082 0J Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX PIPING DRAWINGS YOSNAS ANAL J3d0v3H SWE Eonvo AATWA_ONIONY va 281 39NV H 0 1051 NIVMIS A YN NOISNVdX3 WOVYHdVIG
48. 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 PuTTY Configuration 9 Options controlling SSH connections Data to send to the server Remote command Protocol options Dont start a shell or command at all Enable compression Preferred SSH protocol version Olony O1 92 2only Encryption options Encryption cipher selection policy AES 55 2 only Blowfish 3DES wam below here Arcfour SSH 2 only DES Enable legacy use of single DES in SSH 2 Figure 9 2 PuTTY GUI Basic SSH Options for Running Remote Commands Into the textbox titled Remote command type the full command line you wish to have executed on the remote machine 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 process Page 118 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION 9 2 RS 2
49. Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 149 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART This Page Is Intentionally Blank Page 150 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX D INDOOR OUTDOOR RATIO CHARTS APPENDIX D INDOOR OUTDOOR RESET RATIO CHARTS Table D 1 Header Temperature for a Building Reference Temperature of 50F RESET RATIO p 60 80 90 100 60 100 Air 50 45 40 35 86 30 98 25 15 113 56 58 6 68 62 66 70 86 68 74 80 113 10F 74 82 90 SF 77 86 95 104 113 122 181 140 149 OF 80 90 100 110 120 130 140 150 160 SF 83 94 105 116 127 138 149 160 171 86 98 110 122 134 146 158 170 182 15F 89 102 115 128 141 154 167 180 193 20F 92 106 120 134 148 162 176 190 204 Table D 2 Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp 60F 60 60 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72
50. 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 80 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 a 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 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 appro
51. 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 A control system developed by AERCO and currently used in all or Control Box Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide COMM Comm Communication BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound of water 1 F Cal Calibration CNTL Control Double Block and Bleed Used to define boiler gas trains containing 2 DBB 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 Hex Hexadecimal Number 0 9 A F HX Heat Exchanger Hz Hertz Cycles Per Second Inside Diameter IGN Ignition IGST Board Ignition Stepper Board contained in C More Control Box Page 8 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Phrases Abbreviations and Acronyms Continued Phrase Abbreviation
52. 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 A 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 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 A 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
53. a 100 valve position When 0 20 mA 0 5 signal is used zero is equal to 0 valve position In addition to the current and voltage signals described above the Direct Drive mode can also be 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 Page 72 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION To enable the Direct Drive Mode the following menu setting must be made in the Configuration Menu Table 5 3 Direct Drive Mode Settings Menu Option Setting Boiler Mode Direct Drive Remote Signal To UA ON 9 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 5 5 1 Direct Drive Field Wiring Th
54. application in any closed loop hydronic system the Benchmark s modulating capability relates energy input directly to fluctuating system loads The maximum turn down ratios for the BMK 1000 and BMK 750 are 20 1 and 15 1 respectively Both BMK models provide extremely high efficiencies and make them ideally suited for modern low temperature as well as conventional heating systems The Benchmark Models BMK 750 and BMK 1000 operate within the following input and output ranges Input Range BTU hr Output Range BTU hr Benchmark Model Minimum Maximum Minimum Maximum BMK 750 50 000 750 000 47750 716 250 BMK 1000 50 000 1 000 000 48300 968 000 The output of each boiler model is a function of the unit s firing rate valve position and return water temperature When installed and operated in accordance with this Instruction Manual the BMK 750 and BMK 1000 MBH Boilers comply with the NOx emission standards outlined in e South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the BMK 750 and BMK 1000 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 are capable of operation in the following vent configurations e Conventional Vertical e Conventional Sidewall e Conventional Direct Vent Vertical Sealed Dir
55. boiler end must be left floating Each unit s wiring must conform to the above 5 6 2 ACS Setup and Startup This mode of operation is factory preset and the ACS controls the firing rate air fuel valve 96 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 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 An AERCO Control System ACS and An optional ACS Relay Box are necessary to configure this system Typically 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 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
56. 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 N WARNING N DO NOT USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS N WARNING N 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 N 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 THERE FORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 11 of 192 GF 130 Ph
57. c 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 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 basic procedure for accessing each data log is described in section 9 3 step 10 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 front 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 50am Page 120 of 192 AERCO International Inc e 100 Oritani Dr
58. change the value or setting of a displayed menu option press the CHANGE key The displayed option will begin to flash Press the A 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 41 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION OPERATIHG LEVEL 1 PWD NL LEVEL 2 PWD COMBUSTION CAL HOT USED IH THIS O amp M SEE GF 112 FOR MEHU ITEM DESCRIPTIONS vx DIAGHOSTICS HOT USED IH THIS O amp M SEE GF 112 FOR MEHU ITEM DESCRIPTIONS Oi gt 5 2 4 Y Only if BST is enabled see Chapter 10 Figure 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 Refer to Appendix B for listings and descriptions of displayed startup status and error messages Page 42 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION 3 4 OPERATIN
59. 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 3 4 Check combustion blower for signs of excessive 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 swi
60. 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 in the I O Box see Figure 2 12 Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG There is no polarity to observe when terminating these wires The shield is to be connected only to the terminals labeled SHIELD in the Box The sensor end of the shield must be left free and ungrounded Page 28 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 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 2 10 2 COMBUSTION AIR Terminal The COMBUSTION 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 Th
61. e Blauvelt NY 10913 Page 51 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION 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 BLOWER PROOF SWITCH BLOCKED INLET SWITCH 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 The Air Fuel Valve rotates to the low fire ignition 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 b The igniter relay is activated and provides ignition spark Current to the spark igniter is monitored for proper level If no spark is present the Controller will stop the ignition process at 3 seconds and shut down the boiler Refer to Chapter 8 Troubleshooting for guidance if this occurs c The gas Safety Shut Off Valve SSOV is energized opened allowing gas to flow into the Air Fuel Valve STEPPER MOTOR Figure 3 6 Air Fuel Valve In Ignition Position Page 52 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3
62. 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 O at 5 596 x 0 596 Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide NOx CO 10096 5 696 20 ppm 100 ppm Valve Position Oxygen 02 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 16 Once the oxygen level is within the specified range at 100 record the NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit 17 Lower the valve position to 80 using the Y arrow key OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 59 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP NATURAL GAS Combustion Calibration Continued NOTE The remaining combustion calibration steps are performed using the Combustion Cal M
63. has any authority to expand warranties beyond the face of the said warranty and purchaser shall not rely on any oral statement except as stated in the said warranty An Officer of AERCO must do any modifications to this warranty in writing AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES AERCO disclaims all responsibility for any special incidental or consequential damages Any claim relating to the product must be filed with AERCO not later than 14 days after the event giving rise to such claim Any claims relating to this product shall be limited to the sale price of the product at the time of sale The sale of the product is specifically conditioned upon acceptance of these terms CONDITIONS OF WARRANTY Should an AERCO gas fired natural gas propane and natural gas propane dual fuel only boiler fail for any of the above reasons within the specified time period from the date of original shipment s AERCO shall at its option modify repair or exchange the defective item AERCO shall have the option of having the item returned FOB its factory or to make field replacements at the point of installation In no event shall AERCO be held liable for replacement labor charges or for freight or handling charges AERCO shall accept no responsibility if such item has been improperly installed operated or maintained as defined in the applicable AERCO O amp M manual or if the bu
64. impingement by the elements The outdoor sensor may be wired up to 200 feet from the boiler OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 129 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler 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 M GND 12VDC Power Supply Temp Sensor PN 61043 Modbus Transmitter I O 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 Address 240 12 Go to the Outdoor Temp Point item and enter the Modbus Point 15 COND Of co When ALL C More units h
65. installed If installed check polarity Measure signal level Check continuity of wiring between source and unit 2 Check signal at source to ensure it is isolated 3 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 1 Replace Flame Detector 2 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 1 Gas Shut Off Valve downstream of SSOV Figure 6 1 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 1 SSOV relay failed on IGST board 1 Press CLEAR button and restart unit If fault persists replace Ignition Stepper IGST Board 2 Floating Neutral 2 The Neutral and Earth Ground are not connected at the source SSOV RELAY and therefore there is a voltage measured between the two FAILURE Normally this measurement should be near zero or no more than a 3 Hot and Neutral reversed at SSOV few millivolts 3 Check SSOV power wiring OMM 0082_0J GF 130 AE
66. not show the required over temperature alarm setting press the A V arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210 F is displayed press the SET button to store the setting in memory 6 To calibrate the offset P1 press and hold the SET button for 8 seconds 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 7 Press the SET button again to enter the code The first parameter label SP will appear in the display 8 Using the A and V arrow keys select parameter P1 9 Press SET to view the value stored in memory 10 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 11 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 12 Once the programming mode has been exited the display will show the current outlet water temperature of the boiler OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 67 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4
67. or Disabled Disabled Bldg Ref Temp If Mode Outdoor 40 2309 709 Reset Reset Ratio If Mode Outdoor 0 1 9 9 1 2 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 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 45 of 192 GF 130 Ph 800 526 0288 05 21 2014 CHAPTER OPERATION Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Table 3 4 Configuration Menu Continued Menu Hem Display aN Choices Default Minimum Maximum Max Valve Position 4096 10096 10096 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 10 F 0 Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt EN 096 10096 3096 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 Spark Monitor Enabled or Disabled Disabled Spark Current Display CAUTION DO NOT CHANGE the Analog Output Menu Item from its Default setting Valve Position 0 10V 3 7 TUNING MENU The Tuning Men
68. requirements the installation shall conform to National Electrical Code NEC ANSI NFPA 70 and or the Canadian Electrical Code CEC Part CSA C22 1 Electrical Code For electrical power wiring diagrams see the AERCO Benchmark Electrical Power Guide GF 2060 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 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 center right portion on the front of the unit directly below the C More Control Panel as shown in Figure 2 11 Page 26 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION C MORE CONTROL BOX BOARD ECU FOR C2 SENSOR TERMINAL STRIPS Figure2 11 Input Output 1 0 Box Location The 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 board NOTE Use Figure 2 12 to determ
69. 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 N ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 77 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING 6 2 LOW GAS PRESSURE FAULT TEST Refer to Figure 6 1A and ensure that the leak detection ball valve located at the High Gas Pressure switch is closed on both the Natural Gas and Propane gas trains Low Gas Pressure Fault Test Remove the 1 4 plug from the leak detection ball valve at the Low Gas Pressure switch shown in Figure 6 1A Install a 0 16 W C manometer or a W C gauge where the 1 4 plug was removed 3 Slowly open the ball valve near the Low Gas Pressure switch Place the unit in Manual Mode and adjust the Air Fuel Valve position 96 open between 25 and 30 5 While the unit is firing slowly close the external manual gas shut off valve 6 The unit should shut down and display a GAS PRESSURE fault message and the FAULT indicator should also start flashing at the following approx
70. the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 137 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY This Page Is Intentionally Blank Page 138 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM 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 D 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 d
71. the DELAYED INTERLOCK IN terminals in the 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 isolation valve to operate normally Find the free end of this cable inside the unit s enclosure Figure 2 14 Sequencing Isolation Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve s connector Page 36 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 N WARNING N 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 UN
72. 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 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Page 136 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 8 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 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 When ALL C More units have been configured 10 Go to
73. the on board O sensor to calibrate the unit Have your combustion analyzer serviced 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 Ultra Low NOx Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide NOx CO 10096 5 7 lt 9 lt 100 Valve Position Oxygen O 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 L 1 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 100 record the NOx and readings on the Combustion Calibration Data Sheets provided with the unit Page 186 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX M ULTRA LOW NOx CALIBRATION Ultra Low NOx Natural Gas Combustion Calibration Continued NOTE The remaining combustion calibration steps are performed using the Co
74. 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 FLAME PROVEN Displayed after flame has been detected for a period of 2 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 WARMUP XX sec Displayed for 2 minutes during the initial warm up only OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 145 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 2 Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof Switch opened during purge DURING PURGE or air inlet is blocked AIRFLOW FAULT DURING IGN The Blower Proof Switch opened during ignition AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run DELAYED INTERLOC
75. turn a pump on off and open close a motorized valve as the boiler cycles on and off on demand The Pump Delay Timer feature allows the user to keep the pump running and keep the motorized valve open for up to 30 minutes after the boiler has shut down and the demand is satisfied The Benchmark pump relay SPDT contact is rated for 10 A Resistive 277 VAC 28 VDC 1 3 HP N O 120 240 1 6 HP 120 240 480 VA Pilot Duty 240 277 If pump valve load exceeds the above contact ratings use a separate contact relay See Figures 2 13 and 2 14 for wiring details To identify if the boiler is equipped with the BMK Pump Relay Option part no 69102 look for the label and relay as shown in Figure 2 15 Orange N O O H Yellow INDEPENDENT FUSED CIRCUITS INBUTDUTPUPEGY 10 A RESISTIVE 277 VAC 28 Optional P mp Relay 1 3 HP N O 120 240 VAC 480 VA PILOT DUTY 240 277 VAC IF PUMP LOAD EXCEEDS THE ABOVE CONTACT RATINGS USE A SEPARATE CONTACT RELAY SEE DIAGRAM 2 1b N EX Heating ES Pump Figure2 13 Schematic System Pump Start using Boiler Pump Relay OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 33 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION Orange N O Yellow COM G INPUT OUTPUT BOX Optional Pump Relay
76. 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 Page 74 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION Only the AERCO Control System ACS is necessary to configure this system if only a single valve is 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 se
77. 082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 123 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler 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 Complete section 10 3 3 Outdoor Air 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 124 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 0082 0 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler CHAPTER 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 Wirin
78. 0913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 1 SAFETY PRECAUTIONS 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 of the unit The installer must identify the emergency shut off device 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 the Commonwealth and where the side wall exhaust vent termination is less than s
79. 1 10 9 8765 glama amp BRR amp ia SENSOR COMMON IN AIR AUX SENSOR IN FLOW SENSOR IN SENSOR EXCIT 12 VDC ANALOG IN BMS PWM IN ANALOG OUT R 485 IN GND RS 232 TxD IN RS 232 RxD z o 2 z s a s lt a E 2 o RELAY NOT USED o EXHAUST TEMP TM ow O REMOTE INTLK DELAYED INTLK INPUT OUTPUT BOX S 3 8 o 5 D SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX 63156 6 PIN CONNECTOR SEQ VALVE ACTUATOR CONTROL CABLE 63155 THIRD ANGLE PROJECTION our NHERNANDEZ owe 9 19 11 INTERNATIONAL INC M WIRING SCHEMATIC 120 VAC 60 Hz BMK 1000 amp 750 BOILER 68038 SEE SHEET OF 2 SHEET 20F 2 Drawing Number 68038 rev E Sheet 2 of 2 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 177 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX 1 C MORE WIRING DIAGRAMS This Page Is Intentionally Blank Page 178 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX J RECOMMENDED PERIODIC TESTING APPENDIX J RECOMMENDED PERIODIC TESTING Periodic testing of
80. 125 PSI Kit Watts 9 234 69087 4 92015 23 58037 8 160 PSI Kit Kunkle AERCO International Benchmark 750 1000 Part List 03 07 2014 Inc Blauvelt NY 10913 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 2 of 6 Page 162 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS FRONT VIEW AERCO International Benchmark 750 1000 Part List 03 07 2014 Inc Blauvelt NY 10913 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 3 of 6 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 163 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS AERCO International Benchmark 750 1000 Part List 03 07 2014 Inc Blauvelt NY 10913 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet4of6 Page 164 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS AERCO International Benchmark 750 1000 Part List 03 07 2014 Inc Blauvelt NY 10913
81. 15 SEQUENCING ISOLATION VALVE 34 CHAPTER 3 OPERATION eu qa TE ce Cu ean eaae aoa nae 37 3 INTRODUCTION teta eta eee caus don etae desto 37 3 2 CONTROL PANEL 5 37 3 3 CONTROL PANEL MENUS eden e eet us ee ede ua ee ede 41 3 3 1 Menu Processing 41 3 4 OPERATING MENU w etn ri eee ete eae qu e a Re Q xe ts 43 3 5 SETUP MENU Z M 43 3 6 CONFIGURATION w As 44 3 7 TUNING n etra ee ege e Wein aee e e e eeu c aeqne ea ede ea pa aere 46 3 8 COMBUSTION CAL MENU Ll caus re ae nana 47 3 9 BST Boiler Sequencing Technology 47 3 10 START SEQUENGE io crecer eee e eet p erede 50 3 11 START STOP EEMELS 2 2 aaa dee te ah quts rr e ra ter diverses 53 CHAPTER 4 INITIAL START UP J cocer ona sacs 55 4 1 INITIAL START UP REQUIREMENTS uy saa nter 55 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION 55 4 2 1 Required Tools amp Instrumentation
82. 15F 103 114 125 136 147 158 169 180 191 202 10F 106 118 130 142 154 166 178 190 202 214 5F 109 122 135 148 161 174 187 200 OF 112 126 140 154 168 182 196 210 5F 115 130 145 160 175 190 25 118 134 150 166 182 198 214 121 138 155 472 206 J xh 2 20F 124 142 160 178 196 24 Page 152 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX D INDOOR OUTDOOR RATIO CHARTS Table D 5 Header Temperature for a Building Reference Temperature of 75F RESET RATIO 82 83 85 86 87 89 of 93 95 97 99 96 99 102 105 108 111 140 166 179 192 205 218 145 i73 an ee ems o 150 165 180 195 210 155 187 208 219 J 160 177 194 21 1 17 20 219 NIN o Table D 6 Header Temperature for a Building Reference Temperature of 80F RESET RATIO gt O cO 92 94 96 98 100 102 104 95 98 104 105 110 110 116 115 122 120 128 125 134 130 140 135 146 140 152 164 176 188 200 212
83. 19 125 131 137 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 98 109 120 131 142 153 164 175 186 197 5 101 13 125 187 149 161 179 185 197 209 O 104 117 130 143 156 169 182 195 208 5 07 121 7851 149 463 477 191 205 919 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Table D 4 Header Temperature for a Building Reference Temperature of 70F RESET RATIO Air Temp 65F 73 74 75 76 77 78 79 82 60 76 78 82 84 88 90 92 94 55F 79 82 85 88 91 94 97 100 103 106 50F 82 86 90 94 98 102 106 110 114 118 45F 85 90 95 100 105 110 115 120 125 130 40F 88 94 100 106 112 118 124 130 136 142 35F 91 98 105 112 119 126 133 140 147 154 30F 94 102 110 118 126 134 142 150 158 166 25F 97 106 115 124 133 142 151 160 169 178 20F 100 110 120 130 140 150 160 170 180 190
84. 190 200 210 35F 123 134 145 156 167 178 189 200 126 138 150 162 174 186 198 210 25F 129 142 155 168 181 194 207 7 20F 132 146 160 174 188 202 26 15F 135 150 165 180 195 210 OF 138 154 170 186 202 218 5F 141 158 175 192 209 OF 144 162 180 198 216 Page 154 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX E BOILER DEFAULT SETTINGS APPENDIX E 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 750 MBH or 1000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote 4 20 mA 1 5V Setpoint Direct Drive or Combination Bldg Ref Temp If Boiler Mode Outdoor Reset 0 Reset Ratio 12 If Boiler Mode Outdoor Reset Outdoor Sensor Disabled System Start Tmp 60 F If Outdoor Sensor Enabled Setpt Lo Limit 609 Setpt Hi Limit 1959 Temp Hi Limit 1959 Max Valve Position 100 Pump
85. 288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING Blocked Inlet Switch Test Continued 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 3 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 al lt Flame Detector Connector Boot Flame Signal Generator TO WIRE HARNESS Figure 6 3a Connecting the Flame Signal Generator d Keep the alligator clip away from bare metal parts until step 4c 4 Complete the following with the boiler operating in Manual mode a Ramp the boiler up to 100 fire rate and then turn 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 tha
86. 30 2 10 11 VFD Blower 0 10 amp AGND nnne enne nnne nennen nennen sten 30 220 2 Dee EE Sa ae 30 2 10 12 1 REMOTE INTEK Terminal ee e eoe toro oae ote t o rr sere e ege 30 2 10 12 2 DELAYED INTL K Terminals OUT amp IN 30 2 10 13 FAULT RELAY NC COM amp NO Terminals esses eene nnne 31 2 10 14 AUX RELAY CONTACTS NC COM amp NO Terminals 31 2 11 FLUE GAS VENT INSTALLATION 40 4002 2 0000 G stern essen renes 31 2 12 COMBUSTION AIR re SER re eto Sa Y nh etae no CERE CR Ye 32 2 12 1 Combustion From Outside the Building 32 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 3 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 2 12 2 Combustion Air from Inside the 32 213 DUCTED COMBUSTION AIR e ento Leti ent n e nr en re ta n Re eu re ko onu gea 33 2 14 BENCHMARK PUMP RELAY 4 81 4 2 0 0 ayaqa enint 33 2
87. 32 COMMUNICATION SETUP Regardless of the terminal emulation utilized the following guidelines must be adhered to when setting up the RS 232 communication link Baud Rate The baud rates which be used with the C More Control Panel are o 2400 o 4800 o 9600 Default 19 2K Data Format The program must be set for o 8 data bits o 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 Aerco will appear in the laptop or dumb terminal display with a listing of the following available entry choices Display next Menu Display menu items Display next menu items Change item xx Fault log display Sensor log display Time line display Log off x x D N C F S T L 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 Di
88. 4 NPT 8 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 24 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 9 1 99015 DAMPING ORIFICE SSOV 25 1 94028 13 25 NIPPLE 1 NPT TBE X 13 25 LG 100 1 63147 HARNESS WIRING GAS TRAIN 26 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 11 2 124084 ELBOW 1 4 NPT 1504 M I 27 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 120 1 124862 RESISTOR ASSY 28 1 99017 SNUBBER PRESSURE 1 4 13 1 124083 TEE 1 4 1508 29 1 124151 1 4 NPT SCH 40 X 1 1 2 LG NIPPLE 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 30 2 12607 2 CLOSE NIPPLE 1 4 NPT SCH 40 C S 15 2 9 331 NIPPLE 1 NPT TBE X 1 50 LG 31 1 97005 5 TUBE FLEXIBLE GAS 18 94028 16 3 2 00 NIPPLE 1 NPT TBE X 2 00 LG Not shown on drawing AERCO International Benchmark 750 1000 FM Gas Train 03 07 2014 Inc Blauvelt NY 10913 22140 1 rev E reference PL A 169 Sheet 1 of 1 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 167 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS Benchmark 750 1000 DBB Gas Train 22140 2 rev D Item Qty Part Description Item Qty Part Description 1 1 95026 1 25 NPT 125 THREADED FLANGE 20 1 12609 10 8 11 4 x 1 HEX RED BUSHING 2 1 93046 ELBOW 45 lt MOD DEG gt 1 B I 150 21 1 69038 ACTUATOR SSOV W O P
89. 4 Riverdale Ave Boston MA 02125 1689 Newton MA 02485 Phone 617 288 0629 Phone 617 527 8178 www mapeacard com www gloversheetmetal com 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 250 square inches of free area The free area must take into account r
90. 50F 66 68 70 72 74 76 78 80 82 84 45F 69 72 75 78 81 84 87 90 93 9 40F 72 76 80 84 88 92 96 100 104 108 35F 75 85 90 95 100 30F 78 84 90 96 102 108 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 SF 99 112 125 138 151 164 10F 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 151 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX D INDOOR OUTDOOR RATIO CHARTS Table D 3 Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 65 65 65 65 65 65 65 65 65 65 65 60 68 69 70 71 72 73 74 75 76 77 55 71 73 75 77 79 83 85 87 89 50 74 77 83 86 92 95 98 101 45 77 8t 85 9 97 101 105 109 113 40 80 85 90 95 100 105 110 115 120 125 35 83 89 95 10 107 113 1
91. 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 1 SAFETY PRECAUTIONS N WARNING N ELECTRICAL VOLTAGES UP TO 120 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 N WARNING Z A DOUBLE 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 Z CAUTION A 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 Z 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 5 VALVE OPEN VALVE CLOSED Figure 1 1 Manual Gas Shutoff Valve Page 12 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 1
92. 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 750 or 1000 MBH boiler consists of the following e Complete installation Chapter 2 e Set proper controls and limits Chapter 3 e 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 Intern
93. ADBAND 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 Sht Threshold Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature Span is 40 to 10096 Default is 6096 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 143 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued TUNING MENU DESCRIPTION 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 gre
94. Ain terminals on the Master Unit s Box NOTE 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 ciliis o EG T amam a eieaa Remote Signal Box OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 131 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 5 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 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Remote Setpoint 6 Go to the Head Temp Source item and select FFWD Temp 7 Go to the BST Remote Signal and select either 4 20ma or 0 20ma 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 Page 132 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MO
95. 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 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM 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 A copy of all installation instructions for all Product Approved side wall
96. Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual AERCO USER MANUAL Installation Operation and Maintenance Natural Gas amp Propane Modulating amp BENCHMARK Series Gas Fired Boilers Condensing Hot Water Boiler Models e BMK 750 e BMK 1000 Applicable to Serial Numbers G 14 0752 and above GAS FIRED Latest Update 05 21 2014 G Ar CERTIFIED US www ahridirectory Commercial Boilers LISTED AHRI Standard BTS 2000 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 1 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Mainten
97. Blower Proof switch Defective Blocked Inlet switch Loose temperature to AUX connection Box Defective temperature sensor 1 2 3 4 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 blower running If the resistance reading is erratic or is greater than zero ohms replace the switch Turn off unit and check the continuity of the Blocked Inlet switch If the resistance reading is erratic or is greater than zero ohms replace the switch Check the actual inlet air temperature and measure voltage at AUX input in the Box Verify that the voltage conforms to the values shown in the tabular listing provided in Appendix C Refer to CORRECTIVE ACTION 7 and verify that the voltage conforms to the values shown in Appendix C 9 Check wire connection from 1 Box 0 10V signal to the Blower Motor 9 Loose wire connection between the 10 Measure voltage at the box 0 10V output A voltage of 1 from I O box to the 8 2V equates to a 100 ope
98. CO for proper Warranty Validation It is important to perform the following procedure as outlined This will keep readjustments to a minimum and provide optimum performance OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 61 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP PROPANE Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the natural gas supply valve to the unit 3 Set the control panel ON OFF switch to the OFF position 4 2 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 0 by pressing the Y arrow key Ensure that the leak detection ball valve downstream of the SSOV is open Setthe 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 Benchmark 750 units 3 9 0 2 W C Benchmark 1000 units 7 4 0 2 W C If gas pressure adjustment is required remove the brass hex nut on t
99. DBUS 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 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 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 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 180 181 A Tw El 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 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Remote Setpoint 6 Go t
100. E STRICTLY OBSERVED e DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF VALVE PROVIDED WITH THE UNIT e ALLOW THE UNIT COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING Table 7 1 Maintenance Schedule Labor Time Flame Detector Kit Lean O Sensor Combustion Testing of Safety See ASME Inspect Condancate Dral Inspect Clean Inspect Clean 7 8 Tra Inspect amp Replace amp Replace 30 mins P Gaskets Gaskets Air Filter 59139 Only performed after initial 6 month period after initial startup OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 89 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE 7 2 IGNITER INJECTOR REPLACEMENT The igniter injector P N 58023 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 BLOCKED INLET SWITCH BLOWER PROOF SWITCH BLOWER AIR FUEL VALVE GAS FLEX HOSE NIPPLE BURN
101. EL VALVE O2 SENSOR FLAME DETECTOR STAGED IGNITION SOLENOID BURNER GASKET IGNITER INJECTOR BURNER PLATE Figure 7 5 Burner Assembly Exploded View OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 95 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE Burner Assembly Inspection Continued NOTE The burner assembly is heavy weighing approximately 25 pounds Remove the burner assembly from burner flange by pulling straight up Remove and replace the burner gasket 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 removed in step 16 reinstall all the components in the reverse order that they were removed When reinstalling the burner flange removed in step 15 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
102. EMP LIM CONT PWR HARNESS 19 1 80080 INSULATION SHELL 570 1 124327 HARNESS INTERLOCK HARNESS 580 1 63086 SHELL HARNESS 590 1 63147 HARNESS WIRING GAS TRAIN BLOWER 60 1 65156 FLAME ROD SIGNAL AMPLIFIER 20 1 58061 BMK BLOWER REPLACEMENT KIT 61 1 61030 OUTLET TEMP SENSOR 22 1 81064 GASKET BLOWER 62 1 61024 AIR INLET TEMPERATURE SENSOR 23 1 88004 O RING 112 244 BUNA N 630 1 65104 CABLE H V IGNITION 24 1 24356 1 FLAME DETECTOR KIT 640 1 63083 HARNESS O2 SENSOR 25 1 61026 LEAN OXYGEN SENSOR 650 1 63085 CONTROL HARNESS BMK 1000 amp 750 26 58023 IGNITOR REPLACEMENT KIT 67 1 69038 ACCTUATOR SSOVE w o P O C SWITCH 27 1 59139 AIR FILTER 6 X 4 5 LG 68 1 GP 122774 VALVE VENT 3 4 69 24V POWER SUPLY SEQUENCING CONTROLS 1 65162 ISOLATION VALVE 28 1 123966 SWITCH OVER TEMP AUTO RESET 29 1 123552 SWITCH OVER TEMP MANUAL RESET 30 1 60011 1 SWITCH ASSY BLOWER PROOF NOT SHOWN ON DRAWINGS BELOW AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 07 2014 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 1 of 6 OMM 0082_0J GF 130 AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 161 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS Benchmark 750 1000 Parts List
103. ER PLATE STAGED IGNITION SOLENOID FLAME DETECTOR 7 7 O2 SENSOR PN BURNER STAGED IGNITION ASSEMBLY INJECTOR IGNITOR Figure 7 1 Benchmark Burner Assembly Removed 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 Replacement 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 Page 90 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE Igniter Injector Replacement Continued Disconnect the cable from the igniter injector Figure 7 1 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 e
104. ER TEMPERATURE SWITCHES SENSOR 343 0 12V POWER BOX GND SUPPLY 0 10V AGRD V 6 PIN CONNECTOR 120V OUTLET RECEPTICLE GN D TO CONTROL BOX ENCLOSURE 960 ADDED 24V POWER SUPPLY amp FLAME ROD cg i ON 9 PIN CONNECTOR ERE a tuan anar Ga de REMOVED WIRE 152 ADDED JUMPER WIRE AERCO P N 63145 8 9 13 e 4 n INTERNATIONAL INC WIRE 151 USED AS JUMPER BETWEEN TERMINALS 7 AND 3 1 1 lt Blouvel WIRING SCHEMATIC CHANGE DUE TO I O BOARD CHANGE 6 26 12 4 WIRING SCHEMATIC 120 VAC 60 Hz ADDED DIGITAL TEMP CONTROLLER RENAMED TERMINALS FOR 24 PIN CONNECTOR 5 16 1 2 BK RELEASED FOR PRODUCTION 2 16 12 NH BMK 1000 amp 750 BOILER 68038 IE SHEET 1 OF 2 Drawing Number 68038 rev E Sheet 1 of 2 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 175 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX 1 C MORE WIRING DIAGRAMS This Page Is Intentionally Blank Page 176 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX 1 C MORE WIRING DIAGRAMS 24 PIN CONNECTOR 16 PIN CONNECTOR 12345678 9101112131415 16 17 18 19 20 21 222324 16 15 14 13 12 1
105. ETPOINT M ODE 53 3 l o cos ee eta o eo na 70 5 3 T Setting the Setpolnt os se be e RC ERRARE REA IE a 70 5 4 REMOTE SETPOINT MODESTA coe ere PATRE 71 5 4 1 Remote Setpoint Field ee e Sae NY Y ERES 72 5 4 2 Remote Setpoint Startup steep ness est esee paie 72 5 5 DIRECT DRIVE MODES in uite e e tp een c eene v E Ux 72 525 1 Direct Drive Freld Winih oe t bul e TER voee EUR 73 5 5 2 Direct Drive Start p uie t eee ipee a eve 73 5 6 AERCO CONTROESYSTEM ACS 5 rs ertt scere eine eee a iet cett obe ege i e GPS 73 Page 4 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 5 6 ACS External Field Witing irita evene rue eR ee 74 5 6 2 ACS Setup and Startup eet t ete e e e coeds ube en RR 74 5 7 COMBINATION CONTROL SYSTEM 5 0 0020 1 0 0 60 000001000 nennen nennen nnne nnne nnne nre 74 5 7 1 Combination Control System Field Wiring 75 5 7 2 Combination Control System Setup and Startup
106. G 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 Choices ze Limits Default Minimum Maximum Active Setpoint 40 F 240 F Inlet Temp 40 F 140 F Air Temp 70 F 245 F Outdoor Temp 709 130 Valve Position In 096 10096 Valve Position Out 096 10096 Exhaust Temp E 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 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
107. Hl X31108 3HL NO V NI Q3TIVISNI 38 ISNA NVL H3ZIIVSHID3N 3HL 39vNIVMO 31VSN3QNOO M3dOMd 404 INVI YAZMVYLAAN 31VSN3G0NOO9 OOM3V JHL ONISN NAHM 72 SI3S LINN NI 38 AINO NYO NOlldO 39ONVHViIO ACIS OXZ JHL 31ON 33S Y SALON 019 2 MAIA 4415 Drawing Number SD A 872 rev B OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 159 of 192 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX DIMENSIONAL DRAWINGS This Page Is Intentionally Blank Page 160 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS APPENDIX G PART LIST DRAWINGS Benchmark 750 1000 Parts List Item Qty Part Description Item Qty Part Description EXHAUST MANIFOLD CONTROLS Continued 1 1 43086 MANIFOLD EXHAUST 31 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 2 1 84033 SEAL EXHAUST MANIFOLD 32 1 65085 TRANSFORMER IGNITION 3 1 9 22 PIPE PLUG 1 4 NPT STEEL 33 1 65119 POWER OUTLE
108. INITIAL START UP This Page Is Intentionally Blank Page 68 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 E After reading this chapter parameters can be customized to suit the needs of the specific application 5 2 INDOOR OUTDOOR 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 adjustable number from
109. IT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY CAUTION A All of the installation procedures in Chapter 2 must be completed before attempting to start the unit 3 2 CONTROL PANEL DESCRIPTION All Benchmark Series 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 Chapter OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 37 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION 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 38 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526
110. K 750 amp 1000 Clearances Page 16 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION BASE FRONT Notes 18 454 2 51 i 1 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2 ALL DIMENSIONS ARE SHOWN IN INCHES MILIMETERS Figure 2 1b BMK 750 amp 1000 Anchor Bolt Locations Z WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS CAUTION A While packaged 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 6 inch housekeeping pad to ensure proper condensate drainage see NOTE below If anchoring the unit refer to the dimensional drawings in Figure 2 1b for anchor locations NOTE When using the AERCO Condensate Neutralizer Tank for proper condensate drainage the Neutralizer Tank must be stored in a pit OR the boiler and AERCO Condensate Trap must be elevated higher than 4
111. K OPEN The Delayed Interlock is open DIRECT DRIVE T 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 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 TEMPERATURE The Exhaust Temperature has exceeded 200 F GAS PRESSURE The High Gas Pressure Switch OR Low Gas Pressure Switch FAULT is open HIGH WATER The temperature measured by the Outlet Sensor exceeded TEMPERATURE the Temp Hi Limit setting HIGH WATER TEMP The High Water Temperature Limit Switch is open SWITCH OPEN IGN BOARD A communication fault has occurred between the PMC board COMM FAULT and Ignition board IGN SWTCH CLOSED The Ignition Position Limit switch on the Air Fuel Valve closed DURING PURGE during purge IGN SWTCH OPEN The Ignition Position Limit switch on the Air Fuel Valve DURING IGNITION opened during ignition INTERLOCK OPEN LINE VOLTAGE OUT OF PHASE The Remote Interlock is open The Line Hot and Neutral wires are reversed Ei The Low Water Cutoff board is indicating low water level NETWORK COMM The RS 485 network information is not present or is FAULT corrupted
112. LVE ASSY 3 1 81064 GASKET BLOWER 16 6 52027 8 X 1 25 STUD 30mm LENGTH 4 1 24111 BLOWER AMETEK 8 9 17 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 5 1 59104 OBSERVATION PORT 18 1 59171 REFLECTOR SIGHT GLASS 6 1 24277 STAGED IGNITION 55 19 1 61026 LEAN OXYGEN SENSOR 7 1 66020 FLAME DETECTOR 20 1 61024 AIR INLET TEMPERATURE SENSOR 8 1 88004 O RING 42 244 BUNA N 21 1 56064 NUT M8 X 1 25 HEX JAM GASKET FLAME DETECTOR LOW 9 1 81048 NOX 22 5 56060 NUT M8 X 1 25 FLANGED SERRATED 10 4 54028 SCREW HEX HD SERRATED 5 16 18 23 2 54095 SCREW SOC HD 10 32 X 3 8 LG 11 1 60011 1 SWITCH ASSY BLOWER PROOF 24 1 66026 IGNITOR INJECTOR 12 3 53033 WASHER CLOCKING 25 1 9 21 PLUG HEX HD 1 8 13 1 46026 BURNER BMK 1 0 Part 4 Description A F VALVE ASSY BMK 750 Item 15 24298 1 24298 A F VALVE ASSY BMK 1000 k CO temen Benchmark 750 1000 Burner Assembly 08 06 2013 nc Blauvelt 10913 24276 rev F AP A 171 Sheet 1 of 1 Page 170 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 0 8 lt SIVIEG 7400 01 SNOWLONYISNI 31VSN3QNOO 33S MOO14 JHL 3AO8V NVHL N3H9IH Q3lVAiT3 SIN 3 5 dvML 3IVSN3QNOO OOM3Y Y31109 SO V NI G3TWISNI 38 LSAW M3ZIIVMIQ3N 117080 JHL
113. MM 0082 0J Page 172 of 192 05 21 2014 Ph 800 526 0288 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX H PIPING DRAWINGS g avd 698 5 TLvogo 0 NOLVTIVISNI 10 3015 0432 Su31l08 dldiEInW Sv9 000 OL OSZ AYVWHONSA 1801 AN ONI TWNOLLVNYALNI Nanay W31SAS SNILV3H Q Alddns ee ANWA AAOLNHS 9 310N 33S OM 3unsS3Hd SVO NIVHL SVD WAYOM 0 lv dMnsS3Hd SVO WNWININ NIVLNIVA YH NLE W NIXVW LV 3univeradWat 34055344 S9NIONVTVH NOINN AAWA_NOILLV10SI S3NIVHIS A QN3911 9 310N 33S Yl 380553564 SV9 NIVEL Sv9 WAYOM OY 571130 00 SNOLODMISNI 31VSN30NOO 33S 780014 AHL NVHL NW3H9IH Q3lVA313 38 3lvSN30NOO OOM3V 33108 SO V 311 15 38 LSNW 1 M3ZIIVMln3N 3OvNIVMO 31VSN3QNOO 3adOMd NO4 NVL YAZITVYLNAN 31vSN3QNOO OONZV ONISN N3HM 4 SSJI MO 1 OL 340565344 SVO OL JAYA 44OLNHS 3HL jO WV3HISNMOQO G3TWISNI 38 YOLVINDZY 31415 dn 001 V NVHL N3lV3H9 SI SVO 318 N3HM 9 CALINSNOO 38
114. Manometer The gas supply manometer or gauge is used to monitor the gas pressure on the downstream 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 TO AIR FUEL MANUAL SHUT OFF VALVE VALVE SSOV GAS INLET 1 4 NTP PLUG Install manometer here for combustion LEAK DETECTION BALL VALVE Figure 4 1 1 4 Inch Gas Plug Location Install the 16 W C manometer s as described in the following steps Page 56 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP Installing Gas Supply Manometer 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 5 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
115. NCTION 10 MENU Keypad Six 6 keys 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 BACK A UP Arrow Allows you to go back to the previous menu level without changing any information Continuously pressing this key 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 category If the CHANGE key was pressed and the menu item is flashing pressing the A arrow key will increment the selected setting Y DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the Y arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key is pressed the displayed menu item will begin to flash Pressing the A or Y arrow key when the item is flashing will increment or decrement the displayed setting ENTER Saves the modified menu settings in memory The display will stop flashing 11 AUTO MAN Switch This switch toggles the boiler between the Automatic and Manual modes of operation When in the Manua
116. NG 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 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 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 90 GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter 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 Go to the BST Setpoint item and enter the desired Setpoint Go to the BST Setup Menu item
117. NW dvML 31VSN3ONOO OOM3V JHL 831108 AHL YO V NI Q3TIVISNI 38 ISAW YNVL MJZFIVHIQ3N 3HL 39VNIVHO 31VSN30NOO 3dOMd 3HO4 YSZNVYLNAN 31VSN30NO9 OOM3V JHL ONISN N3HM 310N 20 V6 ev id 1NOMJ 53015 2 1331 SMOTIOJ SV NOLLODHISNOO INJOVPOV Ol S3ONVeV3dIO WDWINIA JFIEILLSNENOD NO Q3TIVISNI 38 AVA 3ONVIIddV SIHL LL SAONVAVATO NOLLV TIVISNI 1 310N 33S MAIA 4015 Drawing Number SD A 871 rev B GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J Page 158 of 192 05 21 2014 Ph 800 526 0288 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS z18 v as AM 110180 ava S d AB NMG JOILON LNOLIM SNOISNSWIG J108 AJIQOAW Ol SdAd3S3H OOV ONIMVYEC SONVYVSTO 3016 04041 3108 Sv9 H8N 0001 064 160L AN yeanelg ONI IVNOLLVNSALNI MYVWHONA lOL LHOSIH SNIII3O ODU 2 INON 540 LHS 29 1331 SMOTIO4 SV AYY NOILODHISNOO 1 OL S3ONVHViIO S NIHOO14 FIGLSNENOD NO GATIVISNI 38 AYN 3ONVIIddV SIHL SJONVHV3 IO NOLVTIVISNI SIVI3Q 303 v400 GlL SNOILONYLSNI ANVL 31IVSN3Q0NOO 335 JHL NVHL N3H9IH G31VA314 38 LSAW dvsul 31VSN3QNOO OOMHJV 3
118. O C SWITCH 3 2 92036 VALVE SSOV 1 NPT 22 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 4 1 69005 ACTUATOR SSOV W REGULATOR 23 1 93290 TEE MXFXF BLACK IRON 1 4 NPT 5 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 24 1 122774 VALVE VENT 3 4 NPT 6 4 12951 2 BUSHING CONTROL BOX 25 3 124151 1 4 NPT SCH 40 X 1 1 2 LG NIPPLE 7 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 26 1 99017 SNUBBER PRESSURE 1 4 8 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 27 1 93187 TEE REDUCING 1 X 3 4 X 1 9 1 99015 DAMPING ORIFICE SSOV 28 3 9 222 ELBOW 90 lt MOD DEG gt 1 HARNESS GAS TRAIN WIRING 4 SEC 100 1 63147 IGN 29 93364 TEE 1 X 1 X 1 2 11 3 124084 ELBOW 1 4 150 M I 30 4 94028 2 00 NIPPLE 1 NPT TBE X 2 00 LG 12 1 12607 2 CLOSE NIPPLE 1 4 NPT SCH 40 C S 31 1 94028 3 50 NIPPLE 1 NPT TBE X 3 50 LG 130 1 124862 RESISTOR ASSY 32 1 94028 1325 NIPPLE 1 NPT TBE X 13 25 LG 14 1 124083 TEE 1 4 NPT 150 33 1 94061 3 00 NIPPLE 3 4 NPT X 3 00 LG 15 2 9 22 PIPE PLUG 1 4 NPT STEEL 34 1 94061 8 00 NIPPLE 3 4 NPT X 8 00 LG 16 2 9 331 NIPPLE 1 NPT TBE X 1 50 LG 35 1 94028 4 25 NIPPLE 1 NPT TBE X 4 25 LG 1 94028 1 17 5 00 NIPPLE 1 NPT TBE X 5 00 LG 36 97005 5 TUBE FLEXIBLE GAS 18 1 3 1 4 NPT MXF BRASS BALL VALVE 18 92006 5 VALVE BALL 1 NPT 37 92077 OPEN 1 BUSHING REDUCING 1 2 NPT X 1 4 19 123311 NPT Not shown on drawing AERCO Internatio
119. OWER 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 Page 88 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 Annual Maintenance Kit Part No 58025 01 24 Month Waterside Fireside Inspection Kit Part No 58025 08 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 08 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare N WARNING TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES AR
120. 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 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 the Configuration Menu Page 70 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION Table 5 1 Constant Setpoint Mode Settings Boiler Mode Co
121. RCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 111 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION SSOV SWITCH OPEN k Actuator not allowing for full closure of gas valve 2 SSOV powered when it should not be 3 Defective Switch or Actuator 4 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 2 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 3 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 4 Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE k Air Fuel Valve out of calibration 2 Air Fuel Valve unpluoged 3 Loose wiring connection to the stepper motor 4 Defective Air Fuel Valve stepper motor 5 Defective Power Supply Board or fuse 6 Defective IGST Board 1 Refer to GF 112 C More O amp M and perform the Stepper Feedback Calibra
122. RCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 9 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Phrases Abbreviations and Acronyms Continued Phrase Abbreviation or Meaning Acronym A resistor placed at each end of a daisy chain or multi drop network in Terminating Resistor order to prevent reflections that may cause invalid data in the communication VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column uA Micro amp 1 million of an ampere Page 10 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 units 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
123. RE SWITCH 4 7 W C 11 2 1124083 TEE 1 4 NPT 150 e 61002 17 BMK1000 HIGH GAS PRESSURE SWITCH 10 5 W C 12 1 93420 UNION FEMALE BLACK MI 280 1 63142 WIRE PRESS SW JUMPER 13 2 9 22 PIPEPLUG 1 4 STEEL 290 1 161450 HARNESS WIRING GAS TRAIN 14 2 190099 x 2 00 SCH 40 BLK STL 300 1 24862 RESISTOR ASSY 15 2 190100 x 3 00 SCH 40 BLK STL 31 1 97005 5 TUBE FLEXIBLE GAS 18 16 1 90107 NIPPLE PIPE NPT SCH 40x 22 LG STL 32 1 93474 1X 1 2 REDUCING COUPLING B I 17 1 90102 NIPPLE x 6 00 SCH 40 BLK STL 33 1 93290 TEE MXFXF BLACK IRON 1 4 NPT 18 1 90105 NIPPLE PIPE NPTSCH40x3 LGBLKSTL 34 1 99017 SNUBBER PRESSURE 1 4 Not shown on drawing AERCO Benchmark 750 1000 Gas Train Propane 04 02 2014 International Inc Blauvelt NY 10913 22140 3 rev C Sheet 1 of 1 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 169 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS Benchmark 750 1000 Burner BOM ref p n 24276 rev F Item Qty Part Description Item Part Description 1 1 42140 PLATE BURNER 14 1 123533 NIPPLE CLOSE 1 8 2 1 81143 GASKET BURNER 15 1 SeeTable A F VA
124. RS232 Adaptor Cable P N 124675 which is designed to 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 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm condition occurs An alarm message will appear in the VFD CLEAR Key Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid Lockout type alarms will be latched and cannot be cleared by simply pressing this key Troubleshooting may be required to clear these types of alarms READY Indicator Lights ON OFF switch is set to ON and all Pre Purge conditions have been satisfied ON OFF Switch LOW WATER LEVEL TEST RESET Switches Enables and disables boiler operation Allows operator to test operation of the water level monitor Pressing TEST opens the water level probe circuit and simulates a Low Water Level alarm Pressing RESET resets the water level monitor circuit Pressing the CLEAR key item 6 resets the display OMM 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 39 of 192 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION Table 3 1 Operating Controls Indicators and Displays Continued ITEM FEATURE FU
125. SHERS Quantity 0 3 as required O2 SENSOR amp WASHERS INJECTOR IGNITOR Figure 8 2 Staged Ignition Connection to Gas Injector Tube Page 114 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE DAMPING ORIFICE BRASS HEX HEAD CAP Remove to access Gas Pressure Adjustment screw COVER SCREW SSOV ACTUATOR COVER Figure 8 3 SSOV Actuator With Gas Pressure Adjustment amp Damping Orifice OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 115 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE This Page Is Intentionally Blank Page 116 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION CHAPTER 9 RS 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 t
126. T DIN MOUNT 34 2 69141 DIN RAIL MOUNT END STOP GAS TRAIN ASSEMBLY 35 1 64081 ECU 1 22140 1 STD FM GAS TRAIN ASSY 36 1 65011 TRANSFORMER 115V 24V 100VA 4 1 22140 2 DBB GAS TRAIN ASSY 37 1 65109 12V POWER SUPLY 1 22140 3 PROPANE GAS TRAIN ASSY 5 1 99017 SNUBBER PRESSURE 1 4 380 1 69145 RAIL DIN 8 1 2 LG 6 1 81155 GASKET 1 1 4 PIPE FLANGE 39 2 65120 TERMINAL BLOCK DIN MOUNTED BLK 7 1 61002 1 PRESSURE SWITCH 2 6 W C FALL 40 2 65121 TERMINAL BLOCK DIN MOUNTED WHT 61002 TERMINAL GROUND BLOCK DIN 9 1 12 HIGH GAS PRESSURE SWITCH 4 7 W C 41 3 65122 MOUNTED 10 1 92077 1 4 NPT MXF BRASS BALL VALVE 42 2 65118 FUSE TERMINAL DIN MOUNTED 43 1 69177 LIMIT CONTROL TEMP CONTROLLER BURNER AIR FUEL VALVE HEAT EXCHANGER 44 1 69005 ACTUATOR SSOV w PRESSURE REG 11 1 46026 BURNER BMK 1 0 45 1 24327 ASSEMBLY POWER SUPPLY COVER 12 1 24367 1 BMK 1000 A F Valve FRU kit 46 1 60019 DISCONNECT FUSIBLE 1 24367 2 BMK 750 A F Valve FRU kit 470 2 124512 FUSE 4 AMP 13 1 24277 STAGED IGNITION ASSY 48 1 123449 SENSOR TEMPERATURE 14 1 81143 GASKET BURNER 49 1 93359 THERMOWELL 15 1 59171 REFLECTOR SIGHT GLASS 50 1 33137 ELECTRICAL PANEL 16 1 59104 OBSERVATION PORT 51 1 181197 CONTROL BOX C MORE 17 1 28317 BMK 750 HEAT EXCHANGER 52 1 69151 PCB ASSY 1 28249 BMK 1000 HEAT EXCHANGER 53 2 124326 RELAY OMRON 20 24 5 54 2 51006 CLIP HOLD DOWN HOSES amp INSULATION 550 1 63097 I O SENSOR COMM HARNESS 18 1 97005 5 TUBE FLEXIBLE GAS 18 560 1 63090 T
127. TION RETRY Since the manual gas shutoff valve is still closed the unit will fail the ignition retry sequence Therefore it will shut down and display FLAME LOSS DURING IGNITION following the failed IGNITION RETRY cycle 11 Open the valve previously closed in step 8 12 Press the CLEAR button The unit should restart and fire BLOWER BLOWER PROOF SWITCH AIR FUEL VALVE iy uy BLOCKED INLET VALVE AIR FILTER MANUAL SHUT OFF VALVE a Figure 6 3 Bare Boiler Partial View OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 83 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 1 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 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 GNITION RETRY cycle a
128. TION 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 750 amp 1000 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 is 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 th
129. agnostics 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 the top down sequence shown in Figure 3 2 enter M lt gt The Menu title and first 10 options will be displayed When viewing menus containing more than 10 options enter lt gt to display the remaining options OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 119 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION Menu Processing Utilizing Rs 232 Communication Continued 7 Shortcut keys are also available to go directly to a specific menu These shortcut keys are mO m1 m2 m3 m4 m5 Default Operating Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu 8 To change a value or setting for a displayed menu option proceed as follows a Enter C followed by the number to the right of the displayed option to be changed and then press lt gt b Enter the desired value or setting for the option and press lt 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
130. 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 protect 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 WARNING Table J1 Recommended Periodic Testing Item Frequency idi ue Remarks Refer to indicated sections of this manual for detailed procedures Gauges monitors and Daily Operator Visual inspection and record readings in indicators operator log Dail Opatatar Visual check against factory recommended Instrument and y p specifications equipment settings Weekly Operator Verify factory settings Semi Service u Annually Technician Verify factory settings Firing Rate Control ZEE Annual Service Check with combustion calibration test y Technician equipment See section 7 4 and Chapter 4 Flue vent stack or Visually inspection condition and check for intake air duct Monthly Opetalar obstructions Spark Igniter Injector Weekly Operator See section 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial section 3 11 Service Check for leakage in accordance with the SSOV Leakage test Annually T den SSOV manufacturer s Siemens echnician recomme
131. ance Manual TABLE OF CONTENTS FOREWORD PAETE 7 CHAPTER 1 SAFETY PRECAUTIONS 22 2222 11 1 1 WARNINGS amp 5 11 1 2 5222 0 I 12 1 3 PROLONGED 5 22222 A ha nen orta nee rrr n eet 13 CHAPTER 2 INSTALLATION aano aote Saa nea ra 15 2 1 INTRODUCTION cere eere nnn 15 2 2 RECEIVING THE UNIT lll c o nete n re and eeu gre e int Qh adeat a ee RE 15 2 3 0 15 2 4 SITE PREPARATION 16 2 4 1 Installation 5 ere tro t ee tre tee vate en tee EY 16 2 42 Setting the Unit u tre me re D E n E ven Ee NEN RETE E 17 2 5 SUPPLY AND RETURN PIPING uuu eene 19 2 6 PRESSURE RELIEF VALVE INSTALLATION esses eene enne enne 19 2 7 CONDENSATE DRAIN amp SSS u S 20 2 8 GAS SUPPLY PIPING PN 22 2 8 1 Gas Supply Specifications ensenen ii eiii E Ea 22 2 8 2 Manual Gas Shutoff Valve eet te nera a a 23 2 8 3 External Gas Supply Regulator
132. and hose connections to the condensate trap inlet and outlet Reconnect trap to exhaust manifold drain Page 96 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE Condensate Drain Trap Maintenance Continued NOTE There are two slightly different types of condensate traps that may be used in your configuration an older style with a separate inlet adapter and a newer style with a built in adapter see Figure 7 6 Maintenance is the same except that the newer style does not need an orifice gasket Step 7 Thumb Screws e THUMB 4 e SCREWS COVER lt _ lt GASKET Condensate FLOAT Trap O Ring GUIDE 3 4 NPT Float Guide Float Adapter Opening O Rings 2 OUTLET P N 24060 Figure 7 6 External Condensate Trap OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 97 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE 7 9 AIR FILTER CLEANING amp REPLACEMENT The Benchmark boiler is equipped with an air filter P N 59139 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
133. 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 COND O1 OO 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 126 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler 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 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 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 th
134. ater than the proportional band setting the fire rate will be 10096 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 WARMUP 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 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 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 144 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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
135. ation amp Maintenance Manual CHAPTER 7 MAINTENANCE 7 10 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 the Boiler Down for an 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 11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing Boiler Back In Service After a Prolonged 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 99 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE This Page Is Intentionally Blank Page 100 of 192 AERCO International Inc e 100 Oritani Dr
136. ational Inc 100 Oritani Drive Blauvelt New 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 55 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 e Digital Combustion Analyzer Oxygen accuracy to 0 4 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
137. ave been configured 13 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 130 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler 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 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 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 180 181 s El Temp Sensor PN 61040 Header Temp Sensor I O Box Step 2 Direct Wired 0 20ma or 4 20ma Wiring 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and
138. bris 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 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Poor combustion calibration 2 Carboned heat exchanger due to incorrect combustion calibration 1 Check combustion calibration using procedures in Chapter 4 2 If exhaust temperature is greater than 200 F check combustion calibration Calibrate or repair as necessary Page 106 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1 Incorrect supply gas pressure 1 Check to ensure gas pressure at inlet of SSOV does not exceed 14 W C 2 Defective SSOV Actuator 2 If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range of 2 0 0 4 W C using HIGH GAS the gas pressure adjustment screw see section 4 3 step PRESSURE 10 the SSOV Actuator may be defective 3 Remove the leads from the High Gas Pressure switch 3 Defective High Gas Pressu
139. ce 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 Box Wire the units using 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 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 75 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION Table 5 5 Combination Mode Settings Internal Setpt Menu Option Setting Boiler Mode Combination Remote Signal Network 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
140. creased O value on the Combustion Calibration sheet Ultra Low NOx Combustion Calibration Readings m Nitrogen Oxide Carbon Monoxide Valve Position Oxygen O NOx CO 6096 596 7 9 ppm 100 ppm 45 5 7 9 ppm 100 ppm 30 596 7 9 ppm 100 ppm 1896 596 7 9 ppm 100 ppm 29 If the oxygen level at the 1896 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 Appendix G 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 1896 after making a change to the idle screw TAC valve 30 This completes the ultra low NOx Natural Gas combustion calibration procedures M 2 REASSEMBLY Once the combustion calibration adjustments are properly set the unit can be reassembled for service operation Reassembly Set the ON OFF switch to 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 Page 188 of 192 AERCO International Inc
141. ct 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 Terminals 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 AUX RELAY CONTACTS NC NO Terminals 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 AUX 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 materials MUST be used for safety and UL certif
142. d Close the Manual Shutoff Valve Figure 8 1 below Attempt to start the unit 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 Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into unit is fluctuating 2 Damping Orifice not installed Stabilize gas pressure going into unit If necessary troubleshoot Building Supply Regulator Check to ensure that the Damping Orifice is installed in the SSOV Actuator shown in Figure 8 3 For IRI DBB Gas Trains the Damping Orifice is installed in the downstream SSOV Actuator Air Fuel Valve hunting at the 8096 Valve Position 1 IGST and Power Supply Boards in Control Box are outdated Check to ensure that the IGST and Power Supply Boards are Rev E or higher OMM 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 113 of 192 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TO AIR FUEL MANUAL SHUT OFF VALVE HIGH PRESSURE GAS SWITCH LEAK DETECTION BALL VALVE SSOV GAS INLET Figure 8 1 Gas Train Component Locations COMPRESSION FITTING amp ELBOW FLAME STAGED DETECTOR IGNITION amp GASKET SOLENOID GAS INJECTOR TUBE BURNER PLATE INDEXING WA
143. d Interlock and Remote Interlock must be in the closed position for the unit to fire 2 10 12 2 1 Remote Interlock In OUT amp IN 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 2 Delayed Interlock In OUT amp IN The Delayed Interlock terminals can be used in one of two ways n 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 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 harness from the Delayed Interlock terminals and conne
144. d by removing the unit front panel from 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 4 before the boiler can be restarted The rotary dial temperature limit switch is manually adjustable from 32 F 212 F 0 C 100 C This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this over temperature switch to the desired setting The digital alarm switch shown in Figures 4 5 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 65 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP Reset button for Manual Temperature Limit Switch Digital Over 1 Temperature Limit Controller Manual Temperature Limit Switch Adjustable Tempera
145. d 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 91 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE Igniter Injector Replacement Continued BURNER PLATE INJECTER IGNITOR X INJECTOR TUBE INJECTOR TUBE mcr Figure 7 3 Igniter Injector Orientation 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 REPLACEMENT The flame detector P N 24356 1 is located on the burner plate at the top of the unit see Figure 7 1 and Figure 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 Replacement Set the control panel ON OFF switch to the OFF position Disconnect AC power from the unit Remove the top shroud from the
146. 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 eno 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter I O 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 Unit s 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 Remote Signal Box Page 134 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler 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 it
147. e 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 CON O af 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 128 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler 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 of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES
148. e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION NOTE The Operation Time T Log can store thousands of records Therefore to view the most recently logged record enter followed by 0 zero and press Enter i e TO 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 595 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 Table 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 b
149. e I O the Box The sensor end of the shield must be left free and ungrounded 180 181 B SHLD 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 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 127 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler 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 item to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the Failsafe Setpoint Go to th
150. e boiler will fire at the 2996 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 142 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION 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 a 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 DE
151. e four 4 pins in the side panels Disconnect the 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 sensor and crush washer on the burner plate Reconnect the sensor lead wire Reinstall the shroud on the unit 7 5 COMBUSTION CALIBRATION Combustion settings must be checked at the intervals shown in Table 7 1 as part of the maintenance requirements Refer to Chapter 4 section 4 3 for combustion calibration instructions 7 6 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 7 7 BURNER ASSEMBLY INSPECTION The burner assembly part no 24276 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 It should be noted that the complete burner assembly also includes t
152. e information on the carrier s paperwork and request a freight claim and inspection by a claims adjuster before proceeding Any other visual damage to the packaging materials should also be made clear to the delivering carrier 2 3 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials After unpacking closely inspect the unit to make sure there is no evidence of damage not indicated by the Tip N Tell indicator Notify the freight carrier 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 ASME Pressure Relief Valve e Condensate Drain Trap no 24060 1 Supply Shutoff Valve e Lifting Bar with attaching hardware 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 15 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 2 4 SITE PREPARATION Ens
153. e of 2 0 0 4 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 L 1 Make gas pressure adjustments using a flat tip screwdriver to obtain a gas pressure within the range of 2 0 0 4 W C OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 185 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX M ULTRA LOW NOx CALIBRATION Ultra Low NOx Natural Gas Combustion Calibration Continued BRASS HEAD CAP Remove to access gas pressure adjustment screw TYPICAL SSOV ACTUATOR WITH REGULATOR Figure M 1 Gas Pressure Adjustment Screw Location 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 2 0 0 4 W C Readjust the gas pressure if necessary 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 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 0 5 have your combustion analyzer calibration checked as soon as possible If the readings differ by more than 1 5 use
154. e 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 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 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 the AERCO Control System The ACS mode is used when it is desired to o
155. e 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 O2 SENSOR Terminals The SENSOR and SENSOR terminals are used to connect an external oxygen sensor to the I O Box The O 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 Terminals The two SPARK SIGNAL terminals amp 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 Terminals The two ANALOG IN terminals and 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
156. ect Vent Horizontal These boilers are capable of being vented utilizing PVC CPVC 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 both Benchmark 750 MBH and Benchmark 1000 MBH boilers AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 7 of 192 05 21 2014 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Phrases Abbreviations and Acronyms Phrase Abbreviation or Acronym nedum A Amp Ampere ACS AERCO Control System AERCO s boiler management systems 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 II AERCO Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Management Technology BTU British
157. em 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 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 135 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler 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 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 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
158. enu 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 60 45 3096 and 18 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 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 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 SET Valve Position will begin to flash Press the A arrow key until SET Valve Position reads 80 Press the ENTER key Next press the down V arrow key until CAL Voltage 80 is displayed Press the CHANGE key and observe that CAL Voltage 80 is flashing 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 Natural Gas Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide Valve Position Oxygen Oz NOx CO 8096 5 696 20 ppm 100 ppm If the oxygen level is not withi
159. ergy Input Boiler Energy Input Air Fuel Valve BTU Hr of Full Capacity Position Open 750 MBH 1000 MBH 750 MBH 1000 MBH 096 0 0 0 0 10 0 0 0 0 18 Stop Level 50 000 50 000 6 796 596 2096 52 000 54 000 6 9 5 4 30 108 000 140 000 14 14 40 246 000 297 000 33 30 50 369 000 443 000 49 44 60 465 000 564 000 62 56 70 554 000 660 000 74 66 80 637 000 789 000 85 79 90 733 000 933 000 98 93 100 750 000 1 000 000 100 100 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 53 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION Table 3 9 Relationship Between Air Fuel Valve Position and Energy Input For 750 MBH amp 1000 MBH Units Running On PROPANE Energy Input Boiler Energy Input Air Fuel Valve BTU Hr of Full Capacity Position Open 750 MBH 1900 MBH 750 MBH 1000 096 0 0 0 0 1096 0 0 0 0 1896 Stop Level 50 000 50 000 6 796 5 096 2096 71 000 71 000 9 5 7 1 30 128 000 181 000 17 18 40 373 000 400 000 5096 4096 5096 508 000 562 000 6896 5696 6096 565 000 703 000 7596 7096 7096 621 000 791 000 8396 7996 8096 660 000 865 000 88 87 90 723 000 963 000 96 96 100 750 000 1 000 000 100 100 Page 54 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph
160. estrictions 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 1000 square inches of free area The free area must take into account any restrictions such as louvers Page 32 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 2 13 DUCTED COMBUSTION AIR The AERCO Benchmark 750 amp 1000 MBH Boilers are UL listed for 100 ducted combustion For ducted combustion air installations the screen inlet air ductwork must then be attached directly to the unit s air inlet 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 heater in a ducted combustion air configuration each unit must have a minimum 6 inch diameter connection at the unit 2 14 BENCHMARK PUMP RELAY OPTION An optional Benchmark pump relay allows the user to
161. even 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 provided however that during said thirty 30 day period a battery operated carbo
162. g 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 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 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 180 181 Tee El 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 125 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler CHAPTER 10 BOILER SEQUENCI
163. h 800 526 0288 Page 105 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION FLAME LOSS DURING IGN continued 6 Carbon or other debris on Burner 7 Staged ignition solenoid valve doesn t open 8 Clogged staged ignition piece 6 Remove View Port and inspect Burner with Boroscope If it is fouled or black with soot remove the Burner and inspect for any carbon build up or debris Clean and reinstall 7 When unit goes to ignition listen for a clicking sound at the staged ignition solenoid valve to ensure it is opening 8 Remove and inspect the igniter injector and inspect the gas injector for blockage HEAT DEMAND FAILURE 1 Worn Flame Detector or cracked ceramic 2 Defective Regulator 1 The Heat Demand Relays on the Ignition Stepper IGST board failed to activate when commanded 2 Relay is activated when not in Demand 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas FLAME LOSS pressure into and out of the valve is correct DURING RUN 3 Poor combustion calibration 3 Check combustion calibration using procedures in Chapter 4 4 De
164. he SSOV actuator to access the gas pressure adjustment screw Figure 4 3 above Make gas pressure adjustments using a flat tip screwdriver to obtain the gas pressure listed above 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 listed in step 10 3 9 0 2 or 7 4 0 2 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 Compare the oxygen readings on the combustion analyzer to the on board 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 Os sensor may be defective and need to be replaced 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 in your analyzer set the oxygen O gt at 5 5 0 596 Propane Combustion Calibration Readings T Nitrogen Oxide Carbon Monoxide Valve Position Oxygen 02 NOx CO 100 5 6 lt 30 ppm lt 100 ppm Page 62 of 192 AERCO International Inc e 100 Oritani Dr e
165. he blower and air fuel valve assemblies for the unit The following parts will be required for reassembly after burner inspection Part No Description 81143 Burner Gasket 81048 Flame Detector Gasket 81064 Blower Gasket OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 93 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE To inspect or replace the burner assembly proceed as follows Burner Assembly Inspection 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 48 32 screw Remove the flame detector and gasket from the burner plate Disconnect the cable from the igniter 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 fro
166. he front panel of the C More Control Box Figure 3 1 can be interfaced to a laptop computer or other suitable terminal using 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 Aquiring 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 PuTTY Configuration PUTTY Configuration Category Category Bg Basic options for your PuTTY session Session Options controlling local serial lines Logging Specify the destination you want to connect to il Logging Select a serial line Terminal E Terminal Keyboard Serial line Speed be Keyboard Serial line to connect to COM1 Bel 3600 Bel
167. he unit and lifting straight up Locate the lifting tab at the top rear of the heat exchanger Refer to Figure 2 2 View B and attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1 The upper end of the lifting bar containing the oval cutout should be positioned over the top of the heat exchanger as shown Using proper rigging equipment capable of supporting 1000 to 1200 Ibs lift the boiler and position it on the housekeeping pad After the boiler is properly set on the pad detach the lifting bar and replace the shroud on the top of the unit Retain the lifting bar for possible reuse at the installation site LIFTING TAB amp LIFTING BAR IN SHIPPING E POSITION VIEW A SHIPPING POSITION VIEW B LIFTING POSITION Figure 2 2 Boiler Lifting Provisions Page 18 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 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 Boi
168. heets must be filled out and returned to AERCO for proper Warranty Validation Prior to performing the procedure in this Appendix the boiler must be set up as described in Chapter 4 section 4 1 through the low NOx combustion calibration in section 4 3 Once that is complete perform the following steps to combustion calibrate the boiler to the ultra low NOx requirement of less than 9 ppm IT IS IMPORTANT TO PERFORM THE FOLLOWING PROCEDURE AS OUTLINED BELOW THIS WILL KEEP READJUSTMENTS TO A MINIMUM AND PROVIDE OPTIMUM PERFORMANCE Ultra Low NOx 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 s to the unit Set the control panel ON OFF switch to the OFF position 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 9e 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 3096 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 the rang
169. 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 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION CHAPTER 2 INSTALLATION 2 1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack inspect and install AERCO Benchmark Boiler Models BMK 750 and BMK 1000 2 2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit The shipping weights for the BMK 750 and BMK 1000 Models are approximately 1100 and 1200 pounds respectively 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 th
170. ication 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 31 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 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 1 9 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 that 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 Meatal Inc 1250 Massachusetts Ave 4
171. imate pressures BMK 750 amp 1000 NATURAL GAS gas trains 2 6 W C 750 PROPANE gas train 4 4 1000 PROPANE gas train 7 5 Fully open the external manual gas shut off valve and press the CLEAR button on the Control Box The fault message should clear the FAULT indicator should go off and the unit should restart Upon test completion close the ball valve and remove the manometer Replace the 1 4 plug removed in step 1 MANUAL SHUT OFF VALVE TO AIR FUEIDS HIGH GAS PRESSURE SWITCH HIGH GAS PRESSURE LEAK DETECTION BALL VALVE LOW GAS PRESSURE SWITCH GAS INLET Z 1 4 NTP PLUG Install manometer LOW GAS PRESSURE here for Low Gas LEAK DETECTION BALL VALVE Pressure Test shown closed Figure 6 1A Low Gas Pressure Fault Test Natural Gas gas train shown Page 78 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING 6 3 HIGH GAS PRESSURE TEST The instructions below apply to both the Natural Gas and Propane gas trains To simulate a high gas pressure fault refer to Figure 6 1B and perform the following steps High Gas Pressure Test Remove the 1 4 plug from the leak detection ball valve at the High Gas Pressure switch shown in Figure 6 1B Install a 0 16 W C manometer
172. ine the functions of the PCB connections Do not use the silkscreened labels on the PCB itself as these may not match OMM 0082 0J AERCO International Inc e 100 Oritani Dr Blauvelt NY 10913 Page 27 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION Z CAUTION N DO NOT make any connections to the Box terminals labeled NOT USED Attempting to do so may cause equipment damage I OUTDOORAIRIN AIR SENSOR CONMON COMBUSTION AIR I O BOX PCB REMOTE INTL K EXHAUST SWITCH IN connection functions rather than the silkscreen labels on the PCB DELAYED INTL K IN NOT USED SPECIILE FAULT RELAY 12 DIP1 MODBUS TERM DIP2 RS232 ENABLE ooooooQ gt gt 8 gece gt RELAY CONTACTS 120 VAC 30 VDC RS 232 Comm 5 AMPS RESISTIVE RxD VFD BLOWER P DANGER 120 VAC USED IN THIS BOX amp Figure2 12 Box Terminal Strips 2 10 1 OUTDOOR AIR IN Terminals The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor AERCO Part No 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
173. ion Operation amp Maintenance Manual APPENDIX H PIPING DRAWINGS APPENDIX H PIPING DRAWINGS 9 310N 33S AN TWA 440LNH 34nsS3Hd SVD XVW AlddN S MI 99 NIVML SVD WAYOM O Y WALSAS lv JYNSSAYd SVD NnNININ NIVLNIVN SNILV3H YH NLA WANIXYN 1v Ronvo 3univa3dW3L 34 553 4 3AYA NOINN SATA 1051 M3NIVHIS A Q N3931 CdAL JAYA 4311384 Drawing Number SD A 870 rev B AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX PIPING DRAWINGS ava ddd g9g v ds SIN ANOS Aad 11050 Ag NMG NOLIVTIVLSNI UNNA 41d LLINW SUi3iOog8 Q3Ml4 SVD XON 000 OL OSL MXNVAHONd8 ODE Nanay WALSAS SNILV3H n di Mddns m di ANWA J4O1nHS 9 310N 33S OM rL 3H4nsSd3Md SV9 XVW IMI OM 40 NIVEL Svo OM LW 35055354 Sv9 NnNININ NIV LNIVIN YH NLE WAOWIXVN LY gonvo 330SS32d 3NIVA NOINA 3NIVA NOLLV IOSI YANIWYLS QN3911 STIVI3Q 304 00 SNOLLONYLSNI INVL 31VSN3QNOO 33S M0014 3408Y NVHL YSHOIH G31VA313
174. isplayed 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 level 96 measured by the sensor 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 O to 9 999 999 Fault Log Displays information on the last 20 faults OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 139 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM 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 Eng
175. it as shown in Figure 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 isolate the unit from the gas supply piping At no time should the gas pressure applied to the unit exceed 14 W C Leak test all external piping thoroughly 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 are as follows e The maximum static pressure to the unit must not exceed the following Natural Gas Propane Benchmark 750 14 W C 14 W C Benchmark 1000 14 W C 16 W C e Supply piping and pressure to the unit must be sufficient to provide the volume of gas while maintaining gas pressure listed below while operating at maximum capacity Natural Gas Propane Benchmark 750 1728 maintaining 4 W C 300 CFH maintaining 7 W C Benchmark 1000 976 CFH maintaining 4 W C 400 CFH maintaining 11 W C Page 22 of 192 AERCO Inte
176. itch Auto Reset See Note 123966 Limit Control Temperature Digital Controller 69177 NOTE If the unit is installed in the state of Kentucky contact your local AERCO Sales Representative for a Temperature Switch rated for 200 F OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 183 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX K RECOMMENDED SPARES This Page Is Intentionally Blank Page 184 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX M ULTRA LOW NOx CALIBRATION APPENDIX M ULTRA LOW NOx CALIBRATION M 1 ULTRA LOW NOx COMBUSTION CALIBRATION The procedures provided in this Appendix are used to combustion calibrate the boiler to produce ultra low NOx emissions of less than 9 ppm when running on natural gas NOTE The instructions below do not apply to units running Propane gas If the ultra low NOx requirement was specified on the Sales Order the Benchmark Boiler was combustion calibrated at the factory prior to shipping However 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 Factory Test Data sheets are shipped with each unit These s
177. l MAN mode the front panel controls are enabled and the 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 Bargraph 20 segment red LED bargraph continuously shows the Air Fuel Valve position in 5 increments from 0 to 10096 Page 40 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 applicable 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
178. l and reduce the O to the specified level Recalibration MUST be performed again from 60 down to 18 after making a change to the idle screw TAC valve 30 This completes the PROPANE combustion calibration procedures 4 5 REASSEMBLY AFTER COMBUSTION CALIBRATION Once the combustion calibration adjustments are properly set the unit can be reassembled for service operation Reassembly After Combustion Calibration Set the 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 Page 64 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP Reassembly After Combustion Calibration Continued 5 Remove the combustion analyzer probe from the 1 4 vent hole in the exhaust manifold Replace the 1 8 NPT plug in the manifold 6 Replace all previously removed sheet metal enclosures on the unit 4 6 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 4 The switches can be accesse
179. lected 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 In Option 2 when the space heating load is such that when all the space heating boilers are at the 10096 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 spa
180. lectrical Power Requirements The Benchmark Boiler accepts 120 VAC single phase 60 Hz 20A The Power Box contains terminal blocks as shown in Figure 2 10 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 8 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 25 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION AERCO INTERNATIONAL INC POWER BOX DANGER HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING INPUT POWER Ll NEU GND eS r E NEU 120 VAC 50 60 HZ SIY 9 9 9 0 O 20 AMP ee 9 9 9 9 9 USE COPPER CONDUCTORS ONLY FOR RELD WIRING Figure 2 10 Power Box Cover Label Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A double 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
181. lers in advance and place them in the proper physical location Refer to Chapter 5 for information on Combination Mode Boilers 2 5 SUPPLY AND RETURN PIPING The Benchmark Boiler utilizes 3 150 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 Refer to Appendix F Drawing AP A 891 for additional dimensional data BOILER HOT WATER OUTLET 1 NATURAL GAS OR PROPANE INLET SECONDARY INLET AIR INLET PRIMARY INTLET DRAIN VALVE EXHAUST MANIFOLD Figure2 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 relief 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 The relief piping must be full size without reduction No valves restrictions or other blockages are allowed in the discharge line In multiple unit installations the discharge lines must not be manifolded together
182. light and 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 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 50 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION TO AIR FUEL as VALVE MANUAL SHUT OFF VALVE GAS INLET SS SSOV Figure 3 3 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 c The VALVE POSITION bargraph will show 100 STEPPER MOTOR Figure 3 4 Air Fuel Valve In Purge Position OMM 0082 0J AERCO International Inc e 100 Oritani Dr
183. lish 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 Comm Address Fahrenheit F or degrees Celsius C Default is F For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload 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 Software Version Mandatory for AERCO OnAER Remote Data Collection This value must match the 4 digit serial on the Code Plate e g G 12 1234 Identifies the current software version of the control box Ver 0 0 to Ver 9 9 Internal Setpoint Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of KC Boiler KC Boiler LN BMK Boiler Std Bi
184. llation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION the isolation valve opens for a programmed interval default 1 minute before closing When the system load is satisfied the BST system will open the isolation valves for all of the boilers The implementation of BST and the installation and use of this valve is optional The boiler is pre wired to accept the sequencing isolation valve Installation consists of installing the sequencing isolation valve in the hot water outlet pipe and then connecting it into the shell harness as described below NOTE When the Sequencing Isolation Valve is used the AUX START ON DLY in the Configuration menu must be set to at least 120 seconds The Sequencing Isolation Valve control is only available when BST is enabled Refer to section 2 10 12 2 and Table 3 4 in section 3 6 and Chapter 10 Installing Sequencing Isolation Valve 1 Install the sequencing isolation valve in the boiler s hot water outlet pipe SEQUENCING ISOLATION VALVE HOT WATER OUTLET Figure 2 13 Sequencing Isolation Valve Installed OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 35 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION Installing Sequencing Isolation Valve Continued 2 The boiler s shell harness has one unused cable One end of this cable is connected to
185. lt NY 10913 Page 117 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION 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 session 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 At the bottom of the Basic Options dialog box left image of Figure 9 1 in the section titled Close window on exit select the
186. m the igniter injector Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Disconnect the unit wiring harness connectors from the air fuel valve and blower motor Disconnect the wire leads connected to the blower proof switch and blocked inlet switch Figure 7 4 and Figure 7 5 Disconnect the gas train from the air fuel valve by removing the four 4 1 2 bolts and nuts Figure 7 4 Disconnect the flex hose from the air fuel valve by loosening the hose clamp Remove the four 5 16 18 hex head screws securing the blower to the burner plate Figure 7 5 Remove the blower and air fuel valve from the burner plate by lifting straight up Also remove the blower gasket Remove the eight 8 3 8 16 nuts from the burner flange Figure 7 4 using a 9 16 wrench Page 94 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE Burner Assembly Inspection Continued REAR 7 FRONT BLOWER BURNER PLATE BLOWER PROOF SWITCH BLOCKED INLET SWITCH IGNITOR INJECTOR STAGED IGNITION ASSEMBLY 1 2 BOLTS amp NUTS 4 GAS TRAIN to A F AIR FILTER VALVE Figure 7 4 Burner Assembly Mounting Details Overhead View BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR FU
187. mbustion 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 1896 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 value of 9 ppm increase the O level up to 196 higher than the listed calibration range Record the increased value on the Combustion Calibration sheet Lower the valve position to 80 using the Y arrow key 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 SET Valve Position will begin to flash Press the A arrow key until SET Valve Position reads 80 Press the ENTER key Next press the down Y arrow key until CAL Voltage 8096 is displayed Press the CHANGE key and observe that CAL Voltage 80 is flashing 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 Ultra Low NOx Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide NOx CO 8096 5
188. mper not installed or removed 2 Energy Management System does not have unit enabled 3 Device proving switch hooked to interlocks is not closed Line and Neutral switched in AC Power Box 2 Incorrect power supply transformer wiring k CORRECTIVE ACTION 1 Check for a jumper properly installed across the interlock terminals in the box 2 If there are two external wires on these terminals check any Energy 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 Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational 1 Check hot and neutral in AC Power Box to ensure they are not reversed 2 Check transformer wiring in AC Power Box against the power box transformer wiring diagram to ensure it is wired correctly Incorrect supply gas pressure 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is between 4 0 W C and 14 W C For IRI gas trains ensure it is between 4 2 W C and LOW GAS 14 W C see section 2 8 1 PRESSURE 2 Defective Low Pressure Gas 2 Measure gas pressure at the Low Gas Pressure switch If it is Switch greater than 2 6 W C measure continuity across the switch and replace if necessary 1 Insufficient water level in system 1 Check system for sufficient
189. n 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 13 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 1 SAFETY PRECAUTIONS 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 instaled 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 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 Board and 2 Product
190. n 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 8096 press the ENTER key to store the selected blower output voltage for the 80 valve position Record all readings on the Combustion Calibration Sheets provided Repeat steps 20 through 27 for valve positions of 6096 45 30 and 18 see NOTE below The oxygen Oz nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table Page 60 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP NATURAL GAS Combustion Calibration Continued NOTE Set the Valve Position at 18 but make adjustments to the Combustion Calibration value designated as 16 NOTE If NOx readings exceed the target values shown 20 ppm increase the level up to 196 higher than the listed calibration range shown in the table Record the increased value on the Combustion Calibration sheet Natural Gas Combustion Calibration Readings E Nitrogen Oxide Carbon Monoxide Valve P
191. n valve position 11 Check the Analog Out option on the C More Configuration 10 Defective Box Menu Valve Position 0 10V should be selected 12 Check Air Fuel Valve position at 096 5096 and 10096 open 11 Wrong 0 10V output selection on the positions The positions on the VALVE POSITION bargraph should match the readings the Air Fuel Valve dial 12 Defective Air Fuel Valve 13 Check igniter injector for soot or erosion of electrode Check potentiometer injector solenoid valve to insure proper open close operation 13 Hard light OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 103 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING PURGE i Blower not running or running too slow Defective Blocked Inlet switch Blockage in air filter 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 2 3 4 5 6 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
192. nal Benchmark 750 1000 DBB Gas Train 03 07 2014 Inc Blauvelt NY 10913 22140 2 rev D reference PL A 170 Sheet 1 of 1 Page 168 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX G PARTS LIST DRAWINGS 750 1000 PROPANE Gas Train p n 22140 3 rev C Qty Part Description Qty Part Description 1 1 95026 25 1258 THREADED FLANGE 19 2 90104 NIPPLE PIPE NPT SCH 40 x 7 00 LG BLK STL 2 1 92103 VALVE SSOV 1 2 NPT 20 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 3 1 69005 SSOV W REGULATOR 21 3 124151 1 4 NPT SCH 40 X 1 1 2 LG NIPPLE 4 1 93422 HEXREDUCING 17x 74 NPT SLK 22 1 1124088 NIPPLE 1 4 C S 2 1 2 LONG 5 2 1123536 BUSHING REDUCING 1 4 X 1 8 NPT 23 2 12951 2 BUSHING CONTROL BOX 6 1 123311 BUSHING REDUCING 1 2 NPT X 1 4 NPT 24 1 92006 3 VALVE FULL PORT BALL 1 2 NPT BRASS 7 3 93419 ELBOW 90 FEMALE NPT BLACK MI 25 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 8 1 93423 ELBOW 45 FEMALE NPT BLK M I 61002 8 BMK750 LOW GAS PRESSURE SWITCH 4 4 W C 9 2 124084 ELBOW 1 4 1508 M I E 61002 8 BMK1000 LOW GAS PRESSURE SWITCH 7 5 W C 10 1 3418 61002 12 BMK750 HIGH GAS PRESSU
193. nal wiring information OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 69 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION 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 Indoor Outdoor Startup Refer to the Indoor Outdoor reset ratio charts in Appendix D 2 Choose the chart corresponding to the desired Building Reference Temperature 3 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 section 3 3 for detailed instructions on menu changing Press the CHANGE key The display will begin to flash Use the A and V 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
194. nd then shut down since the blower is disabled The unit will then display AIRFLOW FAULT DURING PURGE Re enable the blower output drive voltage by performing the following steps a Press the MENU key until CONFIGURATION MENU is displayed Press the A arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key Press the A arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key 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 Goto 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 1 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 Page 84 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0
195. ndations Close manual gas shutoff valve and check meekly Sporali safety shutdown See section 6 7 Check flame strength using the Control egenum WEERIY Panel Operating Menu See section 3 4 Weekly Operator See section 6 4 and alarm Sami Perform a slow drain test in accordance with Slow drain test Operator ASME Boiler and Pressure Vessel Code Annually Section IV High water Service temperature safety Annually Technician See section 6 5 control test Operating controls Annually Operator See section 3 2 OMM 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 179 of 192 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX J RECOMMENDED PERIODIC TESTING Accomplished Item Frequency By Remarks Low air flow Monthly Operator See section 6 8 High and low gas Monthly Operator See sections 6 2 and 6 3 pressure interlocks Air Fuel Valve purge Service position switch Annually Technician i Fuel Valve ignition Annually sales See section 6 11 position switch Technician Check per A S M E Boiler and Pressure Safety valves As required Operator Vessel Code Section IV Inspect burner Semi Service See section 7 7 components Annually Technician Condensate Trap pee Operator See section 7 8 Oxygen Level Monthly Operator Verify oxygen level is between 3 and 8
196. nfiguration 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 44 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 3 OPERATION Table 3 4 Configuration Menu Available Choices or Limits Menu Item Display xu Default Minimum Maximum Internal Setpt Lo Temp Limit Hi Temp Limit 1309 Bir Std Bir Std Dual Unit Bir LN Bir LN Dual yp KC Water Heater KC Water Heater LN BMK Bir LN Innovation WH Unit Size 750 MBH 1000 MBH Only the unit sizes 1500 MBH 2000 MBH available for the Unit 2500 MBH 3000 MBH 1000 MBH Type will be displayed 6000 MBH Fuel Type Natural Gas Propane Natural Gas Constant Setpoint Remote Setpoint Boiler Mode Direct Drive Combination Constant Setpoint Outdoor Reset Remote Signal 4 20 1 5 If Mode Remote 0 20 mA 0 5V 4 20 mA Setpoint Direct Drive PWM Input Legacy BMS 1 5V or Combination Network Outdoor Sensor Enabled
197. nitiate a unit start sequence 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 74 AIR FUEL VALVE COVER Rotate counter clockwise to remove Figure 6 6 Air Fuel Valve Cover Location 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 Setthe units 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 The unit should begin its start sequence and then shut down and display GN SWITCH OPEN DURING IGNITION Replace the wire on the Ignition Switch and press the CLEAR button The unit should restart OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 87 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING Ignition Switch Open During Ignition Continued Purge Position Switch Ignition Position Switch TO BL
198. nstant Setpoint Select desired setpoint using A and V arrow keys 40 F to 240 F Refer to section 3 3 for detailed instructions on changing menu options Internal Setpt 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 e 0 20 mA 0 5 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 an 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 mA 0 to 5 Vdc 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 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 Table 5 2 Rem
199. o the Head Temp Source item and select FFWD Temp 7 Go to the BST Remote Signal item and select Network 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 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 133 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler 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 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 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
200. of the boiler as shown in Figure 7 7 To inspect replace the air filter proceed as follows Air Filter Cleaning amp Replacement 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 a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the inlet flange of the air fuel valve Remove the filter and clamp The filter may be cleaned in 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 FILTER HOSE CLAMP BLOWER AIR FUEL VALVE AIR FILTER 9 MIRROR VIEWPORT GAS TRAIN ASSEMBLY Figure 7 7 Air Filter Replacement Page 98 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Oper
201. on the side of the exhaust manifold as shown in Figure 4 2 Prepare the port for the combustion analyzer probe as follows Accessing Analyzer Probe Port 1 Refer to Figure 4 2 and remove the 1 4 NPT plug from the exhaust manifold 2 f 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 FLUE STARTER SECTION Condensate Drain ANALYZER PROBE EXHAUST Figure 4 2 Analyzer Probe Port Location OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 57 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP 4 3 NATURAL GAS COMBUSTION CALIBRATION Complete the instructions below if the unit will run on Natural Gas rather than PROPANE gas NOTE When installed and operated in accordance with the requirements specified in this section this Benchmark boiler delivers low NOx emissions of 20 ppm at all firing rates Alternatively these boilers can be combustion calibrated to provide ultra low NOx emissions of 9 ppm To combustion calibrate the boiler to produce low NOx emissions of 20 ppm complete the instructions in this section To combustion calibrate the boiler to produce ultra low NOx emissions of lt 9 ppm first complete the instructions in this section and then in addition complete the instructions in A
202. onds 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 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 147 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES This Page Is Intentionally Blank Page 148 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Temperature Sensor Resistance Voltage Chart Balco TEMP F RES OHMS VOLTS 40 779 0 1 93 30 797 5 1 96 20 816 3 1 99 10 835 4 2 02 0 854 8 2 05 10 874 6 2 07 20 894 7 2 10 30 915 1 2 12 40 935 9 2 15 50 956 9 2 17 60 978 3 2 20 70 1000 0 2 23 80 1022 0 2 25 90 1044 4 2 27 100 1067 0 2 30 110 1090 0 2 32 120 1113 3 2 94 130 1137 0 2 36 140 1160 9 2 39 150 1185 2 2 41 160 1209 5 2 43 170 1234 7 2 45 180 1260 0 2 47 190 1285 6 2 50 200 1311 4 2 52 210 1337 7 2 54 220 1364 2 2 56 230 1391 0 2 58 240 1418 2 250 1445 7 OMM 0082 0J GF 130 AERCO International Inc e 100
203. ons and other internal components shown in Error Reference source not found 2 9 POWER BOX WITH HINGED FRONT COVER FRONT UPPER RIGHT CORNER OF UNIT Figure2 8 Power Box With Closed Cover Page 24 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION N WARNING N THE AC POWER OUTLETS SHOWN IN ERROR REFERENCE SOURCE NOT FOUND 2 9 ARE LIMITED TO 600 WATTS 5 AMP SERVICE DO NOT OVER LOAD THESE OUTLETS ALSO THE FUSIBLE LINK SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS OR AC OUTLETS FUSIBLE DISCONNECT AC POWER FUSE BLOCKS OUTLETS 2 2 12 POWER of SUPPLY p tH e H x FLAME ROD SIGNAL eN Ez ES AMPLIFIER TRANSFORMER 115V 24V 24v POWER SUPPLY SEQUENCING VALVE Figure2 9 Power Box Internal Components TERMINAL BLOCKS With the exception of the transformer shown in Error Reference source not found 2 9 all of the components in the Power Box are mounted on a DIN rail NOTE All electrical conduit and hardware must be installed so that 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 E
204. opper components TRAP INLET TOP COVER INTEGRAL ADAPTOR AND THUMB SREWS THUMBSCREW 4 each CONDENSATE COMBUTION TRAP ANALYZER P N 24060 SECTION EXHAUST MANIFOLD HOSE CLAMP 1 DIAM HOSE NOTE HOUSKEEPING 3 4 NPT PAD MUST NOT HOUSE anni NIPPLES SUPPORT FLOOR KEEPING 6 MAXIMUM UNDER THE CONDENSATE PAD ASSEMBLY Y Figure2 6 Sample Condensate Trap Installation OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 21 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 N WARNING N NEVER USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS N CAUTION Many soaps used for gas pipe leak testing are corrosive to metals Therefore piping must be rinsed thoroughly with clean water after soap 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 750 and 1000 MBH units contain either a 1 inch NATURAL GAS or a 1 inch PROPANE gas inlet connection on the rear of the un
205. or 12 months from startup whichever comes first Rev 11 22 2013 Page 190 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual NOTES OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 191 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Change Log Date Description Changed By 03 19 2014 Rev I PIR 780 replaced mechanical latch with magnetic PIR 981 Expanded Table A in Appendix F Part List PIR 934 33 Modified step 13 in Combustion Calibration regarding defective Sensor PIR 934 37 Modified Blocked Inlet Switch Test instructions section 6 8 2 PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Isolation Valve Installation 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 974 Replaced Gas train harness 161450 with 63147 in Appendix G PIR 1000 P N 61026 now labeled Lean Oxygen Sensor 64081 now named ECU PIR 1005 Changed 12 Month Maintenance Kit part number to 58025 01 Chris Blair 05 21 2014 Rev J PIR 749 Added Propane to section 2 8 Gas supply Piping
206. orrectly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 2 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 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 Board PRG SWTCH OPEN DURING PURGE 1 Defective purge switch 2 No voltage present at switch 3 Switch wired incorrectly 4 Defective Power Supply Board or fuse 5 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 Board
207. osition Oxygen 60 5 6 lt 20 ppm lt 100 ppm 45 5 6 lt 20 ppm lt 100 ppm 30 5 6 lt 20 ppm lt 100 ppm 18 5 6 lt 20 ppm lt 100 ppm 29 If the oxygen level at the 18 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 Appendix G Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the O to the specified level Recalibration MUST be performed again from 60 down to 18 after making a change to the idle screw TAC valve 30 This completes the NATURAL GAS combustion calibration procedures 4 4 PROPANE COMBUSTION CALIBRATION Complete the instructions below if the unit will run on PROPANE gas rather than Natural Gas NOTE When installed and operated in accordance with the requirements specified in this section this Benchmark boiler delivers low NOx emissions of lt 30 ppm at all firing rates Unlike units running on Natural Gas there is no ultra low NOx emissions option The Benchmark 750 1000 boiler is combustion calibrated at the factory prior to shipping However recalibration is necessary as part of initial start up 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 AER
208. ote Setpoint Mode Settings Menu Option Setting Boiler Mode Remote Setpoint Remote Signal 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 OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 71 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION 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 unit s 1 Box The Box is located on the front panel of the boiler For either 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the Box For a Network setting the connections are made at the RS 485 COMM te
209. ould start Page 82 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 Set the ON OFF switch to the OFF position Place the unit in the Manual Mode and set the valve position between 2596 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 Set the ON OFF switch to the ON position to start the unit 5 The unit should shut down after reaching the 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 8 Once flame is proven close the manual gas valve located between the SSOV Figure 6 3 and the Air Fuel Valve The unit should shut down and execute an GNITION RETRY cycle by performing the following steps The unit will execute a shutdown purge cycle for a period of 15 seconds and display WAIT FAULT PURGE The unit will execute a 30 second re ignition delay and display WAIT RETRY PAUSE The unit will then execute a standard ignition sequence and display WAIT IGNI
210. ove 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 should fault and display SSOV SWITCH OPEN Replace wire 148 and press the CLEAR button Set the 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 SSOV ACTUATOR ACTUATOR COVER COVER SCREW 1 Figure 6 5 5507 Actuator Cover Location Page 86 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING 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 Setthe 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 I
211. perate 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 73 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 5 MODE OF OPERATION 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 1 14 To enable the ACS Mode the following menu settings must be made in the Configuration Menu Table 5 4 ACS Mode Settings 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 terminals on the ACS boilers 9 through 40 and the RS 485 COMM terminals in the Box the front of the boilers 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
212. ppendix M The Benchmark 750 1000 boiler is combustion calibrated at the factory prior to shipping However recalibration is necessary as part of initial start up 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 performance NATURAL GAS Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running 2 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
213. r Std Dual Boiler LN Bir LN Dual KC Water Heater KC Wtr Heater LN Innovation WH Page 140 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual APPENDIX A BOILER MENU ITEM 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 Default is 130 F 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 If Unit Type Boiler Setpoint Direct Drive Combination or Outdoor Reset Mode Default is Constant Setpoint Mode Remote Signal If Mode Remote Setpoint Direct Drive or Combination Used to set the type of external signal which will be used 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
214. re Measure continuity across the common C and normally Switch closed NO terminals with the unit not firing Replace the switch if continuity does not exist 1 Faulty Water temperature switch 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Incorrect PID settings 2 Check PID settings against Menu Default settings in Appendix E 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 HIGH WATER TEMP water temperature aN 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 occurring faster than units can flow changes to ensure that the rate of flow change is not respond faster than what the units can respond to HIGH WATER 1 See HIGH WATER 1 See HIGH WATER TEMPERATURE SWITCH OPEN TEMPERATURE TEMPERATURE SWITCH OPEN 2 Temp Limit setting is too low 2 Check Temp Limit setting IGN BOARD 1 Communication fault has occurred 1 Press CLEAR button and restart unit If fault pe
215. 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 7 8 CONDENSATE DRAIN TRAP MAINTENANCE 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 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 P N 81092 if using older trap with new parts Reassemble all piping
216. ring Signal is not isolated floating Control Box signal type selection switches not set for correct signal type voltage or current Check wiring continuity between source 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 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 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 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 P
217. rminals in the I O Box The signal must be floating ungrounded at the 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 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 can 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 4 20 1 5 e 0 20 mA 0 5 factory default setting for the Direct Drive mode is 4 20 mA 1 5 With this setting a 4 to 20 mA signal sent by an EMS or BAS is used to change the unit s valve position from 0 to 10096 A 4 mA 1V signal is equal to a 0 valve position while a 20 mA 5V signal is equal to
218. rnational Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 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 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 NATURAL GAS The external natural gas regulator must be capable of regulating 49 000 1 020 000 BTU HR while maintaining a minimum gas pressure of 4 0 W C to the unit PROPANE The external natural gas regulator must be capable of regulating 49 000 1 020 000 BTU HR while maintaining a minimum gas pressure of 11 0 W C to the unit 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 mul
219. rosion 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 COMPRESSION FITTING AND ELBOW FLAME s p STAGED DETECTOR 4 IGNITION amp GASKET 2 WY SOLENOID INJECTOR IGNITOR PLATE INDEXING WASHERS Quantity 0 3 as required O2 SENSOR amp WASHERS 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 NOTE If a replacement igniter injector part no 58023 is being installed a compression nut containing a built in ferrule will be include
220. rsists COMM FAULT between the PMC board and contact qualified Service Personnel Ignition Stepper IGST board OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 107 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1 Air Fuel Valve not rotating 1 Start the unit The Air Fuel Valve should rotate to the 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 2 Defective or shorted switch personnel 2 the Air Fuel Valve does rotate to purge check the ignition switch for continuity between the N O and COM IGN SWTCH CLOSED terminals If the switch shows continuity when not in DURING PURGE 3 Switch wired incorrectly contact with the cam replace the switch 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch 4 Defective Power Supply Board is wired correctly replace the switch or fuse 4 Check DS1 amp DS2 LEDs on Power Supply Board If they 5 Defective IGST Board are not steady ON replace Power Supply Board 5 Check Hea
221. rtbeat LED DS1 and verify it is blinking ON amp po every second If not replace IGST Board 1 Air Fuel Valve not rotating to 1 Start the unit The Air Fuel Valve should rotate to the purge 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 IGN SWTCH OPEN 2 Defective ignition switch service personnel DURING IGNITION 2 If the Air Fuel Valve does rotate to the ignition position check the ignition position switch for continuity between the 3 Defective Power Supply Board N O and COM terminals when in contact with the cam or fuse 3 Check DS1 amp DS2 LEDs on Power Supply Board If they 4 Defective IGST Board are not steady ON replace Power Supply Board 4 Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Page 108 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION INTERLOCK OPEN LINE VOLTAGE OUT OF PHASE PROBABLE CAUSES 1 Interlock ju
222. s 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 96 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 Actuator Y Controlled T Note Modbus Header sensor a Sequencing can be connected to any Vale boiler on the Modbus Network Boiler Boiler Boiler 1 2 8 Note FFWD Header Sensor 0 NOM must be connected to a Master o o f f Y Jom INLET Figure 10 1 Simplified BST Block Diagram OMM 0
223. 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 E 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 Page 76 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 05 21 2014 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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
224. signals must be floating ungrounded signals Connections between the source and the boiler s I O Box see 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 Box 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 Terminals These terminals are only used to connect TO the legacy AERCO Boiler Management System 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 Terminals The two SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit Shields must only be connected to these terminals OMM 0082_0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 29 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 2 10 8 ANALOG OUT Terminals The ANALOG OUT terminals amp output from 0 to 20 mA and may be used to moni
225. t no gas or flame is present in the boiler at this time 5 Wait for the boiler to ramp up to at least 9096 before continuing 6 Cover the combustion air inlet 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 85 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 6 SAFETY DEVICE TESTING SECONDARY WATER INLET RETURN AIR INLET Combustion Air PRIMARY WATER Duct removed INI EXHAUST MANIFOLD 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 Setthe units 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 3 and locate the SSOV Rem
226. tch 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 104 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Delayed Interlock Jumper not properly installed or missing Device proving switch hooked to 1 Check to insure jumper is properly installed across the delayed interlock terminals in the I O Box 2 If there are 2 external wires on these terminals check to see DELAYED I i INTERLOCK OPEN interlocks is not closed if 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 installed to test the interlock Direct drive signal is not present 1 Check I O Box to ensure signal is hooked up Not yet installed Hook up if not installed Wrong polarity If installed check polarity Signal defective at source Measure signal level DIRECT DRIVE SIGNAL FAULT Broken or loose wi
227. ti unit installations other than Massachusetts that EXCEED 7 W C gas pressure a separate external 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 23 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 2 INSTALLATION 1 MANUAL SHUTOFF VALVE GAS INLET X DIRT 11J GAS PRESSURE REGULATOR 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 Figure2 7 Manual Gas Shut Off Valve and Gas Regulator Locations 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 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 Open the hinged cover of the Power Box to access the AC terminal block connecti
228. tion 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 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 SET Valve Position will begin to flash Press the A arrow key until SET Valve Position reads 80 Press the ENTER key Next press the down Y arrow key until CAL Voltage 80 is displayed Press the CHANGE key and observe that CAL Voltage 80 is flashing 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 Propane Combustion Calibration Readings Nitrogen Oxide Carbon Monoxide NOx CO 8096 5 696 30 ppm 100 ppm Valve Position Oxygen 02 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 63 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual
229. tion procedure in Section 6 section 6 2 1 2 Check that the Air Fuel Valve is connected to the Control Box 3 Inspect for loose connections between the Air Fuel Valve motor and the wiring harness 4 Replace stepper motor 5 Check DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 6 Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Page 112 of 192 05 21 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0082 0J GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 WATER HEATER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT Hard Light Off PROBABLE CAUSES 1 Staged Ignition Ball Valve closed 2 Clogged damaged Gas Injector on Igniter Injector Figure 8 2 3 Defective Staged Ignition Solenoid Figure 8 1 1 2 CORRECTIVE ACTION Open the Staged Ignition Ball Valve on the upstream side of the SSOV Figure 8 1 Disconnect the Staged Ignition Assembly solenoid from the Gas injector Tube of the Igniter Injector Figure 8 2 and inspect Gas Injector to ensure it is not clogged or damage
230. tions 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 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 101 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE This Page Is Intentionally Blank Page 102 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE Table 8 1 BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 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
231. tor 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 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 e f On Board Boiler Sequencing Technology BST is enabled the Analog Output terminals are used to drive the isolation valve open and closed When the 4 20mA is selected for the Analog Output the 0 10VDC is disabled at the VFD Blower terminals and the selected output is available at the terminals labeled Analog Output 2 10 9 RS 485 Comm Terminals RS 485 communication terminals GND amp are used when the boiler plant is being controlled by an Energy Management System EMS or AERCO Control System ACS using Modbus RS 485 communication 2 10 10 RS 232 Comm Terminals The RS 232 communication terminals TxD and RxD 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
232. ture Limit Switch auto rest PARTIAL FRONT VIEW WITH PANEL REMOVED Figure 4 4 Over Temperature Limit Switch Locations 4 6 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 5 Limit Control Figure 4 5 Digital Alarm Switch Front Panel Page 66 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 4 INITIAL START UP Table 4 1 Digital Over Temperature Limit Controller Features c MEANING FUNCTION LED Display TEMP status E current water temperature or RST RESET Button Resets the unit after an alarm condition UP Button Increases the displayed temperature wA DOWN Button Decreases the displayed temperature SET SET Button mods to access and store parameters in the Perform the steps in the following procedure to check or adjust the digital alarm switch settings Switch Check or Adjustment 1 Set the ON OFF to the ON position 2 Press the SET button on the Digital Alarm Switch SP will appear the display 3 Press the SET button again The current over temperature limit value stored in memory will be displayed default 210 F 4 If the display does
233. u items shown 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 Menu Hem Display Choices er Limits Minimum Maximum Prop Band 1 F 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 oF 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 OMM 0082_0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 46 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 96 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 ensure the unit conforms to the Nitrogen Oxide NOx and Carbon Monoxide CO emissions specified in Chapter 4 The valve positions 96 and default drive voltages are listed in Table 3 6
234. 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 flame detector lead wire Remove the two 2 screws securing the flame detector to the plate Figure 7 2 on previous page 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 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 Page 92 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 7 MAINTENANCE 7 4 O2 SENSOR REPLACEMENT The Lean Oxygen Sensor part no 61026 is located on the burner plate at the top of the unit see Figure 7 1 and Figure 7 2 The sensor and burner plate may be hot Allow the unit to cool sufficiently before removing or replacing the O sensor Sensor Replacement 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 th
235. ure that the site selected for installation of the Benchmark Boiler includes Access to AC Input Power at 120 VAC Single Phase 60 Hz 20 Amps e Access to one of the following with the unit operating at maximum capacity o For Benchmark 750 amp 1000 a NATURAL GAS line at a minimum pressure of 4 W C o For Benchmark 750 a PROPANE gas line at a minimum pressure of 7 W C o For Benchmark 1000 a PROPANE gas line at a minimum pressure of 11 W C 2 4 1 Installation Clearances Benchmark Models 750 and 1000 are packaged in enclosures 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 are as follows Sides 24 inches e Front 24 inches e Rear 24 inches 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 SIDE VIEW REAR piste d 24 610 _ R xi 24 24 610 610 7 FRONT 4 HIGH PAD SEE NOTE IN PARAGRAPH 2 4 2 Housekeeping pad should not extend under the condensate assembly Figure 2 1a BM
236. 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 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 43 of 192 GF 130 Ph 800 526 0288 05 21 2014 CHAPTER 3 OPERATION Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual Table 3 3 Setup Menu Available Choices or Limits Menu Display m Default Minimum Maximum Password 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 2 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 IP Address Software 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 co
237. water level 2 Defective water level circuitry 2 Test water level circuitry using the Control Box front panel LOW LOW WATER WATER TEST and RESET buttons Replace water level circuitry LEVEL 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 COMMFAULT Unit not seeing information from Check network connections If fault persists contact qualified PRG SWTCH CLOSED DURING IGNITION Modbus network 1 A F Valve rotated open to purge and did not rotate to ignition position Service Personnel 1 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 0082 0J GF 130 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 109 of 192 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION PRG SWTCH CLOSED DURING IGNITION continued 2 Defective or shorted switch 3 Switch wired inc
238. with or lower than 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 AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port Page 20 of 192 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0082 0J 05 21 2014 Ph 800 526 0288 GF 130 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 using the appropriate piping components nipples reducers elbows etc for the boiler installation site 2 Atthe condensate trap outlet install a 3 4 NPT nipple 3 Connect a length of 1 1 0 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 drain is not available a condensate pump can be used to remove the condensate to an appropriate drain The maximum condensate flow rate is 10 GPH The condensate drain trap associated fittings and drain line must be removable for routine maintenance A CAUTION Use PVC stainless steel aluminum or polypropylene for condensate drain piping Figure 2 6 DO NOT use carbon or c
239. ximately at or just below the actual outlet water temperature the unit should shut down The FAULT indicator should start flashing and a 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 Reset button for Manual Temperature Digital Over Limit Switch Temperature Limit Controller Manual Temperature Limit Switch Adjustable Temperature Limit Switch auto rest Front view with Panel removed Figure 6 2 Temperature Limit Switch Location and Setting OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 81 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual 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 Box Figure 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 closed However each of these interlocks may be utilized in the field as a remote stop and start
240. y 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 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 SO 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 OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 121 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual CHAPTER 9 RS 232 COMMUNICATION 9 4 3 Sensor Log The sensor values can be logged at a different rate if needed 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
241. yer has permitted any unauthorized modification adjustment and or repairs to the item The use of replacement parts not manufactured or sold by AERCO will void any warranty express or limited AERCO shall accept no responsibility if such item has been damaged due to contaminated combustion air containing but not limited to sheetrock particles plaster board particles dirt dust lint and corrosive chemicals such as chlorine gas halogenated hydrocarbons and Freon Continued OMM 0082 0J AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 189 of 192 GF 130 Ph 800 526 0288 05 21 2014 Benchmark 750 1000 Boiler Installation Operation amp Maintenance Manual WARRANTY In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item In addition the returned item must include a Returned Goods Authorization RGA label attached to the shipping carton which identifies the item s return address register number and factory authorized RGA number Warranty coverage for all components and equipment mentioned in said warranty are not valid unless the water heater is started up by a factory certified SST Service Start Up and Troubleshooting Technician and an AERCO start up sheet is completed This warranty coverage is only applicable within the United States Canada and Mexico All other geographical areas carry a standard warranty of 18 months from date of shipment

01-Airco BMK 750 IOM

Contents

Download Pdf Manuals

Related Search

Related Contents