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Benchmark 2500 - 3000 Boilers

1. 96 7 8 AIR FILTER CLEANING amp REPLACEMENT nnn nnn nna 97 7 9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF 98 7 10 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWMNN 98 CHAPTER 8 TROUBLESHOOTING GUIDE ereeeeeeen u u u uuu 99 81 INTRODUCTION aa Ea EH 99 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 111 CHAPTER 9 RS 232 COMMUNICATION eren nennen 113 9 3 INTRODUCTION Z ua Cee T ERR OEIL nene LOIR Cone CREDE RR 113 9 1 1 Acquiring the PUTTY Application 113 9 1 2 Running a Command on a Remote Machine Using PuTTY enne enne nnne 114 9 2 RS 232 COMMUNICATION ua tania na sana sa rana naa aan 115 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION esses 115 9 4 DATA LOGGING rionn a C eet Ende C e ee elated 116 QA T Ida 117 9 4 2 Operation MMe EOB iret RH 117 9 4 33 SONMSOM 118 CHAPTER 10 BOILER SEQUENCING TECH
2. 3015 ON3Z 43108 Q33l4 SVD HEWN 0008 29 660 AN IVNOLLVNSBINI WYVNHONIS CLEARANCE DRAWINGS Benchmark 2500 3000 Boilers APPENDIX H CLEARANCE DRAWINGS APPENDIX H NI Q3AO1dWN3 38 ANO 39NVHV31O 305 019 Z 4114 8z 001 1H93IH 9 NM _ 72 INONJ 5305 1HD64 1331 SMOTIO3 Sv NOILOQNISNOO 1 39 0 OL S39ONVMY319 WNWININ Z 9NINOO14 JISUSNENOD NO Q3TIVISNI 38 AVN SONWdd SIHI GF 137 SNOISN3MIQ ASIQON OL JHL 53753535 OON3V OMM 0094 0E SIONVEVSTO NOIVTYVISNI rQVd HO9IH 8 v Ph 800 526 0288 Drawing Number SD A 898 rev C AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 SOS 154 204 03 20 2014 APPENDIX I Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS PARTS LIST DRAWINGS Benchmark 2500 3000 Parts List is Qty Part Description Qty Part Description EXHAUST MANIFOLD CONTROLS Continued 1 1 39156 MANIFOLD EXHAUST 30 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 2 1 84040 SEAL MANIFOLD 31 1 181197 CONTROL BOX C MORE 3 6 922 PIPE PLUG 1 4 NPT STEEL 32 1 65085 TRANSFORMER IGNITION 330
3. IGN SWTCH OPEN DURING IGNITION Air Fuel Valve not rotating to ignition position Defective ignition switch Defective Power Supply Board or fuse Defective IGST Board 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 2 If the Air Fuel Valve does rotate to the ignition position check the ignition position switch for continuity between the N O and COM terminals when in contact with the cam Check DS1 amp DS2 LEDs on Power Supply Board If they 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 Co Page 106 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION INTERLOCK OPEN PROBABLE CAUSES Interlock jumper not installed or removed Energy Management System does not have unit enabled 1 2 COR
4. 1 A 50 RS 485 IN GND 2 L 4 2 RELAY N C O4 NO RELAY n c OLN NOT USED o 6 5 ovr O sp tN DELAYED INTLK 4 2 INPUT OUTPUT BOX SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX 63156 6 PIN CONNECTOR SEQ VALVE Miet i SONON CABLE 507 50 10 1112 EXHAUST TEMP T tv THESE DRAWINGS ANOTOR SHICHCATONS AP D PROPERTY OF ARCO BEDINATONAL IC THEY ARE N STECI CONFOUNCE AND SHALL NOT REPROOUCED COPED USED AS THE BASE FOR MANUFACTURE OR SALE OF APPARATUS WITHOUI PERMISSION Of THE OWNER FOR REVISION SEE FIRST PAGE keo ato ANGLE PROCT N c ARE IN INCHES AND ALL TOLERANCES ABE AS FOLLOWS UNLESS OTHERWISE SPECIFIED XX 015 XXX t 005 FRACTIONS 1 306 ANGUS DIAMETERS ON A COMMON AWS 7 015 TOTAL CRMCAL DIMENSION C PERPENOICULABTY PARALLELGM FLAINESS 015 TOTAL ALL OMENSONS ARE ASTER ANSH OR PLATING ZW lt avou D oem 88 2013 INTERNATIONAL INC m WIRING SCHEMATIC 208 VAC 3 PHASE BMK 2500 FM Lx Drawing Number 68060 rev B Sheet 2 of 2 OMM 0094 OE GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 181 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This
5. 12V POWER SUPPLY FUSE BLOCKS 2 TERMINAL BLOCKS Figure 2 9 Power Box Internal Components With the exception of the transformer shown in Figure 2 9 all of the components in the Power Box are mounted on a DIN rail Page 24 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers inhibit service maintenance or prevent access between the unit and walls or another unit 2 9 1 Electrical Power Requirements Each Benchmark Boiler model is available in two voltage configurations as follows BMK 2500 amp BMK 3000 e 208 VAC Three Phase 60 Hz 10 Amps e 460 VAC Three Phase 60 Hz 5 Amps The Power Box contains terminal blocks as shown in Figure 2 9 In addition a label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2 10 AERCO INTERNATIONAL INC AERCO INTERNATIONAL INC POWER BOX POWER BOX DANGER HIGH VOLTAGE DANGER HIGH VOLTAGE DISCONNECT POWER BEFORE SERVICING DISCONNECT POWER BEFORE SERVICING INPUT POWER INPUT POWER Li L2 15 208 VAC Li L2 L3 460 eo 3 PHASE 3 PHASE e e 9 60 HERTZ 60 HERTZ GND os 20 AMP GND NEU 15 AMP o USE
6. IN3AdIHS NI AT3IvMvd3S 38V 31VSN30NOO 29 NOIVOlGIML ATA ANIA c SM313WILN39 SIHONI NI 34V NMOHS SNOISN3NIO TV 1 lv HSM LINN 135 310N 335 Vd 3H380N09 v 46 GIN H23338 NONN09 21 NNOlLdO NOLLOANNOO 5 8 SCYVGNVLS 1534 YSEWNVHO NOILSNENOO SHJONVHOX3 IV3H 8 HO Vuo es vs H3ls NOBNVO VF MJONVHOX3 TIVM 670 X 00 8 S8 13315 SS3INIVIS S3 gnl 1Y3H SS6 v Orc vS ld3ilS SSiINIVIS v l I33HS38fll M3MOT SS6 v Ovc vS I33lS SS3TNIVIS v L L33HS38nl M3ddh SS6tv Ovz VS l33lS SS3TNIVIS v L LNIOP 04749 919 5 13315 NOBNVO 1 5569 5 13315 SSdINIVIS L amp 3NNI TI ayo c vs I33ls NOBMVO v L M3lnO TI NOLLOQMISNOO dO S VI2131VNW SHS INOLLSNEWOS AHS 3ONVN3INIVA 218155399 OL SIHL 41 89 4 Cao NOLLOANNOD LINGNOD 91019313 y NOLLOANNOO SVOJ 2 1 99 SILON Drawing Number AP A 900 rev C AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 0E Page 153 of 204 03 20 2014 Ph 800 526 0288 GF 137 J 78027 An wed 0062
7. TANVd SOV vi 3449nSS38d SVD XVW O Y 1v 3u4nSSdNd SV9 WOWININ NIVLNIVW YH ALE WOWIXVW LY dds W3lSAS 3HnSS33d Drawing Number SD A 962 rev A GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE Page 196 of 204 03 20 2014 Ph 800 526 0288 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS A38 219021 21 0 5 A8 NMO v 96 v as nt MA 9 400 011 SNOLORMISNI YNVL 31VSN3QNOO 335 4OO014 SH 3AOBV 3IVidIHVWS XNVI NVHL G31VA313 38 1SnW 31VSN3qNOO OON3V M3108 NO V Q3TMWISNI 38 3009 W901 AG Q3MIno3H SSJINN TWNOlLdO SI MOlvin938 SVD V MOT38 HO OM tl lv 344n8 1509 Z NOILYTIVISNI d22 XNVI H3ZIVMIQ3N JHL 39vNIVHMO SLVSNSGNOD 33dOHd NVL YAZMVYLNSN 31VSN30NO2 OON3V ONISN N3HM 8 Sulvd Z JONVYVSIO 3015 0432 INW GSLINSNOO GINOHS 5 S3002 1v201 NOLLVTIVISNI TVOIdAL V SI SIHL HEW 0009 0002 uVWHON38 O 3O WOWINIA G33Ino3s S H3TIO8 MNVWHON38 NIVINIVW 1SnW 33108 21601 AN INVId N31l08 30 NOISAG JHL 1Y MOTI 3lVviMdOHddV 3GlAONd OL Q3Zls 38 LSNW dWnd 331108 9 ONI HYNOLLYNESINI P E X LLL N QS 944L v QS S44 v QS V GS 44 V QS 2 05 NOLLVTIVISN
8. MEN S d d OUTDOOR AIR IN FAULT RELAY 12 LI DIP1 MODBUS TERM mE DIP2 RS232 ENABLE AUX RELAY AIR SENSOR COMMON I O BOX PCB REMOTE INTL K COMBUSTION AIR O2 SENSOR e NOTE EXHAUST SWITCH IN NOT USED E Refer to this image for PCB ei connection functions rather SPARK SIGNAL than the silkscreen labels lt DELAYED INTL K IN O2 SENSOR on the PCB NOT USED NOT USED 12v OUT etr e ANALOG IN e e e e RELAY CONTACTS 120 VAC 30 VDC 5 AMPS RESISTIVE BLOWER u DANGER 120 VAC USED IN THIS BOX Figure 2 12 I O Box Terminal Strips 2 10 1 Outdoor Air In OUT amp Air Sensor Common COM The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor AERCO P N GM 123525 as required primarily for the Indoor Outdoor reset mode of operation It can also be used with another mode if it is desired to use the outdoor sensor enable disable feature This feature allows the boiler to be enabled or disabled based on the outdoor air temperature The factory default for the outdoor sensor is DISABLED To enable the sensor and or select an enable disable outdoor temperature see the Configuration Menu in Chapter 3 The outdoor sensor may be wired up to 200 feet from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O PCB Figure 2 12
9. 1 WALSAS 5 1_ AlddNs 31VSN3QNOO WilSAS AMVONOO3S hom 3ATVA TI3HS NI nu RS B X Niy 8 3LON 33S Tid YOLVINDIY 59 ONIONGSY 3YNSSIYd mm SY WilSAS AMVQNO23S rL 3NhSS3Nd SVO a T S NOMINI Xu INANI WOWIXV LV 8313AVIQ SLI SAWIL S OL 38 H19N31 3dld NOWWOO 03S 14 O r NVHL 5531 Q3ZIS 38 LSNW ANWA 33l138 3dld NONAWOO AYVWIYd Drawing Number SD A 959 rev A OMM 0094_0E Page 193 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS 3iva Oddy SIN 31VOS ZivOZi 31V0 5 NOLLVTIVISNI LUNAINN 5 0008 0002 NVWHON38 vNOLIVNSSTNI DG IE X Nanay W31SAS AYVONOOSS AlddNs W31SAS ANVONOO3S bu o NI SEA t gt X Say 3ATVA Td ONIONGSY 3YNSSAYd W3lSAS ASVONOO3S YOLVeVdAS WALSAS 5 YSLAWNVIC SLI SAWIL S OL 38 LSNW HIO9N31 3dld NOWWOO 03S 14 0 NVHL SS31 4043 Q3ZIS 38 LSNW S313AVIQ 3dld NOWNWOO 3002 1901 A8 G3MInO3N SSFINN TWNOlLdO SI YOLVINDAY SVO V MOT38 YO OM 8 STIIVL3d v400 GlL SNOILONYLSNI 1 3IVSN3QN
10. 31VSN3QNOO OOM3V 3108 NO V NI Q3TIVISNI 38 LSNW NVL M3ZIIVMIQ3N 39VNIVHO 31VSN3QNOO 33dONd 3O4 ANYL YAZMVYLNAN 31VSN3QNOO9 OON3V JHL ONISN N3HM SS31 YO 1 OL NMOG 3 H SS3Hd SVD ONING OL SAIWA 4SOLNHS 3Hl 4O WV3HNISNMOG Q3TIVISNI 38 ISAW YOLVINOAY FTALS df 53901 V NVHL M31Vv389 SI JYNSSIYd SVO 318VIIVAV N3HM ST3NVd 3015 WONJ 9 5 GINOHS S3XO8 LINGNOD S3HO1IMS 39lAN3S SNOILO3NNOO 21419313 ONidid TIY SH3AOO STI3NVd 33108 40 1VAOW33 39N3334331NI IN3A33d OL SONILLIJ 331v3H WO3J 9 WAWININ v 913 SMOHT3 SNOIN Y9 SONILLIS 131100 LIINI 331VM 31V2901 G3LINSNOOD 38 Q noHS 5 53000 1v901 ONIMVHG NOILLVTIVISNI TVOIdAL V SI SIHL 1N3AdIHS NI AT3lVsvd3s GSGMIONI 33v SWALI TV HOO14 3Hl 3 O8V 81 1H9I3H V OL ATIVOILYSA Q3dld 38 GINOHS 3ATVA 33l138 JHL 318VIIVAV SI 30013 ON N3HM NIVYG 3OO14 1S3NV3N JHL OL Q3dld 38 GINOHS 39MVHOSIGQ JAVA 33 133 NIVMO V OL ALIAVHO A8 AT33M4 NIVMO OL SAINTA JHL LINYSd OL Q39NvNS3V 38 GINOHS 3SOH 31VSN3QNOO JAVA NIVHO TISHS ONIMVHO TVNOISN3WIQ 33S M431V3H JHL OL SNOILO3NNOO Nidid JO SNOILYOOT ONY S3ZIS 1 303 3009 W901 A8 Q33MInO3M 553730 WNOlLdO SI YOLVINDSY SVD V MOT138 1V 5 L S310N lt N
11. Page 88 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE Igniter Injector Maintenance Procedures Cont 4 Refer to the partial exploded view in Figure 7 2 Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly Disconnect the staged ignition assembly from the igniter injector Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Check the igniter injector for evidence of erosion or 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 BLOWER PLENUM COMPRESSION STAGED IGNITION FITTING amp SOLENOID ELBOW FLAME DETECTOR amp O2 SENSOR GASKET amp WASHER FLEX GAS HOSE NIPPLE f FLAME INJECTOR IGNITOR OBSERVATION ASSY WITH INDEXING PORT CLOCKING WASHERS 0 3 as needed BURNER PLATE FLANGE Figure 7 2 Igniter Injector amp Flame Detector Mounting Details 7 Next loosen and remove the igniter injector from the burner plate using a
12. While it is possible to change the settings of temperature related functions the unit is factory preset with settings that work well in most applications It is suggested that an AERCO representative be contacted prior to changing any temperature related function settings For descriptions of temperature related functions and their factory defaults refer to Appendices A and E 5 4 1 Remote Setpoint Field Wiring The only wiring connections necessary for the Remote Setpoint mode are connection of the remote signal leads from the source to the units I O Box The I O Box is located on the front panel of the boiler For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals the I O Box The signal must be floating ungrounded at the I O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG Polarity must be observed The source end of the shield must be connected at the source When driving multiple units each unit s wiring must conform to the above OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 65 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION 5 4 2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled no startup instru
13. 201 29 1 Table F 6 Header Temperature for a Building Reference Temperature of 80F RESET RATIO s o so sa ee so on o os 80 80 80 80 80 80 80 80 84 85 86 87 88 89 90 91 92 86 88 90 92 94 96 98 100 102 104 89 92 95 98 101 104 107 110 113 116 96 100 98 104 108 112 116 120 124 128 140 152 164 176 188 200 212 132 145 158 171 184 197 210 136 150 164 178 192 206 140 155 170 185 200 205 144 160 176 122 200 148 165 182 199 26 T 134 152 170 188 206 T o ola ou 2 nmn nmn I Sm 02 10F OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 151 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS Table 1 7 Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air 90F 90 90 90 90 90 90 90 90 90 90 85F 93 94 95 96 97 98 99 100 101 102 80F 96 98 75F 99 102 106 65F 105 110 60F 108 114 55F 111 118 50F 114 122 45F 117 126 40F 120 130 134 145 156 167 178 189
14. 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 OUT OF RANGE 1 Combustion Calibration incorrect 2 Blocked inlet air duct or louver Check Combustion Analyzer and recalibrate Boiler Page 108 of 204 03 20 2014 2 Unblock air inlet and measure open area for combustion air to the room AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION RECIRC PUMP FAILURE REMOTE SETPT SIGNAL FAULT RESIDUAL FLAME 1 Internal recirculation pump failed 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 Replace recirculation pump Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check continuity of wiring between source and unit
15. A8 G3YINDAN SSIINN TWNOldO SI YOLVINDSY SV9 V MO138 YO OM tl 1V 8 SlIVI30 00 1 SNOILONYLSNI MNVL 31VSN3QNOO 33S YOO14 JAO8V NVHL M3HO9IH Q31VA313 LSNW 31VSN3QNOO OON3V N31l08 1 lid V NI Q3T1VISNI 38 LSNW YNYL 211 39vNIVHO 31VSN3Q0NOO 3dOSd 303 WNVL YSZMVYLNSN 31VSN30NOO OON3V ONISN N3HM Z SS31 MO OL NMOG 3H SS3Hd SV9 FHL ONING OL 3ATVA 4SOLNHS 3HL 30 WV3M1SNMOQ 5 38 LSNW YOLVINDAY 3115 dQ 201 V abl NVHL H31v3N9 SI JYNSSIYd SVD 318VlIVAV N3HM ST3NVd N31V3H JO TVAOW3H 3ON3834H31NI 1IN3A33d OL SONILLIJ 331V3H N3lVM WOsJ 9 WNWININ v O13 SMOST3 SNOINQ 9 SONILLI 131100 ANY 131NI 31V201 Q3L10SNOO 38 GINOHS 53000 1v201 ONIMVYG NOILYTIVISNI T VOIdAL V SI SIHL IN3AdIHS NI A13lvavd3s GSGNIONI SWALI Tv 3HL 3AO8V 81 V OL ATIVOlLH3A Q3dld 38 GINOHS JAYA 3311338 JHL 318VIIVAV SI 30014 ON N3HM NIVHQ 1S3HV3N JHL OL Q3dld 38 GINOHS 393VHOSIQ JAYA 33 19 NIVHO 30013 V OL ALIAVHO Al33H4 OL SAINTA LINNSd OL GINOHS 3SOH 31VSN3QNOO JAYA TTI3HS Z 9NIMVHO 33S 31V3H OL SNOLLO3NNOO YSHLO 9Nldld JO SNOIIV2O1 S3ZIS 1VnlOv MO L r S31ON NOISNVdX3
16. AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP 4 5 OVER TEMPERATURE LIMIT SWITCHES The unit contains three 3 types of over temperature limit switches These switches consist of a manual reset switch a rotary dial adjustable switch and a digital alarm switch These switches are mounted on a plate as shown in Figure 4 5 The switches can be accessed by opening the front panel door of the unit The manual reset switch is not adjustable and is permanently fixed at 210 F This switch will shut down and lock out the boiler if the water temperature exceeds 210 F Following an over temperature condition it must be manually reset by pressing the manual reset button shown in Figurer 4 5 before the boiler can be restarted The rotary dial over temperature switch is manually adjustable from xxx to yyy F This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this over temperature switch to the desired setting The digital alarm switch shown in Figures 4 5 and 4 6 is preset at the factory to 210 F and should not be changed If an over temperature condition is detected this switch automatically shuts down the boiler and sounds an audible alarm If desired the over temperature alarm switch settings can be checked or adjusted using the procedure i
17. 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 1 Replace Flame Detector Check open close indicator window of Safety Shut Off Valve SSOV and ensure that the SSOV is fully closed If not fully closed replace the valve and or actuator Close the 2 Gas Shut Off Valve downstream of SSOV Figure 2 7 Install a manometer or gauge at the leak detection port between the SSOV and Gas Shut Off Valve If a gas pressure reading is observed replace the SSOV Valve and or Actuator SSOV FAULT DURING See SSOV SWITCH OPEN PURGE 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 and SURE therefore there is a voltage measured between the two Normally this 3 Hot and Neutral reversed at SSOV measurement should be near zero or no more than a few millivolts Check SSOV power wiring OMM 0094 GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 109 of 204 03 20 2014 Benchmark 2500
18. Drawing Number SD A 963 rev A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 0E Page 197 of 204 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS This page intentionally blank Page 198 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX L C MORE CONTROL PANEL VIEWS APPENDIX L 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 oooo 7 7 GREEN LED P N 124948 ENCLOSURE P N 124951 ROCKER SWITCH P N 124947 POWER SUPPLY BOARD V F D DISPLAY NODULE P N 124362 PIN 124527 IGNITION STEPPER BOARD FISH PAPER PIN 124361 INSULATOR P N 124960 pe FRONT FACE PLATE BENCHMARK PRSH BUTTON P N 124949 P N 124954 VERTICAL OVERLAY BENCHMARK P N 124718 Figure L 1 Benchmark Control Panel Exploded View OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 199 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX L C MORE CONTROL PANEL VIEWS INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR
19. Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Outdoor Reset Go to the Head Temp Source item and select FFWD Temp Go to the BST Outdoor Sens item and select Enabled Go to the Outdoor Temp Source item and select Outdoor Temp OND When ALL 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 124 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 4 Option 4 Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor NOTE Both Header Sensor AND Outdoor Sensor must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode User Manual OMM 0080 GF 129 for more information Step 1 Modbus Header Sensor Wiring 1 Using Shielded pair 18 22 AWG cable connect the Temperature Transmitter AERCO P N 65169 terminal Pin B to the RS485 terminal on the I O Box of any of the Boiler units and Pin A of the Temperature Transmitter to the RS485 terminal on the I O Box of any of the Boiler units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor AERCO PN 24410 to pins 2 and 3 of the Temperature Transmitter 3
20. Running a Command on a Remote Machine Using PuTTY 1 Bring up the PuTTY application and select the server you wish to connect to 2 Atthe bottom of the Basic Options dialog box left image of Figure 9 1 in the section titled Close window on exit select the Never radio button This will keep the window open after the command has finished executing so that you can see any results in the terminal window In the menu bar along the left side of the dialog box click the SSH menu near the bottom The following screen will be presented Category Session Options controlling SSH connections i ha Logging Terminal 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 1 2 2only Encryption options Encryption cipher selection policy AES SSH 2 only Blowfish 3DES wam below here Arcfour SSH 2 only DES Enable legacy use of single DES in SSH 2 Figure 9 2 GUI Basic SSH Options for Running Remote Commands 4 Into the textbox titled Remote command type the full command line you wish to have executed on the remote machine Page 114 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 9 RS232
21. Temperature Terminating Resistor A resistor placed at each end of a daisy chain or multi drop network in order to prevent reflections that may cause invalid data in the communication uA Microamp 0 000001 amp one millionth of an amp VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column W C Page 10 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 1 SAFETY PRECAUTIONS CHAPTER 1 SAFETY PRECAUTIONS 1 1 WARNINGS amp CAUTIONS Installers and operating personnel MUST at all times observe all safety regulations The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions In addition to all the requirements included in this AERCO Instruction Manual the installation of 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 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
22. 200 138 150 162 174 186 198 210 25F 129 142 155 168 181 194 207 20F 132 146 160 174 188 202 216 15F 135 150 165 180 195 210 10F 138 154 170 166 200 218 SF 141 158 175 192 200 T X OF 144 162 180 198 2160 T Page 152 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX G DIMENSIONAL DRAWING DIMENSIONAL DRAWING APPENDIX G ENPE Qddv 7 o06 v av 3215 Fos 34 A amp NMd SONIMVYC TvNOISN3NIQ dillo8 SVD 0008 HVAHON38 1601 AN Weaneig e IWNOLVNSGINI 2202 205 NNOO LATINI STIVI3Q 303 00 SNOILONYLSNI ANVL 31VSN3QNOO 33S 40014 JHL 3AO8V NVHL qQ3lVA313 38 LSNW 31VSN3QNOO OON3V ANY 3308 JHL YO V NI Q3TIVISNI 38 LSNW 1 33ZrIV31n3N moo IODS 86 GG zz aU fosi v HIN 8 0 914 91 47 NNOD ULNO XALVM LOH dAVIS Al NOILO3S 3000 3WSV o0 oz Allovdvo 1495 9159 4 dWAL VA 43135 NiA 3ovdMns 9 1H SS38d 1531 W WIXVN 09 9154 5534 ONDISOM JHL 3OVNIVMO 31VSN3QNOO 304 5INVL MJZIIVHIQ3N 31VSN3ONOO OOM3V ONISN N3HM
23. 6 Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Page 110 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8 2 to troubleshoot faults which may occur without a specific fault message being displayed TABLE 8 2 BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Clogged damaged Gas Injector on Igniter Injector Figure 8 1 2 Defective Staged Ignition Solenoid Figure 8 1 1 Disconnect the Staged Ignition Assembly solenoid from the Gas injector Tube of the Igniter Injector Figure 8 1 and inspect Gas Injector to ensure it is not clogged or damaged Close the 2 Manual Shutoff Valve 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 Damp
24. 7 PIN CONNECTOR EXHAUST HEADER INLET OUTLET TEMP TEMP SENSOR SENSOR SENSOR SENSOR i E i z AIR FUEL VALVE 1 T 8 7 RP JUMPER WIRE 18 Y 154 AERCO P N 63145 wh yY Tear pq D 209 x 136 s Fa b 613 MANUAL RESET AUTO RESET I CANH _ 614 OVER TEMPERATURE SWITCHES i 192 i AN 141 190 195 A A A 6 PIN CONNECTOR A A 190 Hm 204 191 gt 203 EN T A 192 gt gt 206 193 gt gt 209 194 gt gt 208 EN at S 1 0 BOARD J7 PIN2 7 TO SEQUENCEING VALVE HARNESS TO CONTROL BOX PIN 63155 ENCLOSURE POWER BOX E 960 ADDED 24V POWER SUPPLY vy D 974 REMOVED DELAT RELAY WIRING 2 30 13 JC ANGREFROACTON SY 3nd e ON PIN CONNECTOR TT ead CIS INTERNATIONAL INC C 764 REMOVED WIRE 152 ADDED JUMPER WIRE AERCO P N 63145 8 15 13 MC vM WIRE JUM BETWEEN MINA ANI W y e 720 REMOVED 110V RECEPTICAL WIRING ruzori2 IC UE DEUM vac RELEASED FOR PRODUCTION 5 2 JC T T m sev REVSIONS I 68040 THESE DRAWINGS ANDIOR SPECIRCATONS AFE THE PROPERTY OF ALACO INTERNATIONAL INC THEY ARE ISSUED IN STRICT CONFDENGE AND SMALL 8 REPROOUCED COPED USED AS MHE BASS FOR MANUFACTU
25. 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 130 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive NOTE Both Header Sensor AND ProtoNode SSD Device must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode User Manual OMM 0080 GF 129 for more information Step 1 MODbus Header Sensor 1 Using Shielded pair 18 22 AWG cable Connect the Temperature Transmitter AERCO P N 65169 terminal Pin B to the RS485 terminal 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 downstream of the LAST boiler in the plant s supply water header e There is no polarity to be
26. 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1 Actuator not allowing for full 1 Observe operation of the Safety Shut Off Valve SSOV closure of gas valve through indicator on the Valve actuator and ensure that the valve is fully and not partially closing 2 SSOV powered when it should 2 If the SSOV never closes it may be powered continuously not be Close the gas supply and remove power from the unit SSOV Refer fault to qualified service personnel SWITCH OPEN 3 Defective Switch or Actuator 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 4 Incorrectly wired switch switch or actuator 4 Ensure that the SSOV Proof of Closure switch is correctly wired Air Fuel Valve out of calibration 1 Refer to GF 112 C More O amp M and perform the Stepper Feedback Calibration procedure in Section 6 section 2 Air Fuel Valve unplugged 6 2 1 3 Loose wiring connection to the 2 Check that the Air Fuel Valve is connected to the Control stepper motor Box FAILURE motor motor and the wiring harness 5 Defective Power Supply Board or 4 Replace stepper motor fuse e Check DS1 amp DS2 LEDs on Power Supply Board If they 6 Defective IGST Board are not steady ON replace Power Supply Board
27. 40 F to 240 F 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 Remote Signal If Mode Remote Setpoint Direct Drive or Combination Setpoint Direct Drive Combination or Outdoor Reset Mode Default is Constant Setpoint Mode 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 Reset Ratio is adjustable from 0 1 to 9 9 Default is 1 2 Outdoor Sensor Allows outdoor sensor function to be enabled or disabled Default is disabled System Start Tmp If Outdoor Sensor is Enabled If outdoor sensor is enabled this menu item allows the system start temperature to be set from 30 to 100 F Default is 60 F Setpoint Lo Limit Used to set the minimum allowable setpoint 40 F to Setpoint Hi Limit Default is 60 F Setpoint Hi Limit Used to set the maximum allowable setpoint Setpoint L
28. 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 L 2 Benchmark Control Panel Rear View Page 200 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers APPENDIX M RECOMMENDED SPARES APPENDIX M RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix I for the locations of the recommended and optional spare parts listed in the following Tables Table M 1 Recommended Emergency Spare Parts DESCRIPTION PART NUMBER 208 230 VAC or 460 VAC Blower 24351 or 24350 SSOV Actuator Regulator Combo Used on e ALL FM gas train models 69005 e Downstream SSOV of IRI gas train models SSOV Actuator Without Proof of Closure Switch Used orn 69038 e Upstream SSOV of IRI gas train models Temperature Switch Manual Reset 123552 Table M 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER 12 Month Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 10 Table M 3 Optional Spare Parts DESCRIPTION PART NUMBER C More Control Box 181197 Bumer BMK 2500 46039 BMK 3000 46038 O Sensor 61026 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 201 of
29. Bisovelt NY 40013 Whole Boiler 28536 1 28382 1 Sheet 4 of 7 Page 158 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS Benchmark 3000 Benchmark 3000 Standard FM Gas Train Double Block amp Bleed Gas Train P N 22171 P N 22173 See full drawing below See full drawing below Benchmark 2500 Benchmark 2500 Standard FM Gas Train Double Block amp Bleed Gas Train P N 22190 P N 22211 See full drawing below See full drawing below AERCO Benchmark 2500 3000 Part List 02 10 2014 International Inc Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 5 of 7 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 159 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS REAR VIEW LEFT SIDE VIEW FRONT VIEW AERCO Benchmark 2500 3000 Part List 02 10 2014 International Inc Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 6 of 7 Page 160 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS Power Box P N 24353 2 AERCO Benchmark 2500 3000 Part List 02 10 2014 International
30. C ONTRO BOX CONNECTORS 24 PIN CONNECTOR 16 PIN CONNECTOR 123 45 67 8 9 10 1112131415 16 17 18 19 20 21 222324 16 15 14 13 12 11 10 9 87654321 LN AN N AN N AN ANA AA IN AIR AUX SENSOR FLOW SENSOR IN i o OUTDOOR AIR SENSOR DELAYED INTLK Pi 5 a INPUT OUTPUT BOX SG 8 e 2 8 9 28 9 o NA NZ SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX PIN CONNECTOR SEQ VALVE ACTUATOR CONTROL CABLE 63155 weeeaneeces mm mnn ime INTERNATIONAL INC D hum BLAUVELT NY 10913 WIRING SCHEMATIC 460 3 PHASE _ SEE SHEET 1 OF 2 _ wu BMK300 wev tcv REVISIONS Dae 68041 E oS Eee SHEET 2 OF 2 Drawing Number 68041 rev E Sheet 2 of 2 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 177 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 178 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS CONTROL BOX CONNECTIONS 7 PIN CONNECTOR 19 PIN CON
31. COPED OR USED AS DAE BASS FOR MANUACTURS SALE OF APPARATUS WINO PERMESON OF ME OWNER DIMENSIONS ARE AFTER ANISH SHEET 1 OF 2 Drawing Number 68063 rev A Sheet 1 of 2 OMM 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 187 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 188 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS CONTROL BOX CONNECTORS 24 PIN CONNECTOR 16 PIN CONNECTOR 123 4 567 8 91011121314151617 18 19 20 21 222324 16 15 14 13 12 11 10 9 87 6854 32 NA A AA A SNS As ZA ZA N IN o ANALOG IN ovr O5 SENSOR COMMON FLOW SENSOR IN SENSOR EXCIT 12 VOC BMS PWM IN DELAYED INTLK 507 50 SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX 63156 6 PIN CONNECTOR SEQ VALVE CONTROL CABLE GERGO INTERNATIONAL INC BLAUVELT NY 10913 c b o mE WIRING SCHEMATIC 460 VAC MID ANGE eee CEVANSe VUN ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE AS FOLLOWS
32. Defective I O Box 10V equates to a 10096 open valve position 11 Check the Analog Out option on the C More Configuration 11 Wrong 0 10V output selection on the Menu Valve Position 0 10V should be selected control box 12 Check Air Fuel Valve position at 096 5096 and 10096 open 12 Defective Air Fuel Valve potentiometer positions The positions on the VALVE POSITION bargraph should match the readings on the Air Fuel Valve dial 13 Hard light 13 Check igniter injector for soot or erosion of electrode Check injector solenoid valve to insure proper open close operation OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 101 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION AIRFLOW FAULT DURING PURGE PROBABLE CAUSES 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 CORRECTIVE ACTION 1 Start the unit If the blower does not run check the blower solid state relay for input and output voltage If the relay is OK check the blower Start the unit If the blower runs
33. Inc Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 7 of 7 OMM 0094 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 161 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS BMK 3000 FM Gas Train BOM P N 22171 rev F ITEM QTY P N DESCRIPTION 1 1 123542 FLANGE 2 1252 2 NPT 2 2 123548 NIPPLE 2 NPT X 3 00LG 3 1 9 9 REDUCING TEE 2 X 1 2 X 2 NPT B I 4 2 94027 10 NIPPLE 2 NPT TBE X 2 50 LG 5 1 123540 VALVE BALL 2 FULL PORT 6 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 7 1 99015 DAMPING ORIFICE SSOV 8 1 94027 32 NIPPLE 2 NPT X 8 00 LG 9 1 69005 ACTUATOR SSOV W REGULATOR 10 2 12951 2 BUSHING CONTROL BOX 11 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 12 1 124136 VALVE SSOV 2 NPT 13 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 15 1 123547 NIPPLE 2 NPT TBE X 2 00 LG 16 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 17 1 93384 2 TEE 18 1 93382 2 NPT CAP 19 1 9 4 ELBOW 90 2 NPT 20 2 99017 SNUBBER PRESSURE 1 4 21 1 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 22 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 23 1 97005 2 TUBING FLEXIBLE GAS 12 24 1 124083 TEE 1 4 NPT 150 25 2 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 26 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 27 1 124084 E
34. Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES e Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header 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 I O 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 temper
35. PARTS LIST DRAWINGS AERCO Benchmark 3000 DBB Gas Train 07 15 2013 International Inc Blauvelt NY 10913 22173 rev G Page 2 of 2 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 165 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS BMK 2500 FM Gas Train BOM P N 22190 rev B Item Qty P n Description 1 1 123542 FLANGE 2 1254 2 NPT 2 1 93069 BUSHING REDUCING 1 1 2 TO 2 NPT 3 1 94060 2 NIPPLE 1 1 2 NPT X 2 00 LG 4 1 9 420 TEE REDUCING 1 1 2 X 1 2 X 1 1 2 5 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 6 2 94060 3 NIPPLE 1 1 2 NPT X 3 00 LG 7 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 8 1 9 323 ELBOW 90 DEGREE 1 1 2 9 1 94060 8 NIPPLE 1 1 2 NPT X 8 00 LG 10 1 124150 VALVE SSOV 1 1 2 NPT 11 1 69005 ACTUATOR SSOV W REGULATOR 12 1 94060 3 50 NIPPLE 1 1 2 NPT X 3 50 LG 13 1 93456 TEE REDUCING 2x1 5x2 14 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 15 1 93382 2 NPT CAP 16 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 17 1 93035 ELBOW STREET 1 4 NPT 18 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 19 1 97005 2 TUBE FLEXIBLE GAS 12 LG 20 1 124084 ELBOW 1 4 NPT 150 21 2 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 22 1 124083 TEE 1 4 NPT 1508 23 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 24 1 61002 1
36. Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bldg Ref Temp 70 F If Boiler Mode Outdoor Reset Reset Ratio 1 2 If Boiler Mode Outdoor Reset Outdoor Sensor Disabled System Start Tmp 60 F If Outdoor Sensor Enabled Setpt Lo Limit 60 F Setpt Hi Limit 195 F Temp Hi Limit 195 F Max Valve Position 100 Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Position 0 10V CAUTION DO NOT Change Lo Fire Timer 2 sec OMM 0094 0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 145 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX D BOILER DEFAULT SETTINGS Appendix D Boiler Default Settings MENU amp OPTION FACTORY DEFAULT Configuration Menu Continued Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 Integral Gain 1 00 Derivative Time 0 0 min Page 146 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING APPENDIX E RECOMMENDED PERIODIC TESTING WARNING Periodic testing of all boiler controls and safety
37. Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 70 5 9 0 5 lt 20 ppm lt 100 ppm If the oxygen level is not within the specified range adjust the level using the A and Y arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the A arrow key increases the oxygen level and pressing the down Y arrow key decreases the oxygen level Once the oxygen level is within the specified range at 7096 press the ENTER key to store the selected blower output voltage for the 7096 valve position Record all readings on the Combustion Calibration Sheets provided Page 56 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 2500 Natural Gas Combustion Calibration Cont 28 Repeat steps 20 through 27 for valve positions of 5096 40 30 and 16 The oxygen O2 nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table NOTE If NOx readings exceed the target values shown 20 ppm increase the O level up to 196 higher than the listed calibration range shown in the table Record the increased O value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position Oxygen 0 Nitrogen Oxide NOx Ca
38. e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers Installation Operation amp Maintenance Manual IOMM 6 8 AIRFLOW FAULT TESTS inerte 80 6 8 1 Blower Proof Switch Test teda topped 80 6 8 2 Blocked Inlet Switch estu yu L reote np tee Pe een vk p eda eeu 80 6 9 SSOV PROOF OF CLOSURE 82 6 10 PURGE SWITCH OPEN DURING PURGE sesenta rnnt rana nana 83 6 11 IGNITION SWITCH OPEN DURING IGNITION eese inan 84 6 12 SAFETY PRESSURE RELIEF VALVE TEST sesenta nnn nna 85 CHAPTER 7 MAINTENANDCGE 7 cantu ci nt Su SS TS S aan 87 7 1 MAINTENANCE SCHEDULE a aaa nint sa sa sa sara aan 87 T 2 GNITER INJEGTOR timet Ortu eed ce HERR 88 VSF AME DETECT QR em ote qaya aa dro o qapas SS qusa qayay asqa pus sqa pasas apas 90 7 4 O SENSOR91 T 5 SAFETY DEVICE TES TING isu Tu e o ie i kaqa not edite 91 7 6 BURNER ASSEMBLY INSPECTION nnn nini nnn ni nn na na na naa aan 92 5 TRAP uu u
39. rather than current signal is used to control the remote setpoint a DIP switch adjustment must be made on the CPU Board located in the Control Box Assembly Contact your local AERCO representative for details To enable the Direct Drive Mode the following menu setting must be made in the Configuration Menu Menu Option Setting Boiler Mode Direct Drive Remote Signal 4 20mA 1 5V 0 20mA 0 5V or Network Refer to section 3 3 for instructions on changing menu options If the Network setting is selected for RS 485 Modbus operation a valid Comm Address must be entered in the Setup Menu Refer to Modbus Communication Manual GF 114 for additional information Page 66 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION 5 5 1 Direct Drive Field Wiring The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The signal must be floating ungrounded at the I O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG Polarity must be observed The source end of the shield must be connected at t
40. 00 C More Year 0 99 11 C More Serial 0 9999 0000 C More Alpha A Z A 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 configuration settings which may or may not be displayed depending on the current operating mode setting NOTE The Configuration Menu settings shown in Table 3 4 are Factory Set in accordance with the requirements specified for each individual order Therefore under normal operating conditions no changes will be required Page 40 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER OPERATION Table 3 4 Configuration Menu Available Choices or Limits Menu Item Display BE a Default Minimum Maximum Internal Setpt Lo Temp Limit Hi Temp Limit 130 F KC Boiler KC Boiler LN BMK Boiler Std BMK Boiler LN BMK Blr Std Dual BMK Blr LN KC Unit Type Water Heater BMK Boiler LN KC Wtr Heater LN Innovation WH BMK Blr LN Dual Unit Size 750 MBH 800 MBH 1
41. 1 63108 SSOV RELAY JUMPER GAS TRAIN 34 1 93230 SNUBBER 1 22171 BKM 3000 FM GAS TRAIN ASSY 35 1 64081 ECU O2 SENSOR 1 22173 3000 DBB GAS TRAIN ASSY 36 1 65011 TRANSFORMER 115V 24V 100VA 1 22190 BKM 2500 FM GAS TRAIN ASSY 37 1 65109 12V POWER SUPLY 1 22211 BKM 2500 DBB GAS TRAIN ASSY 380 1 69161 1 DIN RAIL 39 2 65120 TERMINAL BLOCK DIN MOUNTED BLK BURNER AIR FUEL VALVE AND HEAT EXCHANGER 40 2 65121 TERMINAL BLOCK DIN MOUNTED WHT 1 46039 BMK 2500 BURNER 41 3 65122 TERMINAL GROUND BLOCK DIN MOUNTED 1 46038 BMK 3000 BURNER 42 2 65118 FUSE TERMINAL DIN MOUNTED LIMIT CONTROL TEMPERATURE DIGITAL 9 1 26015 BMK 2500 BURNER ASSY 43 1 64088 CONTROLLER 1 26014 BMK 3000 BURNER ASSY 440 1 38035 I O PANEL COVER 10 1 24277 STAGED IGNITION ASSY 450 1 38036 POWER PANEL COVER 11 1 81180 BURNER GASKET 46 1 65128 3 POLE 20A BREAKER 12 1 81173 RELEASE GASKET 470 2 124512 FUSE 4 AMP 13 1 81185 LOWER RELEASE GASKET 48 1 123449 SENSOR TEMPERATURE 14 1 43091 AIR FUEL VALVE PLENUM 49 1 93359 THERMOWELL 15 1 24311 AIR FUEL VALVE KIT 500 1 63105 I O SENSOR COMM HARNESS 510 1 63104 I O INTERLOCK HARNESS HOSES GASKETS amp INSULATION 52 2 69141 DIN RAIL MOUNT END STOP 16 1 97005 9 FLEX TUBE 48 536 1 124310 TRANSFORMER 460V 17 1 80081 SHELL INSULATION 54 1 33170 MOUNTING PANEL 55 1 124324 GROUND BAR BLOWER 56 1 65162 24V POWER SUPPLY Sequencing Valve ig 1 1 243500 BL
42. 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS Table F 1 Header Temperature for a Building Reference Temperature of 50F RESET RATIO 60 6 80 83 90 94 100 105 100 105 113 68 86 113 Table F 2 Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp 60F 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72 50F 66 68 70 72 74 76 78 80 82 84 45F 69 72 75 78 81 84 87 90 93 40F 72 76 80 84 88 92 96 100 104 108 35F 75 85 90 95 100 30F 78 90 96 102 108 25F 81 88 95 116 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 5bF 99 112 125 138 151 164 10 102 116 130 144 158 172 186 200 214 15 105 120 135 150 165 180 195 210 20F 108 124 140 156 172 188 200 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 149 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers
43. 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION CHAPTER 2 INSTALLATION 2 1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack inspect and install the AERCO Benchmark Boiler Model BMK 2500 and BMK 3000 2 2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit The shipping weight for these BMK models is approximately 2200 pounds The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage The unit should be completely inspected for evidence of shipping damage and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed NOTE AERCO is not responsible for lost or damaged freight Each unit has a Tip N Tell indicator on the outside of the crate This indicates if the unit has been turned on its side during shipment If the Tip N Tell indicator is tripped do not sign for the shipment Note the information on the carriers paperwork and request a freight 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 a close inspection of the unit should be made to ensure that there is no evidence of damage no
44. 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX M RECOMMENDED SPARES This page left intentionally blank Page 202 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX N LIMITED BENCHMARK WARRANTY APPENDIX N 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
45. 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor Step 1 MODbus Header Sensor Wiring 1 Using Shielded pair 18 22 AWG cable connect the Temperature Transmitter AERCO P N 65169 terminal Pin B to the RS485 terminal on the I O Box of any of the Boiler units and Pin A of the Temperature Transmitter to the RS485 terminal 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 e ground for the shield is at the SHLD terminal in the I O the Box e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 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
46. 3 for instructions on changing menu options While it is possible to change other temperature related functions for combination mode these functions are preset to their factory default values These default settings work well in most applications It is suggested that AERCO be contacted prior to changing settings other than the unit s setpoint For a complete listing of temperature related function defaults see Appendix D To set the unit to the manual mode press the AUTO MAN switch The MANUAL LED will light To set the unit back to the auto mode press the AUTO MAN switch The MANUAL LED will go off and the REMOTE LED will light When the boiler is switched to ACS control the ACS controls the valve position There are no setup requirements to the boiler s in this mode OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 69 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION This Page Is Intentionally Blank Page 70 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING CHAPTER 6 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 sa
47. 5 16 nut driver Replace the top shroud on the unit and return boiler to service use r y L1 AIR FUEL VALVE MANUAL T AIR FILTER SHUT OFF HOSE CLAMP VALVE m m s AIR FILTER Figure 7 7 Air Filter Location OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 97 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE 7 9 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time one year or more the following instructions must be followed Shutting Boiler Down for Extended Period Set ON OFF switch on the front panel to the OFF position to shut down the boiler s operating controls Disconnect AC power from the unit Close the water supply and return valves to isolate boiler Close external gas supply valve Open relief valve to vent water pressure 7 10 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing Boiler in Service After Long Shutdown Review installation requirements included in Chapter 2 Inspect all piping and connections to the unit Inspect exhaust vent and air inlet duct work if applicable Perform initial startup per Chapter 4 Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of th
48. 70 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 7096 5096 4096 30 and 16 as described in the following steps These steps assume that the inlet air temperature is within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O level up to 196 higher than the listed calibration range Record the increased value on the Combustion Calibration sheet Press the MENU key on the front panel of the C MORE and access the Setup menu Enter password 6817 and then press the ENTER key Press the MENU key on the front panel of the C MORE until Combustion Cal Menu appears on the display Press the A arrow key until SET Valve Position appears on the display Press the CHANGE key SET Valve Position will begin to flash Press the A arrow key until the SET Valve Position reads 70 Press the ENTER key Next press the down Y arrow key until CAL Voltage 70 is displayed Press the CHANGE key and observe that CAL Voltage 70 is flashing The oxygen level at the 7096 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the following values Combustion Calibration Readings 70 valve Position
49. COMMUNICATION Running a Command on a Remote Machine Using PuTTY Continued 5 You are now ready to execute this command on the remote machine simply click the Open button at the bottom of the dialog You will have to provide an account name and password in the terminal window to complete the process 9 2 RS 232 COMMUNICATION SETUP Regardless of the terminal emulation utilized the following guidelines must be adhered to when setting up the RS 232 communication link e Baud Rate The baud rates which can be used with the C More Control Panel are o 2400 o 4800 o 9600 Default o 19 2K e Data Format The program must be set for 8 data bits 1 stop bit o no parity o either Xon Xoff or No flow control 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS 232 communication is accomplished as follows Menu Processing Utilizing Rs 232 Communication Start the emulator software program and ensure that the specified baud rate and data formats have been entered Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS 232 password jaguar in lower case letters and press Enter Welcome to will appear in the laptop or dumb terminal display with a listing of the following available entry choices Display next Menu Display menu items Display next menu items Cxx
50. CONNECTOR 123 45 67 8 91011121314151617 18 19 20 21 222324 16 15 14 13 12 11 10 9 8765432 s IS 18 3 18 13 5 18 S s Q 1 5 19 12 If is ig 5 2 p 8 2 ojoj jojn 41 9 xx o N lt IN SENSOR COMMON IN AIR AUX SENSOR FLOW SENSOR IN ANALOG IN BMS PWM IN OUTDOOR AIR SENSOR RELAY 7 NOTUSED r EXHAUST TEMP our O o INPUT OUTPUT BOX 5 8 8 2 SEQ VALVE XFMR 24 V POWER CABLE TO POWER BOX 63156 6 PIN CONNECTOR SEQ VALVE ACTUATOR CONTROL CABLE ARCO INTERNATIONAL INC BLAUVELT NY 10713 WIRING SCHEMATIC 208 VAC 3 PHASE BMK 2500 3000 DBB 68062 LO B SHEET 2 OF 2 FOR REVISION SEE FIRST PAGE I Ll I MATL SPEC TONS ARE Tre Pi D OR USED AS THE BASG FOI Drawing Number 68062 rev B Sheet 2 of 2 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 185 of 204 GF 137 Ph 800 526 0288 03 20 2014 Lun Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 186 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS 19 18 17 AN 19 PIN CONNECTOR 15 15 14 13 12 11 10 9 87 5 p 8 9 PIN CONNE
51. Change item xx Fault log display Sensor log display Time line display Log off F S T L OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 115 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 9 RS232 COMMUNICATION MENU PROCESSING UTILIZING RS 232 COMMUNICATION Continued NOTE The Level 1 password 159 must be entered to change options in the Setup Configuration and Tuning Menus The Level 2 password 6817 must be entered to view or change options in the Calibration and Diagnostics Menus With the exception of the password entry all other keyboard entries can be made using either upper or lower case To view the available menus in the top down sequence shown in Figure 3 2 enter M lt Rtn gt The Menu title and first 10 options will be displayed When viewing menus containing more than 10 options enter N lt Rtn gt to display the remaining options Menu Processing Utilizing Rs 232 Communication Shortcut keys are also available to go directly to a specific menu These shortcut keys are mO m1 m2 m3 m4 m5 Default Operating Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu 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 Rtn gt b Enter the desired v
52. Chris Blair AERCO International Inc AERCO International Inc 2014 Page 204 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137
53. 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 Mandatory for AERCO OnAER Remote Data Collection This value must match the 4 digit serial on the Code Plate e g G 12 1234 Software Version Internal Setpoint Identifies the current software version of the control box Ver 0 0 to Ver 9 9 Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of KC Boiler KC Boiler LN BMK Boiler Std Bir Std Dual Boiler LN Bir LN Dual KC Water Heater KC Wtr Heater LN Innovation WH Page 134 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set
54. Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 5096 5 596 6 5 30 ppm 100 ppm 40 4 5 5 5 lt 30 ppm lt 100 ppm 30 6 0 6 5 lt 30 ppm lt 100 ppm 14 6 0 7 0 lt 30 ppm lt 100 ppm 29 If the oxygen level at the 14 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 5 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 5096 down to 14 after making a change to the idle screw TAC valve 30 This completes the BMK 3000 Natural Gas combustion calibration procedures 4 4 REASSEMBLY Once the combustion calibration adjustments are properly set the unit can be reassembled for service operation Reassembly 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 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 7 This concludes reassembly of the unit after combustion calibration Page 60 of 204 03 20 2014
55. Page Intentionally Blank Page 182 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS 9 PIN CONNECTOR DIAMETERS ON A COMMON AXS 7 DIS TOTAL MATL SPEC CONTROL BOX CONNECTIONS 84321 7 PIN CONNECTOR 7N 7N N N 19 PIN CONNECTOR 16 PIN CONNECTOR AN VN VIN VIN Z 2 s 8 9533 AN ANA AN m gt z z Z 5 n RINE g S 33 22 3 jo conneclor i Ferr A 141 s H EXHAUST HEADER INLET OUTLET SENSOR SENSOR SENSOR SENSOR i z s i 1 8 558 T 88 g o 3 Y gt 5 s S 4 5 0 SN i s L z All EL VALVE E q Ya m PER WIRE MI jd P N 124149 3 Y n itu gums cmm SENSOR v A ij 20 ES SE t 2 2 136 FN 613 123456789 344 T MANUAL RESET AUTO RESET OUO tox i CANH _ 614 DIGITAL
56. UNLESS OTHERWISE SPCORED JX 015 005 FRACTIONS 1 324 ANGLES 41 3 PHASE BMK 2500 3000 DBB FOR REVISION SEE FIRST PAGE DAMES ON A COMMON f 015 TOTAL PE DWG WO Wy eco cam CRITICAL DIMENSION C 68063 THESE ORAWINGS AND OR SPECICATION ARE THE PROPERTY OF ABRCO INTERNATIONAL INC THEY ARE SSUED IN STRICT CONPOENCE AND PERPENDICULARITY PARALLEUSM FLATNESS 015 TOTAL A SHALL NOT RE REPROCUCED COPED OR USED AS TE BASS FO MANUFACTURE OR SALE Of APPARATUS PERMESON OF THE OWNER ALL DIMENSIONS ARE AFTER FNSH OR PLATING SHEET 2 OF 2 Drawing Number 68063 rev A Sheet 2 of 2 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 189 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 190 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS PIPING DRAWINGS APPENDIX K 19021 31V0 5 NOLLVTIVISNI LNN 3I9NIS XON MO 000 0002 NVWHON38 PG JE NIVYG 31VSN3QNOO Alddf s WALSAS SNILV3H 3NIVA STIIVI3O 400 011 SNOILONYLSNI 31VSN3QNOO 33S 80014 JHL 3AO8V NVHL M3H9IH Q3lv A313 5
57. VOLTAGE CHART 143 APPENDIX D BOILER DEFAULT SETTINGS 145 APPENDIX E RECOMMENDED PERIODIC TESTING 147 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 5 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers Installation Operation amp Maintenance Manual IOMM APPENDIX INDOOR OUTDOOR RESET RATIO CHARTS 149 APPENDIX G DIMENSIONAL U tnnt natn innt tani tna tata inan tan 153 APPENDIX H CLEARANCE DRAWINGS I 154 APPENDIX I PARTS LIST DRAWINGS I U U uuu u u 155 APPENDIX J C MORE WIRING DIAGRAMS eese uuu u 171 APPENDIX PIPING DRAWINGS III IIIa cds vau coxa epo cy cR ni C ue Dua sau 191 APPENDIX L C MORE CONTROL PANEL VIEWS eese 199 APPENDIX M RECOMMENDED 201 APPENDIX LIMITED WARRANTY U U risus u uuu u 203 Page 6 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers FORWARD FOREWORD The AERCO Benchmark BMK 2500 and 3000 MBH Boilers ar
58. 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 I O Box PCB The sensor end of the shield must be left free and ungrounded When mounting the sensor it must be located on the North side of the building where an average outside air temperature is expected The sensor must be shielded from direct sunlight as well as impingement by the elements If a shield is used it must allow for free air circulation 2 10 2 COMBUSTION AIR Terminal The COMBUSTIAN AIR terminal is used to monitor the combustion air temperature sensor This input is always enabled and is a to view only input that can be seen in the operating menu The sensor is an AERCO BALCO wire sensor P N 12449 A resistance chart for this sensor is OMM 0094 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 27 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 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 O SENSOR O2 amp O2 The SENSOR and SENSOR terminals are used to connect an external oxygen sensor to the I O Box PCB The concentration is displayed in the operating menu of the C More Control system after a 60 seco
59. Y 1Y AYNSSAYd SV9 WOWINIW NIVLNIVA YH NLE WOWIXVA LV dWfd AYYNINd JAYA 331133 Drawing Number SD A 960 rev A GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE Page 194 of 204 03 20 2014 Ph 800 526 0288 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS 3iva Oddy v 96 v GS SIN IWS A38 219021 S4 15008 dW3l ONIdld LOH OIIS3AOG 9NIV3H NOLLWTIVISNI 319NIS MOT 0008 0002 NVAHON38 ynon vnan ODE AlddnS d 1 3 VA WALSAS NE os Sx I MONSN3S Se M3Qv3H SOV PN 3NWA 71113 34nSS3Nd NOIVNHVd3S W31SAS Z A 3000 W901 AG Q3MInO3H SSFINN TWNOlLdO SI MO1V1n93M SVD V MOT38 MO O M tl 1V 8 SIIVL3d 400 011 SNOILONYLSNI ANVL 31VSN3QNOO 33S 730014 JHL 3AO8V NVHL M3H9IH G3IVA313 5 dVYL 31VSN3Q0NOO OOM3V Y31108 YO V NI Q3TIVISNI 38 LSNW NVL YAZMVYLNAN JHL 39VNIVMO 31VSN3Q0NOO 33dOHd N3ZIIVHIDn3N 31VSN3QNO9 OOM3V JHL ONISN N3HM 4 SS31 YO tl OL NMOG 3H SS3Hd SVO JHL ONING OL 3ATVA 4JOlnHS IVNANYW 30 WV3HISNMOQ Q3TIVISNI 38 LSNW YOLVINDSY 371415 d 5201 V 1 NVHL N3lV3M9 SI 3MnSS3Md SVD i 18VillVAV N3HM 9 ST3NVd 3015 WOMJ AVMV 9 38 3SIM3MI1 GINOHS S3XO8 LINGNOD S3HOLIMS 3OIAM3S SNOILO3NNOO 914193713 ONidid TIV SH3AOO S
60. and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 2 6 W C for BMK 2500 and 3 5 W C for BMK 3000 The FAULT indicator should also start flashing Reduce the gas pressure back to the value recorded in step 5 This pressure should be within the range of 2 0 W C 0 2 W C for BMK 2500 and 2 3 W C 0 2 W C for BMK 3000 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 Page 74 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault proceed as follows Low Water Level Fault Set the ON OFF switch to the OFF position Close the water shut off valves in the supply and return piping to the unit 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 3096 Set the ON OFF switch to the ON position The READY light should remain off and t
61. as shown in Figure 2 7 Maximum allowable gas pressure to the boiler is 14 W C Page 22 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 8 3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions see sections 2 8 3 1 and 2 8 3 2 below Regulators must conform to the following specifications e The external natural gas regulator must be capable of regulating 200 000 3 180 000 BTU HR of natural gas while maintaining a gas pressure of 8 0 W C minimum to the unit e A lock up style regulator MUST be used when gas supply pressure will exceed 14 W C 2 8 3 1 Massachusetts Installations Only For Massachusetts installations a mandatory external gas supply regulator must be positioned as shown in Figure 2 7 The gas supply regulator must be properly vented to outdoors Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator 2 8 3 2 All Installations Except Massachusetts For multi unit installations other than Massachusetts that EXCEED 7 W C gas pressure a 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 ven
62. calibrated the on board O2 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 at 5 196 0 596 Combustion Calibration Readings 100 6 valve Position Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 10096 4 596 5 696 lt 30 ppm 100 ppm 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 4 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 Page 58 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 3000 Natural Gas Combustion Calibration Cont 16 Once the oxygen level is within the specified range at 100 record the O2 NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit 17 Lower
63. combo boilers switch over to space heating but there is a call for domestic hot water the ACS Relay Box switches the combo units back to the domestic load The ACS in combination with the ACS Relay Box will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand When the combo units are satisfying the domestic load they are in the constant setpoint mode of operation When the combo units switch over to space heating their mode of operation changes to follow the ACS command For more information concerning the operation of the ACS consult the ACS Operations Guide GF 131 For more information on the ACS Relay Box see section 2 14 in the same manual 5 7 1 Combination Control System Field Wiring Wiring for this system is between the ACS the ACS Relay and the terminals in the I O 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 Menu Option Setting Boiler Mode Combination Remote Signal Network Internal Setpt 40 F to 190 F Refer to section 3
64. 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 Item Frequency Accomplished By Remarks Refer to indicated sections of this m anual for detailed procedures Gauges monitors and indicators Daily Operator Visual inspection and record readings in operator log Instrument and Daily Operator nim Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Technician Verify factory settings Check with combustion calibration test equipment Anndaly Splice See section 7 4 and Chapter 4 Flue vent stack or Visually inspection condition and check for Monthly Operator intake air duct obstructions Spark Igniter Injector Weekly Operator See section 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial section 3 11 SSOV Leakage test Annually Service Technician EUR Patage us Kidd manufacturer s Siemens recommendations Close manual gas shutoff valve and check safety Flame failure Weekly Operator shutdown See section 6 7 Check flame streng
65. 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 mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO 2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN O0 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 1 15 02 5 21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 16pm 130 179 OPEN OPEN OPEN OPEN 0 0 1 15 02 5 11pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 1 15 02 5 06pm Page 118 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers 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 a
66. must be made in the Configuration Menu Menu Option Setting Boiler Mode Direct Drive Remote Signal Network RS 485 Refer to section 3 3 for instructions on changing menu options 5 6 1 ACS External Field Wiring Wiring connections for RS 485 Modbus control are made between the 485 A and 485 B terminals on the ACS boilers 9 through 40 and the RS 485 COMM terminals in the I O Box on the front of the boilers OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 67 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION Wire the units using shielded twisted pair wire between 18 and 22 AWG Observe the proper polarity for the ACS RS 485 COMM wiring connections Shields should be terminated only at the ACS and the boiler end must be left floating Each unit s wiring must conform to the above 5 6 2 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 the ACS mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 7 COMBINATION CONTROL SYSTEM CCS NOTE Only ACS can be utilized for the Combination Control System A Comb
67. not in addition to any other express or implied warranties in any documents or under any law No salesman or other representative of AERCO 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 responsibi
68. not firing Replace the switch if continuity does not exist HIGH WATER TEMP Faulty Water temperature switch Incorrect PID settings Faulty shell temperature sensor Test the temperature switch to insure it trips at its actual water temperature setting Check PID settings against Menu Default settings in Appendix D If the settings have been changed record the current readings then reset them to the default values Using the resistance charts in the Appendix C Measure the resistance of Shell sensor and BTU sensor at a known water temperature ML 4 Unit in Manual mode 4 If unit is in Manual Mode switch to Auto Mode 5 Unit setpoint is greater than Over 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 If the system is a variable flow system monitor system flow occurring faster than units can changes to ensure that the rate of flow change is not faster respond than what the units can respond to 1 See HIGH WATER See HIGH WATER TEMPERATURE SWITCH OPEN i me TEMPERATURE SWITCH OPEN 2 Temp HI Limit setting is too low Check Temp HI Limit setting IGN BOARD 1 Communication fault has occurred Press CLEAR button and restart unit If fault persists contact COMM FAULT between the PMC board and qualified Service Personnel Ig
69. on board O 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 5 Combustion Calibration Readings 100 6 valve Position Valve Position Oxygen 02 Nitrogen Oxide NOx Carbon Monoxide CO 100 5 0 6 0 lt 20 ppm 100 ppm OMM 0094 0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 55 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 2500 Natural Gas Combustion Calibration Cont 15 If the oxygen level is not within the required tolerance the gas pressure on the downstream side of the SSOV must be adjusted using the gas pressure adjustment screw on the SSOV Figure 4 4 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 O2 NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit Lower the valve position to
70. rate to use when transferring data For further configuration options data bits stop bits parity OMM 0094 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 113 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 9 RS232 COMMUNICATION flow control you can use the Serial Configuration panel right image in Figure 9 1 by selecting Serial in the left navigation pane Now to connect to the remote server simply click the Open button at the bottom of the dialog box A new terminal window will pop up and ask you to log in So that you don t have to enter this information every time you wish to connect to your server you can save this configuration by typing an appropriate name in the Saved Sessions text box in the PuTTY Basic Options window left image of Figure 9 1 and then clicking the Save button In the future you can select the name you chose in the list box and click the Load button to initialize this particular configuration 9 1 2 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
71. scheduled basis Test schedules must conform to local jurisdictions The results of the tests should be recorded in a log book See Chapter 6 Safety Device Testing Procedures OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 91 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE 7 6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top of the unit s heat exchanger The burner assembly may be hot Therefore allow the unit to cool sufficiently before removing the burner assembly NOTE In order to do this procedure most efficiently with a minimum of steps a simple support rig has been designed to hold up the blower and Air Fuel Valve assembly while the blower plenum is removed to allow the burner assembly to be removed for maintenance Using this support will relieve the blower s weight from bearing down upon the connection to the gas train This support rig prevents having to dismantle the entire blower and A V Valve assembly from the gas train The support rig is available as an after market part The following parts will be required for reassembly after burner inspection Part No Description 88173 Burner Upper Release Gasket 81180 Burner Gasket Middle 81185 Burner Lower Release Gasket 81048 Flame Detector Gasket 1 each To inspect or replace the burner assembly proceed as follows Burner Assembly Inspection and Maintenanc
72. terminals from the Direct Drive source to the Ain and Ain terminals on the Master Unit s I O Box NOTE e Shielded pair 18 22 AWG cable is recommended for this connection Polarity must be observed e The ground for the shield is at the driver signal source Remote Signal i sarai a A e Remote Signal 1 0 Box Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Go to the BST Menu and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint Go to the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the Head Temp Source item and select FFWD Temp Go to the BST Remote Signal and select either 4 20ma or 0 20ma of When ALL C More units have been configured 8 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0094 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 127 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive NOTE Both Header Sensor AND the ProtoNode SSD Device must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNod
73. 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 NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation End of Extracted Information From 248 CMR 5 08 2 Page 14 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20
74. 0 Boilers CHAPTER 2 INSTALLATION To use this option you must disconnect the harness from the Delayed Interlock terminals and connect the proving device in its place Should the proving switch not prove within the programmed time frame the unit will shut down The AUX START ON DLY can be programmed from 0 to 120 seconds This option is located in the Configuration Menu Chapter 3 2 10 13 Fault Relay NC COM amp NO The fault relay is a single pole double throw SPDT relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed The fault relay connections are shown in Figure 2 12 2 10 14 Auxiliary Relay Contacts NC COM amp NO Each unit is equipped with a single pole double throw SPDT relay that is energized when there is a demand for heat and de energized after the demand for heat is satisfied The relay is provided for the control of auxiliary equipment such as pumps and louvers or can be used as a unit status indictor firing or not firing Its contacts are rated for 120 VAC 5 amps Refer to Figure 2 12 to locate the AUXILLIARY RELAY terminals for wiring connections 2 11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide GF 2050 must be consulted before any flue or combustion air ventin
75. 00 Boilers Installation Operation amp Maintenance Manual IOMM TABLE OF CONTENTS FOREWORD 7 CHAPTER 1 SAFETY PRECAUTIONS U U eene U ansa sna taam uuu u 11 13 WARNINGS amp CAUTIONS civ tie eh EE eie ce eee ec er Pe e eee ER e Rr 11 1 2 EMERGENCY SHUTDOWN inini ect eet rede cel ederet eva cn are duda ee david eae eva cn cheek ade evadat 12 1 3 PROEONGED SHUTDQONWN 8 eee SS u ves ev Rives e a dev awe Ya Pr ie 12 CHAPTER 2 INSTAEEATI ON 7 reete AT I nea Fm ae en seen bern s ideat 15 21 INTRODUCTION ec S ea dvi SE h 15 2 2 RECEIVING THE UNIT y tad l am o ee 15 2 3 UNPACKING oe bt m kan san 15 24 SITE BREPARATION rro tetra e recette d etti d nante aene 16 2 44 InstallationiCleaFances 5 olt e e et AS a Saha u uiae edet Rel a aaa Duss 16 2 4 2 Setting the Unlt a 3 cre teneor e Ree arman 17 2 5 SUPPLY AND RETURN PIPING iiir ette uuu 19 2 6 PRESSURE RELIEF VALVE INSTALLATION 19 2 7 CONDENSATE DRAIN amp PIPINGuuuuu l L D S D u nnne nennen ii 20 2 8 GAS SUPPLY PIPING ii iioii de oe he eed ooo eoe dave etate ete ta vel soe ee favet ato taeda ee 22 2 8 1 Gas Supply SpecifiCatioris au ee tete e Pe p meae Ib a S
76. 000 MBH 2500 MBH Only the unit sizes 1500 MBH 2000 MBH or available for the Unit 2500 MBH 3000 MBH 3000 MBH Type will be displayed 6000 MBH Fuel Type Natural Gas or Propane Natural Gas Constant Setpoint Remote Setpoint Constant Boiler Mode Direct Drive Setpoint Combination p Outdoor Reset Remote Signal If Mode Remote 4 20 Setpoint Direct Drive or pu in ie Hay Network 1 5V Combination P gacy Outdoor Sensor Enabled or Disabled Disabled Bldg Ref Temp If Mode Outdoor 40 F 230 F 70 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 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 44 of 204 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION Table 3 4 Configuration Menu Continued Menu Item Display e 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 Ena
77. 014 Benchmark 2500 3000 Boilers CHAPTER 1 SAFETY PRECAUTIONS N WARNING N A THREE POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL SUPPLY LINE OF THE UNIT THE SWITCH MUST BE INSTALLED IN AN EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY DISCONNECT ELECTRICAL SERVICE DO NOT AFFIX SWITCH TO UNIT SHEET METAL ENCLOSURES CAUTION N Many soaps used for gas pipe leak testing are corrosive to metals The piping must be rinsed thoroughly with clean water after leak checks have been completed CAUTION N DO NOT use this boiler if any part has been under water Call a qualified service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the manual gas shutoff valve Figure 1 1 located external to the unit NOTE The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel MANUAL GAS SHUT OFF VALVE E VALVE OPEN VALVE CLOSED Figure 1 1 Manual Gas Shutoff Valve 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 6 of this manual be performed to verify all system operating parameters If there is an emergency turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit T
78. 1 open end wrench 8 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present clean the component using fine emery cloth Repeated carbon build up is an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion calibration procedures Prior to reinstalling the igniter injector a high temperature conductive anti seize com pound must be applied to the threads OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 89 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE Igniter Injector Maintenance Procedures Cont NOTE If a replacement igniter injector part no 66026 is being installed a compression nut containing a built in ferrule will be included with the replacement part If needed 3 indexing washers are also included These washers may be needed to properly position the gas injector tube of the igniter injector within the 120 angle range shown in Figure 7 3 BURNER PLENUM FLAME OBSERVATION PORT O2 SENSOR IGNITER INJECTOR SN ANGLE OF GAS INJECTOR 1 Figure 7 3 Igniter Injector Orientation Viewed Looking Down from Above 10 Reinstall the igniter injector the burner plate Torque
79. 1 LOW GAS PRESSURE SWITCH 3 6 W C 25 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 26 2 9 22 PIPE PLUG 1 4 NPT STEEL 27 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 28 2 12951 2 BUSHING CONTROL BOX 29 1 99017 SNUBBER PRESSURE 1 4 30 1 61002 3 HIGH GAS PRESSURE SWITCH 2 6 W C 31 1 63109 GAS TRAIN HARNESS BMK 3000 32 1 124862 RESISTOR ASSY 33 1 99015 DAMPING ORIFICE SSOV AERCO Benchmark 2500 FM Gas Train 10 31 2013 International Inc Blauvelt NY 10913 22190 rev B Page 1 of 2 Page 166 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS AERCO International Inc Blauvelt NY 10913 Benchmark 2500 FM Gas Train 10 31 2013 22190 rev B Page 2 of 2 OMM 0094 GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 167 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS BMK 2500 DBB Gas Train BOM P N 22211 rev B Item Qty P n Description 1 1 123542 FLANGE 2 125 2 NPT 2 1 93069 BUSHING REDUCING 1 1 2 TO 2 NPT 3 1 94060 2 50 NIPPLE 1 1 2 NPT X 2 50 LG 4 1 9 420 TEE REDUCING 1 1 2 X 1 2 X 1 1 2 5 1 9 43 BUSHING REDUCING 1 2
80. 1 rev A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 0E GF 137 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS A38 219021 A8 NMO 296 v as nod Ee SIN 21VOS 3002 W907 A8 G33I00338 SSIINN TVNOldO SI YOLVINDSY SV9 V MO138 HO OM 1 LV CL 571 1 v400 l SNOLLONYLSNI 1 31IVSN30NOO 33S HOO01J SHL 3AO8V NVHL H3H9IH Q3lvA313 38 LSNW 3ivSN3O0NOO OON3V ONY 531109 SO lid V NI G3TIVISNI ISAW 1 M3ZIVMIDn3N 39VNIVMO 3lvSN3Q0NOO H3dONd 3043 N3ZITVHIT3N 31VSN30NOO OO3H3V 1 ONISN N3HM ZI ST3NVd 3015 9 38 5 GINOHS saxog LINGNOD S3HOLIMS JJAYIS SNOLLO3NNOO 21519373 ANY SNIdid NY SH3AOO ST3NVd M31l08 JO WWAOWSY HUM 3ON3H34H3lNI 1N3A3Md OL SONILLI WO3 9 40 V 213 SMOST3 SNOIN SONILLIJ LIINI S31VM 31v201 LI 4N3AdIHS NI AT31VMVd3S Q3Q 019NI 34v SWIL TW OL SIOMINOO SNIQ108 JHL Q3TIOMINOO YO AlLNVISNOO G 31V33dO 38 TIVHS dWnd W31SAS JHL 6 SNIdid AlddNS W3lSAS MNVL 3833308 JHL NI LVLSWNOV JHL MOSN3S M3Q0V3H SOV JHL TIVISNI 8 Q3110SNOO 38 GINOHS 5 53009 W901 SNIMYMQ NOLVTIVISNI TVOIdAL V SI SIHL 2 OF 3O WOWININ S M31108 MNVWHON38 NIVINIVN ISAN 3108 5311089 LV 5 MOTI 3iViMdOMddVv JH
81. 24 V POWER CABLE 1234 TO POWER BOX z a 6 PIN CONNECTOR SEQ VALVE ACTUATOR CONTROL CABLE 63155 ANGLE PIC 6CYON 4 57 oval ex de E 89089 n WIRING SCHEMATIC 208 VAC SEE SHEET 1 OF 2 _ BME 3900 REV REVISIONS sv cco 68040 Drawing Number 68040 rev E Sheet 20f2 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 173 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 174 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS 19 PIN CONNECTOR 16 PIN CONNECTOR 9 PIN CONNECTOR ANZ Ns EXHAUST HEADER INLET OUTLET TEM TEMP SENSOR SENSOR SENSOR SENSOR NZ AIR FUEL VALVE Y hk L R WIRE 18 ns Fant UPN SN A dhe 613 123456789 i CANH 614 DIGITAL CONTROL OVER TEMPERATURE SWITCHES A 192 A 141 A 190 J 4 195 Tx 6 PIN CONNE
82. 3 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION CHAPTER 3 OPERATION 3 1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark Boiler using the Control Panel mounted on the front of the unit It is imperative that the initial startup of this unit be performed by factory trained personnel Operation prior to initial startup by factory trained personnel may void the equipment warranty In addition the following WARNINGS and CAUTIONS must be observed at all times 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 UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY N CAUTION N 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 ope
83. 4 2 TEE 13 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 14 1 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 15 1 69005 ACTUATOR SSOV W REGULATOR 16 1 69038 ACTUATOR SSOV W O P O C SWITCH 17 1 99015 DAMPING ORIFICE SSOV 18 1 124862 RESISTOR ASSY 19 1 123769 VALVE SOLENOID N O 1 NPT 20 2 9 222 ELBOW 90 lt MOD DEG gt 1 21 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 22 2 94028 2 00 NIPPLE 1 NPT TBE X 2 00 LG 23 1 94028 11 00 NIPPLE 1 NPT TBE X 11 LG 24 4 12951 2 BUSHING CONTROL BOX 25 1 123311 BUSHING REDUCING 1 2 NPT X 1 4 NPT 26 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 27 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 28 1 93382 2 NPT CAP 29 1 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 30 1 124084 ELBOW 1 4 NPT 1502 31 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 32 1 99017 SNUBBER PRESSURE 1 4 33 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 34 2 9 22 PIPE PLUG 1 4 NPT STEEL 35 1 63109 GAS TRAIN HARNESS BMK 3000 36 1 63043 HARNESS WIRING IRI 37 1 97005 2 TUBING FLEXIBLE GAS 12 38 1 93035 ELBOW STREET 1 4 NPT 39 2 123533 NIPPLE CLOSE 1 8 40 2 93445 COUPLING REDUCING 1 4 x 1 8 NPT BLK MI AERCO Benchmark 3000 DBB Gas Train 07 15 2013 International Inc Blauvelt NY 10913 22173 rev G Page 1 of 2 Page 164 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I
84. 4 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 63 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION Indoor Outdoor Startup Refer to the Indoor Outdoor reset ratio charts in Appendix F Choose the chart corresponding to the desired Building Reference Temperature Go down the left column of the chart to the coldest design outdoor air temperature expected in your area Once the design outdoor air temperature is chosen go across the chart to the desired supply header temperature for the design temperature chosen in step 3 Next go up that column to the Reset Ratio row to find the corresponding reset ratio 6 Access the Configuration Menu and scroll through it until the display shows Bldg Ref Temp Building Reference Temperature If necessary refer to 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 Press the CHANGE key The display will begin to flash Use the A and V arrow keys to select the Reset Ratio determined in step 5 Press ENTER to save the change This completes 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired Commo
85. 7 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE 7 2 IGNITER INJECTOR The igniter injector part no 66026 is located on the burner plate at the top of the boiler In addition to providing the ignition spark required to light the burner the igniter injector also contains a gas injector tube which connects to the staged ignition assembly Figure 7 1 shows the complete burner assembly removed from the boiler and indicates the location of the igniter injector flame detector and other related components BLOWER AIF VALVE PLENUM BLOWER PLENUM O2 SENSOR BURNER PLATE BLOCKED FLANGE INLET SWITCH IGNITOR INJECTOR ASSEMBLY FLAME NET BURNER DETECTOR 7 FLAME OBSERVATION PORT m Figure 7 1 Benchmark 2500 3000 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 Maintenance Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Disconnect the cable from the igniter injector Figure 7 1
86. 70 Valve Position Valve Position Oxygen O Nitrogen Oxide NOx Carbon Monoxide CO 7096 4 596 5 696 lt 30 ppm 100 ppm If the oxygen level is not within the specified range adjust the level using the A and Y arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the A arrow key increases the oxygen level and pressing the down V arrow key decreases the oxygen level Once the oxygen level is within the specified range at 7096 press the ENTER key to store the selected blower output voltage for the 7096 valve position Record all readings on the Combustion Calibration Sheets provided Repeat steps 20 through 27 for valve positions of 7096 5096 4096 30 and 1496 The oxygen O2 nitrogen oxide NOx and carbon monoxide CO should remain within the same limits for all valve positions as shown in the following table OMM 0094 0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 59 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 3000 Natural Gas Combustion Calibration Cont NOTE If NOx readings exceed the target values shown 20 ppm increase the O level up to 196 higher than the listed calibration range shown in the table Record the increased O value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position
87. 94 100 106 112 118 124 130 136 142 35F 91 98 105 112 119 126 133 140 147 154 25F 97 106 115 124 133 142 151 160 169 178 20F 100 110 120 130 140 150 160 170 180 190 15F 103 114 125 136 147 158 169 180 191 202 10F 106 118 130 142 154 166 178 190 202 214 5F 109 122 135 148 161 174 187 200 213 OF 112 126 140 154 168 182 196 210 5F 115 130 145 160 175 190 205 118 134 150 166 182 198 214 T 15F 121 138 155 172 189 D6 20F 124 142 160 178 196 214 L T Page 150 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS Table F 5 Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air 79 80 82 83 84 85 86 87 65F 89 91 93 95 97 99 60 87 90 96 99 102 105 108 111 55 50F 45F 99 105 40F 25 20F 15F 10F 166 179 192 205 218 SF 179 187 201 25 _ OF _ 180 195 210 5F 187 203 249 10F 194 231 j 15F
88. 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 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 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 39 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION Table 3 3 Setup Menu Menu Item Display Choices tid Default Minimum Maximum Passsword 0 9999 0 Language English English Time 12 00 am 11 59 pm Date 01 01 00 12 31 99 Unit of Temp Fahrenheit or Celsius Fahrenheit Comm Address 0 127 0 Baud Rate 2400 4800 9600 19 2K 9600 Upload Timer 0 0 Unit Alpha A 2 Unit Serial 0000 9999 0000 Unit Year 0 99
89. AL MATL SPEC 5990 Ww nev tco DA s CRITICAL DIMENSION 68060 THESE DRAWINGS AND OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE ISSUED IN STRICT CONFDENCE AND PERPENOICULARITY PARALLELS MUFLATNESS 015 TOTAL B SHALL NOT RE REPROOUCED COMED OR USED AS THE BASS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE Own ALL DIMENSIONS ARE AFTER FNSH OR PLATING SHEET 1 OF 2 Drawing Number 68060 rev B Sheet 1 of 2 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 179 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 180 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS CONTROL BOX CONNECTORS 24 PIN CONNECTOR 12345678 91011121314151617 18 19 20 21 222324 ANS NIS ISIN R S 8 8 8 18 8 amp S 8 4 16 PIN CONNECTOR 16 15 14 13 12 11 10 9 87654321 C 2 0000 211 HOT ren OUTDOOR AIR SENSOR SENSOR COMMON IN AIR AUX SENSOR IN n 4 o2 N C FLOW SENSOR IN SENSOR EXCIT 12 ANALOG IN BMS PWM IN
90. AOW3Y HUM 39N3N33831NI 1N3A3Sd OL SONILLIJ 33 v3H WOMJ 9 40 WNWININ v 913 SMOHT3 SNOINn 9 131100 ISNI 331VM 31V901 G3LINSNOD CGINOHS SAILIYOHLNY ONY 53000 W307 NOILVTIVISNI 1VOIldAL V SI IN3WdIHS NI AT31vsvd3s 33v SWALI TV MOOT4 JHL 3AO8V LHSISH V OL ATIVOLLH3A 3dld 38 GINOHS 3938VHOSIQ 3A 1VA 43J3f138 JHL 3TBVIIVAV SI NIVHO 30014 ON N3HM NiVMG MOO 4 1S3HV3N JHL 01 Q3dld 38 GINOHS JAVA 33 13 NIV3GQ Y00774 V OL ALIAVHS A8 AT33Md NIVYG OL 5010714 FHL OL GSONVYNV 38 GINOHS ISOH 31VSN3QNOO9 3ATVA TISHS Z ONIMVMO TVNOISN3AId 33S N31v3H JHL OL SNOHO3NNOO MN3H10 ANY Nidid dO SNOlIV9O1 S3ZIS WNLOV l SALON TO SE UO NIVMG 31VSN3QNOO x Nini W31SAS ONILVSH 3ATvA NIVHO TI3HS 8 310N MOlV1093M 5 9 AdO1nHS SVD wvlL dYNSSSYd SVD OM 07 1Y 3H0SS3Hd SVD WANWININ NIVLNIVA YH NLE WOWIXVN LY Drawing Number SD A 958 rev A GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE Page 192 of 204 03 20 2014 Ph 800 526 0288 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS NOILVTIVLSNI AJVQNOO3S A3VWl3d MO 0008 0002 NVAWAHON38 ynon viia 31vq SIN 3195 219021 31V0 Aa NMG 3009
91. APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS Table F 3 Header Temperature for a Building Reference Temperature of 65F RESET RATIO 83 86 89 45 77 81 85 93 97 101 105 109 113 40 85 90 95 100 105 110 115 120 125 35 83 89 95 101 107 113 119 125 131 137 30 86 93 100 107 114 121 128 135 142 149 25 89 97 105 113 121 129 137 145 153 161 20 92 101 110 119 128 137 146 155 164 173 15 95 105 115 125 135 145 155 165 175 185 10 98 109 120 131 142 153 164 175 186 197 5 101 143 125 137 129 161 173 185 197 209 0 104 117 130 143 156 169 182 195 208 5 107 121 135 149 163 177 191 205 219 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Table F 4 Header Temperature for a Building Reference Temperature of 70F RESET RATIO Ew t Air Temp GF 73 74 ro Jv 80 jJ 60F 76 78 82 86 88 90 92 9 55F 79 82 85 88 91 94 97 100 103 106 50F 82 90 94 98 102 106 110 114 118 45F 85 90 95 100 105 110 115 120 125 130 40F 88
92. Benchmark 2500 3000 Boilers Installation Operation amp Maintenance Manual IOMM AERCC USER MANUAL Natural Gas Modulating amp Condensing Hot Water Installation Operation and Maintenance Boiler Models 2500 BENCHMARK 2500 3000 e BMK 3000 Gas Fired Boilers Applicable to Serial Numbers G 14 0304 and Above Benchmark GAS FIRED m Pa aC CERTIFIED Latest Update 03 20 2014 Pal C US www ahridirectory Commercial Boilers LISTED AHRI Standard BTS 2000 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 1 of 204 Ph 800 526 0288 03 20 2014 GF 137 Benchmark 2500 3000 Boilers Installation Operation amp Maintenance Manual IOMM Technical Support Mon Fri 8am 5pm EST 1 800 526 0288 www aerco com Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnishing performance or use of this material Page 2 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 30
93. Benchmark 2500 DBB Gas Train 10 31 2013 International Inc Blauvelt NY 10913 22211 rev B Page 1 of 2 Page 168 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS 36 42 49 41 38 9 35 17 12 43 AERCO Benchmark 2500 DBB Gas Train 10 31 2013 International Inc Blauvelt NY 10913 22211 rev B Page 2 of 2 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 169 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS This page intentionally blank Page 170 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS 19 18 17 ei APPENDIX J C MORE WIRING DIAGRAMS 19 PIN CONNECTOR 16 15 14 13 NAR 12 11 10 29 ems CONTROL BOX CONNECTIONS 16 PIN CONNECTOR 161514131211 10 98 7 6 5 4 3 2 1 IN ANANAS AA AAA ie IR 9 PIN CONNECTOR 171 70 69 68 67 66 65 z z it
94. Boilers CHAPTER 7 MAINTENANCE Burner Assembly Inspection and Maintenance Procedures Cont Remove the eight 8 3 8 16 nuts using a 9 16 wrench attaching the blower plenum to the burner beneath see Figure 7 4a amp 7 4b Remove the blower plenum from between the blower and the burner and set aside for later reassembly O2 sensor and flame observation port remain assembled to the plenum flange NOTE The burner assembly is heavy weighing approximately 65 Ibs Remove the burner by pulling straight up Remove and replace the burner gasket s see Figure 7 5 IMPORTANT ALL THREE gaskets provided for maintenance MUST be installed during this procedure as shown in Figure 7 5 even if there is only one existing gasket being replaced Note that the LOWER RELEASE GASKET has tabs which the others do not NOTE During reassembly apply a light coating of high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is properly positioned as indicated in Figure 7 3 Torque the igniter injector to 170 180 in Ibs Beginning with the burner assembly reinstall all the components in the reverse order that they were removed When reinstalling the blower plenum removed in step 11 tighten the 3 8 16 nuts using a typical torque pattern for example loosely tighten one nut then loosely tighten a second nut on the opposite side a third at 90 deg
95. CE Burner Assembly Inspection and Maintenance Procedure Cont BLOWER 3 8 16 PLENUM i HEX NUTS lt 1 8 each 5 16 x 1 3 4 BOLTS 5 16 WASHERS amp NYLOCK NUTS 4 each BLOWER AIF VALVE PLENUM t GAS INLET BLOWER PIPE PROOF SWITCH MANUAL SHUT OFF AIR FUEL VALVE VALVE BLOCKED INLET SWITCH AIR FILTER RAIN Figure 7 4b Burner Assembly Mounting Details BMK 2500 Shown NOTE IMPORTANT The LOWER RELEASE Use ALL THREE gaskets provided even if there GASKET P N 81185 features is only one existing gasket being replaced four tabs around its periphery 81173 UPPER RELEASE a 81180 MIDDLE BURNER GASKET 81185 LOWER RELEASE GASKET BARE BURNER INSTALLED IN HEAT EXCHANGER ASSY Figure 7 5 Bare Burner and Replacement Gaskets Location OMM 0094 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 95 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE 7 7 CONDENSATE DRAIN TRAP The Benchmark Boiler contains a condensate trap as shown in Chapter 2 Figure 2 5 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 Procedu
96. CO CONTROL SYSTEM ACS 67 5 6 1 ACS External Field Wiring u eret iter rero ene ere nita ce eo eee Pa uae gen eo 67 5 6 27ACS Setup ANG ere rp Hee sper tnter iste 68 5 7 COMBINATION CONTROL SYSTEM CCS 68 5 7 1 Combination Control System Field Wiring 69 5 7 2 Combination Control System Setup and Startup eene 69 CHAPTER 6 SAFETY DEVICE TESTING U U 71 6 1 TESTING OF SAFETY DEVICES I ELI ge HE ee ana 71 6 2 LOW GAS PRESSURE FAULT TEST sana Sana ua saa aan 72 6 3 HIGH GAS PRESSURE TEST uuu p tec des ne mi eI SEND 73 6 4 LOW WATER LEVEL FAULT TEST tnnt tritani 75 6 5 WATER TEMPERATURE FAULT TEST ennt natara nina rana a s 76 6 GINTERLOCK TESTS d ier datei E de ie ese teet TT 6 6 1 Remote Interlock Testi Hr f eee eee ze Pe eere yh th weavers 77 6 6 2 Delayed Interlock Test u e eerte eee ere e rer erae e ep e reo peer Suq 77 5 FLAME FAULT TESTS ELI eU LI LEER 78 Page 4 of 204 AERCO International Inc
97. CONTROL OVER TEMPERATURE SWITCHES SENSOR 363 i hehh i E AGRD 6 PIN CONNECTOR 8 TO BOARD J7 PIN 2 350 7 TOSEQUENCENG VALVE HARNESS TO CONT BOK P N 63155 366 AN 330 POWER BOX INTERNATIONAL INC c D 100 ORTTANI DR BLAUVELT N Y ALOWESONS AREN NCES AND TOLERANCES ARE WIRING SCHEMATIC 208 VAC s 960 ADDED 24V POWER SUPPLY SN MM ONE END 3 PHASE BMK 2500 3000 DBB 900 3 RELEASE FOR PRODUCTION 9 10 13 AV eco kxo CRMCAL DIMENSION THESE ORAWINGS AND OR SPECIFICADONS ARE THE PROPERTY OF INTEINADONAL INC THEY ARE BSUED IN CONFIDENCE AND SHALL NOT M REPRODUCED COMED OR ULED AS THE AUS FOR MANUFACTURE SALE OF APPARATUS WITHOUT PERMIEDON OF THE OWNER PERPENCICLLARITY PARALLEUSM RATNESS 015 TOTAL DIMENSIONS ARE AFTER FINGH OR PLATING NO N SMEET 1 OF 2 Drawing Number 68062 rev B Sheet 1 of 2 OMM 0094 GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 183 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 184 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS 24 PIN CONNECTOR 16 PIN
98. COPPER CONDUCTORS ONLY FOR FIELD WIRING USE COPPER CONDUCTORS ONLY FOR FIELD WIRING 72085 P N 72084 Figure 2 10 Power Box Cover Labels 208VAC Left and 460VAC Right Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A three pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enclosures of the unit After placing the unit in service the ignition safety shutoff device must be tested If an external electrical power source is used the installed boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction In the absence of such requirements the installation shall conform to National Electrical Code NEC ANSI NFPA 70 and or the Canadian Electrical Code CEC Part 1 CSA C22 1 Electrical Code For electrical power wiring diagrams see the AERCO Benchmark Electrical Power Guide GF 2060 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 25 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 10 FIELD CONTROL WIRING Each unit is fully wired from the factory with an internal operating control system No field control wiring is required for normal o
99. CTOR PN 190 A A 191 foes tS Sa AN 192 gt A 193 gt gt 209 A A 3 Pa 194 E 208 195 gt TO BOARD 47 PIN2 SOLENOID gt gt TO SEQUENCEING VALVE HARNESS P N 63155 x2 xF x FUSE 960 ADDED 24V POWER SUPPLY 460 V TRANSFORMER 974 REMOVED 2 SEC RELAY NN EC 317 THRDANOLEPROJECTON cmo usse jeoles SINIZ a INTERNATIONAL I REMOVED WIRE W152 ADDED JUMPER WIRE AERCO P N 63145 8 14 13 MC c D za AREO ly m WIRE 151 USED AS JUMPER BETWEEN TERMINALS 7 AND 3 me REMOVED 110 RECEPTICAL WIRING WIRING SCHEMATIC 460 VAC 3 PHASE LAL oH M RELEASED FOR PRODUCTION isa a w rev REVISONS 68041 THESE OR AWiNGS AND OR SPCORCADnONS ARE THE PROPERTY OF INTERNATIONAL INC THEY ARE SUED 1 STRICT CONMOENCE AND E SHALL NO M REPRODUCED COMED OR USED AS THE BASS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT Of THE OWNER EET 1 OF 2 Drawing Number 68041 rev E Sheet 1 of 2 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 175 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 176 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS
100. CTOR CONTROL BOX CONNECTIONS 7 PINCONNECTOR 16 PIN CONNECTOR AN A 7 8 5 g RRR I S ud p connector 50 EXHAUST HEADER INLET OUTLET TEMP TEMP TEMP TEMP SENSOR SENSOR SENSOR SENSOR AN AN 5 e 255 4 gt gt o 9 z 8s M 59 gu g AIR FUEL VALVE NA N qaaa SOLENOID JUMPER WIRE P N 124149 3 N 123456789 DIGITAL CONTROL OVER TEMPERATURE SWITCHES 192 PUMP 141 150 195 A 6 PIN CONNECTOR 190 Tx in vane CANH 5 4 TO BOARD J7 PIN2 TO SEQUENCEING VALVE HARNESS P N 63155 PERCO INTERNATIONAL INC DR BLAUVELT NY ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE PEFD AS FORLOING UNLESS OTHERWISE s WIRING SCHEMATIC 460 VAC LT Na 3 PHASE BMK 2500 3000 DBB 960 RELEASE FOR PRODUCTION M74 CE DIAMETERS ON A COMMON ANG 6 015 WAT PEC sev sco sr CETCAL C 68063 THESE DRAWINGS AND OR SPECIFRCATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL INC THEY ARE SSUED IN STRCT CONFOENCE AND PEFENOCULABTUPARALELSWRAINESS 915 TOTAL SHALL NO BE IPRODUCID
101. ED 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 Theunit should start OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 77 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 7 FLAME FAULT TESTs Flame faults can occur during ignition or while the unit is already running To simulate each of these fault conditions proceed as follows Flame Fault Tests Set the ON OFF switch to the OFF position Place the unit in the Manual Mode and set the valve position between 2596 and 3096 Close the manual gas shutoff valve located between the Safety Shut Off Valve SSOV and the Air Fuel Valve see Figure 6 4 4 Setthe ON OFF switch to the ON position to start the unit 5 The unit should purge and light the Pilot Flame then it should shut down after reaching the main burner ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve previously closed in step 3 and press the CLEAR button Restart the unit and allow it to prove flame Once flame is proven close the manual gas valve located between the SSOV Figure 6 4 and the Air Fuel Valve 9 The unit should shut down and Lockout flashing FLDR in the display 10 Open the valve previously closed in step 8 11 Press the CLEAR button The u
102. ETAL PANEL ASSEMBLY OTHER ACCESSORIES amp PARTS 72 1 30115 BACK PANEL LEFT 84 1 39164 AIR INLET ADAPTER 73 1 30116 BACK PANEL RIGHT 85 2 38034 AIR INLET COVER PANEL SEE 74 2 35022 TOP RAIL 870 1 TABLE A PRESSURE TEMP GAUGE SEE 75 1 25068 ASSEMBLY FRONT FRAME 880 bci TABLEA PRESSSURE RELIEF VALVE KIT 76 1 25078 FRONT PANEL ASSY 890 1 123540 EXT MANUAL SHUT OFF VALVE 77 1 72068 DOME LABEL 90 1 69126 LOW WATER CUTOFF CAPACITOR ASSY 78 2 59179 HANDEL CONCEALED 91 1 123863 1 8 NTP BALL VALVE 79 4 59133 LATCH 92 1 92094 3 4 DRAIN VALVE 80 1 30118 FRONT TOP PANEL 930 1 59043 CONDENSATE FLOAT 81 1 30119 BACK TOP PANEL 940 1 24060 COND TRAP ASSY 82 2 30117 SIDE PANEL 95 1 59178 1 8 AIR VENT 1 74027 BMK 3000 LOGO 96 1 90052 NIPPLE 1 8 X 1 50 LG 1 74030 BMK 2500LOGO 97 1 24353 1 0 POWER BOX ASSY 110 V MOTORIZED SEQUENCING VALVE 100 0 1 92084 6 OPTIONAL Not shown on drawings shown below Used only on 460 v units TABLE A Item 88 Item 87 Description Available in Kit Number 92016 1 69087 5 30 PSI KIT CONBRACO 58048 C30 92016 2 69087 5 50 PSI KIT CONBRACO 58048 C50 92016 3 69087 6 60 PSI KIT CONBRACO 58048 C60 92016 4 69087 6 75 PSI KIT CONBRACO 58048 C75 92016 5 69087 6 100 PSI KIT CONBRACO 58048 C100 92016 6 69087 6 125 PSI KIT CONBRACO 58048 C125 92016 7 69087 7 150 PSI KIT CONBRACO 58048 C150 92016 8 69087 5 50 PSI KIT WATTS 58048 W50 92016 9 69087 6 60 PSI KIT
103. FD Blower 0 10 amp AGN a s dot eeu te Be eis a dette 29 pAitosipADderncm EE 29 2 10 13 Fault Relay NC COM amp 30 2 10 14 Auxiliary Relay Contacts NC COM amp NO en nne a 30 2 11 FLUE GAS VENT INS TALA T O uuu n u sa n Q au ES a Q n nsns nsns nnne nennen 30 2 T2 COMBUSTION AR ici as ie e ce eie ieu 31 2 12 1 Combustion From Outside the Building 31 2 12 2 Combustion Air from Inside the Building nn nnn nannte nnns 31 2 143 DUCTED u 2 aus eei oett eed avis Dees Yo aba ieee vie uqa Ta 31 2 14 SEQUENCING VALVE INSTALLATION IL L T M N a nennen kas 31 3 OPERATION q aqa u hac currente ayaka assaka a 33 fece 33 3 2 CONTROL PANEL DESCRIPTION unn tnnt a na ra sa nasa sa saa ana 33 3 3 CONTROE PANEL MENVUJS iR eet aed h DU ge Le n eL DURER 37 3 3 1 Menu Processing Procedure ccccccssssscccecessesesaesecececseseeaesecececsesesaeseeeesceeeeaeseeececeeseeaeseseesceeseaueaesecscseseaaaeees 37 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 3 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers Installation Operation amp Maintenance Manual
104. Hours 25 hours 225 hours 72 hours ae SEE Disabled Enabled Disabled BST Temp Hi Limit 40 F 210 F 210 F BST Setpt Lo Limit 40 F BST Setpt HI Limit 60 F BST Setpt HI Limit BST Setpt Lo Limit 220 F 195 F BST Prop Band TF 120 F 100 F BST Intgral Gain 0 00 2 00 0 50 BST Deriv Time 0 00 Min 2 00 Min 0 10 Min BST Deadband Hi 0 25 1 BST Deadband Lo 0 25 1 Deadband En Time 0 120 Sec 30 Sec BST FR Up Rate 1 120 20 BST Bldg Ref Tmp 40 F 230 F 70 BST Reset Ratio 0 1 9 9 1 2 System Start Tmp 30 F 120 F 60 F BST COMM MENU Disabled Enabled Disabled Comm Address 0 127 0 BST Min Addr 1 128 1 BST Max Addr 1 128 8 SSD Address 0 250 247 SSD Poll Control 0 1000 0 OMM 0094_0E GF 137 Ph 800 526 0288 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 45 of 204 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION Available Choices or Limits Menu Item Display Default Minimum Maximum Err Threshold 1 9 5 SSD Temp Format Degrees Points Degrees BST Timer 0 9999 sec 0 3 10 START SEQUENCE When the Control Box ON OFF switch is set to the ON position it checks all pre purge safety switches to ensure they are closed These switches include e Safety Shut Off Valve SSOV Proof of Closure POC switch e Low Water Level switch e High Water Temperature switch e High Gas Pressure switch e Low Gas Pressure switch e Blower Proof switch e Blocked
105. I SNidid 21153000 Q3O0N3AWOO3H NOILVTIVISNI SLVIdLYVWS OL X343 G ONIZIS MNVL 333308 OLOL dS 3 ln9 sNOLVOrlddv 3lvidlNVWS OL 33433 Si3Nvd 3015 9 38 JSIMSXM GINOHS S3X08 LINGNOD SSHOLIMS 3O9lAM3S SNOLLO3NNOO 214193713 ANY ONidid TIY SM3AO9 ST3NVd 331108 JO TWAOWSY HLIM 3ON3H3JM3INI IN3A3Hd OL SONILLIJ M31V3H WONJ 9 JO WnWININ v 913 SMO813 SNOIN v SONILLIY 131000 L31NI 31V2901 LNSWdIHS NI AT3ivavd3s 33v SWALI mv HOO1d4 JHL 3AO8V 8l 1H9I3H V OL ATIVOLLH3A Q3dld 38 GINOHS 393VvHOSIO JAVA J3lT38 1 318V1IVAV SI ON N3HM NIVHO 30014 1S3NV3N 3HL OL Q3dld GINOHS 39NVHOSIQ 3A1VA 33l13H NIVHO 30014 Y OL ALAVHO Al33M3 OL SAINTA LIWNSd OL Q39NVHMV 38 GINOHS ISOH 31VSN3QNOO 3ATVA NIVHO THS Z 9 7TVNOISN3WIG 33S Ol SNOLLOANNOD YSHLO Nldld JO SNOILVOOT S3ZIS TWNLOV Alddns aye NIVMO TIJHS JAYA 1113 SNIOnG33 55344 NOISNVdX3 431VM W31SAS YOLVYVdsS HIV WALSAS NV 834308 nyna 7 W31SAS MOSN3S H3Q0V3H SOV 6 310N 335 MOlvin934 Sv9 A4SOLNHS SVD vL 3HhsSS3sNd SVD XVW Ti O v LY 34055359 SV9 WOWINIA NIVLNIVIA SH n18 LY JAYA 4303 L ni8 WW
106. IOMM 3 4 OPERATING MENVU ani decedere tate eco i tet at ee ed test 39 9 5 SETUP MENU tie se ce testet eR eret tete 39 3 9 cte i roce goto cse 40 3 7 i oce eee e M ie I eaa edet 42 3 9 COMBUSTION GAL MENU rt ee or cere D Do eu de eats 43 3 9 BST BOILER SEQUENCING TECHNOLOGY MENU I ener nnne 43 START SEQUENCE iu lute ee etie and UI abel saz Demi eI n mi 46 32 START STOP EBEVELS 5 S dip 50 CHAPTER 4 INITIAL START UbD ruri III nianna nananana oanade anndan iani aani 51 4 1 INITIAL START UP REQUIREMENTS 51 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION 51 4 2 1 Required Tools amp Instrumentation 52 4 2 2 Installing Gas S pply Manomet r L L I GUS u an 52 4 2 3 Accessing the Analyzer Probe Port 54 4 3 NATURAL GAS COMBUSTION 54 4 4 REASSEMBLY nete ner recedat fta tes 60 4 5 OVER TEMPERATURE LIMIT SWITCHES cccccccceccceceseceseeeseeecesesecesececeseseceseseseseseseseseseseseseseeess 61 4 5 1 Digi
107. Inlet switch If all of the above switches are closed the READY light above the ON OFF switch will light and the unit will be in the Standby mode When there is a demand for heat the following events will occur NOTE 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 46 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION HIGH GAS PRESSURE NATURAL SWITCH GAS INLET v SSOV LOW GAS PRESSURE SWITCH Figure 3 3a BMK 2500 SSOV Location HIGH GAS PRESSURE NATURAL SWITCH GAS INLET SSOV TO 2 AIRIFUEL VALVE LOW GAS PRESSURE SWITCH Figure 3 3b BMK 3000 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 w
108. L 3GIAOMd OL Q3ZIS 38 1SnW dWNd 337108 8 LLL N QS 944 v O0S S44 V QS v4 V QOS 44 V OS ZLL v Q0S NOLLVTIVISNI ONidid OUSSNOG Q30N3AWOO3M SONIMVYC NOLLVTIVISNI 31V1d1HVAS 01 X343 G ONIZIS ANVL 334308 0101 45 30109 SNOliVOliddv 3lvidiMNVWS OL 33433 v ONIMvHO TVNOISN3NWIQ 3108 NvAHON38 3lviMdOHddV 33S 37109 OL SNOLLO3NNOO YSHLO ONidid 40 SNOUYJOT S3ZIS WNLOV MOO14 JHL 3AO8V 81 1H9I3H V OL ATIVOILYSA QO3dld 38 GINOHS 394VvHOSIQO 3A TVA 3iBvilvAY SI NIVMQ 30014 ON N3HM NIVMO 30014 1S38V3N 3Hl OL O3dld 38 Q nOHS 393vHOSIOQ JAWA 336133 NIVY MOO14 V OL ALIAVM9 AB AT3344 OL SAINTA LINYSd OL 38 GINOHS 3SOH 31VSN3QNOO 3ATVA NIVHO TISHS Z 57 130 S1OMINOO NOllV9 1ddV 3i31dWOO 5 WVWHOVIG OSOO SVL 30109 SNOLWWWOMdd 9NILV3H OUS3AOQ SNLLV3H NOLLVNIBNOO 33S 1 S310N SNOLLWONMddV 15009 3afnivsdW3l XNVI 34408 33108 M 9Nldld MHQ 5NIUV3H NOILVNIBWOO 31V Td LH VAS MO 0008 0002 AYVWHONIS INI INON INI AlddNS WALSAS y NYNL3Y WilsAS 331lO8 3lVSN3QNOO JAVA TI3HS MNVL 334308 NYL NOISNVdX3 3dAL WSvslHdvia 8 31ON 1 15 L 310N 8 310N MOlV1n93M 5 9 HONSN3S S Y A1N3A OLLWWOLNY YONSNAS 43Qv3H SOV AIOLNHS SVD
109. L GAS COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated at the factory prior to shipping This gas pressure must be within the following ranges for each model of boiler at full fire BMK Boiler Model Nominal Gas Pressure BMK 2500 2 0 W C 0 2 W C BMK 3000 2 1 W C 0 2 W C Recalibration as part of initial start up is necessary due to changes in the local altitude gas BTU content gas supply piping and supply regulators Combustion Calibration Test Data sheets are shipped with each unit These sheets must be filled out and returned to AERCO for proper Warranty Validation It is important to perform the following procedure as outlined This will keep readjustments to a minimum and provide optimum performance Instructions for natural gas combustion calibration follow with the BMK 2500 instructions first followed by the BMK 3000 instructions Page 54 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 2500 Natural Gas Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running Open the natural gas supply valve to the unit Set the control panel ON OFF switch to the OFF position 4 Turn on external ac power to the unit The display will show loss of power and the time and date Set the
110. LBOW 1 4 NPT 150 28 1 63109 GAS TRAIN HARNESS BMK 3000 29 1 124862 RESISTOR ASSY 30 2 93290 TEE MXFXF BLACK IRON 1 4 NPT 31 1 93035 ELBOW STREET 1 4 NPT AERCO Benchmark 3000 FM Gas Train 07 15 2013 International Inc Blauvelt NY 10913 22171 rev F Page 1 of 2 Page 162 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS AERCO Benchmark 3000 FM Gas Train 07 15 2013 International Inc Blauvelt NY 10913 22171 rev F Page 2 of 2 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 163 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS BMK 3000 DBB Gas Train BOM P N 22173 rev G ITEM QTY P N DESCRIPTION 1 1 123542 FLANGE 2 12542 2 NPT 2 2 123548 NIPPLE 2 NPT X 3 00 LG 3 1 9 9 REDUCING TEE 2 X 1 2 X 2 NPT 4 1 94027 10 NIPPLE 2 NPT TBE X 2 50 LG 5 1 94027 36 NIPPLE 2 NPT TBE X 9 00 LG 6 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 7 1 123540 VALVE BALL 2 FULL PORT 8 1 9 4 ELBOW 90 2 NPT 9 2 95030 FLANGE SSOV 2 NPT 10 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 11 2 123547 NIPPLE 2 NPT TBE X 2 00 LG 12 1 9338
111. LVE 1 CONDENSATE DRAIN PORT Figure 2 5 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2 6 The following general guidelines must be observed to ensure proper condensate drainage e The condensate trap inlet Figure 2 6 must be level the exhaust manifold drain port e The base of the condensate trap must be supported to ensure that it is level horizontal e The trap must be removable for routine maintenance Page 20 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION While observing the above guidelines install the condensate trap as follows Condensate Trap Installation Connect the condensate trap inlet to the exhaust manifold drain connection by inserting the drain port directly into the trap adaptor inlet and then tightening the inlet thumbscrew as shown in Figure 2 6 The inlet features two integral O rings to prevent leakage 2 Atthe condensate trap outlet install a 3 4 NPT nipple Connect a length of 1 diameter polypropylene hose to the trap outlet and secure with a hose clamp Route the hose on the trap outlet to a nearby floor drain If a floor drain is not available a condensate pump can be used to remove the condensate to drain The maximum condensate flow rate is 30 GPH The condensate drain trap associated fittings and dra
112. M 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS MENU LEVEL amp OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint Remote Setpoint or Outdoor Reset Mode When in the Constant Setpoint Mode this value is equal to the Internal Setpoint setting in the Configuration Menu When in the Remote Setpoint Mode this value is the setpoint equivalent to the remote analog signal supplied to the unit When in the Outdoor Reset Mode this is the derived value from the charts in Appendix 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 displayed in F default or C only if outdoor sensor is installed and enabled Valve Position In Desired input valve position This would normally be the same as the fire valve position shown on the bargraph valve position out when the boiler is operating Exhaust Temp Displays the exhaust temperature in F default or C Flame Strength Displays flame strength from 0 to 100 Oxygen Level Displays the real time combustion oxygen
113. MASTER only Goto the BST Setpoint item and enter the desired Setpoint Goto the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Constant Setpoint Goto the Head Temp Source item and select Network Goto 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 O1 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 122 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 3 Option 3 Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor NOTE Both Header Sensor AND Outdoor Sensor must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode User Manual OMM 0080 GF 129 for more information Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit connect the Header Temperature Sensor AERCO PN 61040 to the Feed Forward FFWD terminals on the P 1 Harness Via the terminal block labeled Header Temp sensor in the I O Box NOTES The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header Shielded pair 18 22 AWG cable is recommended for header sen
114. NECTOR 16 PIN CONNECTOR 9 PIN CONNECTOR 19 18 17 16 15 14 13 12 n 10 9 8 AN ANA AN AKA ANANAS ANANAS AN N N EI z 2 Ph B 8 es R IRIE Je js e ss 8 3 jumper wire inside 9 pin connector 141 2 i GAS IGNITOR S XFMER 3 EXHAUST HEADER INLET OUTLET Ch n A TEMP TEMP TEMP 9 4 i Z Q SENSOR SENSOR SENSOR SENSOR 3E x B 8 e AIR FUEL VALVE i Ayr J NN jumper wire p n 154 ISP SIN Y s A J 270 id 209 db 136 TO 123456789 MANUAL RESET AUTO RESET CANH _ 614 DIGITA CONN OVER TEMPERATURE SWITCHES 192 m a a 141 190 nash A 195 TO BOARD J7 2 TO SEQUENCEING VALVE HARNESS P N 63155 POWER BOX cm on Seat ARGO INTERNATIONAL INC c sss Z 100 ORITANI BLAUVELT N Y OIMENSONS ARE N INCHES AND ALL TOLERANCES ARE m WIRING SCHEMATIC 208 VAC 960 ADDED 24V POWER SUPPLY CE ME save ME MRNA MM NOU d 3 PHASE BMK 2500 FM 3 RELEASE FOR PRODUCTION 9 0 13 AV DIAMETERS ON A COMMON AS f 015 10t
115. NICATION 9 1 INTRODUCTION The RS 232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line Fault and Sensor log displays NOTE The information in this chapter does not apply when implementing BST The RS 232 port on the front panel of the C More Control Box Figure 3 1 can be interfaced to a laptop computer or other suitable terminal using a RS 232 adapter cable RS 232 communication can be accomplished using any Dumb Terminal emulation such as PuTTY which is not included with Microsoft Windows but can be downloaded for free on the internet Source and instructions for using Putty are provided here 9 1 1 Acquiring the PuTTY Application Download the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable Will start it 1 1 1 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 o AL r SS R PuTTY Configuration AESA R PuTTY Configuration Category Category f Session Basic options
116. NOLOGY 119 10 T INTRODU GTION d eed e e tede ER ec ed erede 119 10 2 AERCO BST QUICK START CHART u tacitae beside ak s nie e tea asus sa luas 120 10 3 BST IMPLEMENTATION INSTRUCTION 121 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor 121 10 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor 122 10 3 3 Option Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor 123 10 3 4 Option 4 Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor 125 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive 127 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive 128 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive 129 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive 131 APPENDIX A BOILER MENU ITEM DESCRIPTIONS 133 APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES 139 APPENDIX C SENSOR RESISTANCE
117. O2 level 95 measured by the sensor y 2 Run Cycles Displays the total number of run cycles from 0 to 999 999 Run Hours Displays total run time of unit in hours from 0 to 9 999 999 Fault Log Displays information on the last 20 faults OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 133 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION SETUP MENU Password Allows Level 1 or Level 2 password to be entered Entering the Level 1 Password 159 allows options in the Setup Configuration and Tuning Menus to be modified Entering the Level 2 Password 6817 allows options in the Calibration and Diagnostics Menus to be changed or activated in addition to all Level 1 Menu options Language Permits selection of English Spanish or French for displayed messages Default is English Time Displays time from 12 00 am to 11 59 pm Date Displays dates from 01 01 00 to 12 31 99 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C Default is F Comm Address Baud Rate For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Allows communications Baud Rate to be set 2400 to 19 2K
118. OO 33S 40014 3A08V NVHL M3H9IH G31VA313 5 31VSN3Q0NOO OON3V Y31108 NO V NI Q3T VISNI 38 1 M3ZIIVMIQ3N JHL 39VNIVHO 31VSN30NOO 3M3dOMd HOJ MNVL YAZMVYLNAN 31VSN3Q0NO9 3HL ONISN N3HM 4 SS31 HO OL NMOG 330SS33d SVD JHL NIY OL 3ATVA 4SOLNHS TVONVA 30 NWV331SNAOQGQ Q3TIVISNI 38 LSAW 3O01V109338 FTALS d 5901 V bl NVHL N3lV3H9 SI 330SS33d SVD 318VIIVAV N3HM STANVd H3lV3H 30 TVAON33 HLM 39ON38H33831NI IN3 3Hd OL SONILLIJ M3lv3H M31VM WOMJ 9 JO WAWININ v O13 SMOST3 SNOINN SONILLI3 131100 LIINI N31VM 31V901 GAaLINSNOD 38 GINOHS SAILIMOHLAY 53009 WOOT ONIMVHG NOLLVTIVISNI TVOIdAl V SI SIHL 4N3AdIHS NI AT3lvMvd3S Q3QfoNI 33v SWALI Tv HOO14 3HL 3AO8V 81 1H9I3H V OL ATIVOILYSA Q3dld 38 GINOHS 394VHOSIO 3ATVA 33l134 JHL 318VIIVAV SI 0014 ON N3HM NIVHQ 1S34V3N JHL OL Q3dld 38 GINOHS JAVA 33l138 NIVMG 3O014 V OL ALIAVHO A8 AT3344 NIVMQ OL SAINTA JHL LINYSd OL 38 GINOHS 3SOH 31VSN3QNOO 3ATVA NIVMQ TI3HS VNOISN3WIQ 33S M3lV3H FHL OL SNOILO3NNOO 33H10 ONIdid JO SNOIIVOO1 ANY 53215 WWNLOV 5310 TO sb ANVL NOISNVdX3 31VSN3QNOO JAVA TT3HS 3LON 33S MOlv1n93M 5 9 34O1nHS SVD vi 34nSS3Hd SVD XVN O
119. OWER 460V 570 1 63103 SHELL HARNESS 24351 BLOWER 208V 58 1 63109 GAS TRAIN HARNESS BMK 3000 19 1 81157 BLOWER GASKET 59 1 61024 AIR INLET TEMPERATURE SENSOR 20 1 88015 BLOWER O RING 60 1 123449 SENSOR TEMPERATURE 21 1 66020 FLAME DETECTOR 61 1 61030 SENSOR OUTLET TEMPERATURE 22 1 61026 SENSOR O2 62 1 69151 PCB ASSY 23 1 59104 OBSERVATION PORT 630 1 63110 BLOWER CONTROL WIRE 24 1 58023 IGNITOR REPLACEMENT KIT 640 1 65104 CABLE H V IGNITION 25 1 88014 AIR FILTER 650 1 63059 HARNESS DRIVE REACTOR BMK 3 0 66 1 63083 HARNESS O2 SENSOR 670 1 63111 HARNESS CONTROL CONTROLS 68 1 63004 HARNESS 460V TRANSFORMER 27 1 123966 ADJUSTABLE TEMP LIMIT SWITCH 690 1 63090 HARNESS ASSY TEMP LIM CONT PWR 28 1 123552 OVERTEMP MANUAL RESET SWITCH 29 1 60011 2 BLOWER PROOF SWITCH Not shown on drawing Only used in 460 v units AERCO International Inc Benchmark 2500 3000 Part List 02 10 2014 Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 1 of 7 OMM 0094 GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 155 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS Part OT Item Part et Item Qty Number Description Qty Number Description SHEET M
120. PTIONS v E 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 Appendix B for listings and descriptions of displayed startup status and error messages Page 38 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 03 20 2014 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION 3 4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3 2 This menu is Read Only and does not allow personnel to change or adjust any displayed items Since this menu is Read Only it can be viewed at any time without entering a password Pressing the A arrow key to display the menu items in the order listed Top Down Pressing the Y arrow key will display the menu items in reverse order Bottom Up Table 3 2 Operating Menu Menu Item Display Available Choices or Limit Default Minimum Maximum Status Message Active Setpoint 40 F 240 F Inlet Temp 40 F 140 F Air Temp 70 F 245 F Outdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Out 0 100 Exhaust Temp F F Flame Strength 0 100 Oxygen Level 0 21 Run Cycles 0 999 999 999 Run Hours 0 999 999
121. RE SALE OF APPARATUS WITHOUT PERMISSION Of THE OWNER l SHEET OF 2 Drawing Number 68040 rev E Sheet 1 of 2 OMM 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 171 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS This Page Intentionally Blank Page 172 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS CONTROL BOX CONNECTORS 24 PIN CONNECTOR 16 PIN CONNECTOR 123 4 567 8 91011121314151617 18 19 20 21 222324 16 15 14 13 12 11 10 9 87654321 N S AN AN AN AN AN AN ESSSSSSSSOSSOOS 5566069 EEEEEEFEEERE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 Tt 9 10 1112 AT SPIN lt SINS AT J 5555655515 z z z g ki 2 9 2 m m N e f sri 2 DO d ds 00 00 O O O a z e z 2 3 9 ua Hi HIE rre AE 3 z BN Im a 9 z x gt x o pee d 23 fd P PR E amp 507 2 9 8 sz s 4 a S INPUT OUTPUT BOX S 3 g JE 4 2585 82 AVA SEQ VALVE XFMR
122. RE TEST To simulate a high gas pressure fault refer to Figure 6 2a and 6 2b and perform the following steps 1 4 NPT PLUG And Ball Valve install manometer here for HIGH GAS PRESSURE FAULT TEST HIGH GAS V NATURAL PRESSURE GAS INLET SWITCH 5 gt gt SSOV HIGH GAS BALL VALVE LOW GAS PRESSURE MANUAL SWITCH SHUT OFF VALVE Figure 6 2a BMK 2500 High Gas Pressure Fault Test OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 73 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING NATURAL GAS INLET SSOV LOW GAS MANUAL PRESSURE SHUT OFF SWITCH VALVE HIGH GAS PRESSURE SWITCH 1 4 PLUG and Ball Valve HIGH GAS install manometer here for HIGH BALL VALVE GAS PRESSURE FAULT TEST Figure 6 2b BMK 3000 High Gas Pressure Fault Test High Gas Pressure Test Remove the 1 4 plug from the leak detection ball valve shown in Figure 6 2b Install a 0 16 W C manometer or W C gauge where the 1 4 plug was removed Slowly open the leak detection ball valve Start the unit in Manual mode at a valve position firing rate between 25 and 30 With the unit running monitor the gas pressure 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 The unit should shut down
123. READY Indicator Lights ON OFF switch is set to ON and all Pre Purge conditions have been satisfied 8 ON OFF Switch Enables and disables boiler operation Allows operator to test operation of the water level monitor LOW WATER LEVEL Pressing TEST opens the water level probe circuit and simulates a 9 TEST RESET Switches Low Water Level alarm Pressing RESET resets the water level monitor circuit Pressing the CLEAR key item 6 resets the display OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 35 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION Table 3 1 Operating Controls Indicators and Displays Continued ITEM CONTROL NO INDICATOR OR FUNCTION DISPLAY MENU Keypad Six 6 keys which provide the following functions for the Control Panel Menus Steps through the main menu categories shown in Figure 3 2 MENU The Menu categories wrap around in the order shown Allows you to go back to the previous menu level without BACK 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 10 A UP Arrow CHANGE key was pressed and the menu item is flashing pressing the A arrow key wi
124. RECTIVE ACTION Check for a jumper properly installed across the interlock terminals in the I O box 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 Device proving switch hooked to 3 Check that proving switch for any device hooked to the interlock interlocks is not closed circuit is closing and that the device is operational 1 Line and Neutral switched in AC 1 Check hot and neutral in AC Power Box to ensure they are not LINE VOLTAGE Power Box reversed OUT OF PHASE 2 Incorrect power supply 2 Check transformer wiring in AC Power Box against the power box transformer wiring transformer wiring diagram to ensure it is wired correctly 1 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 LOW GAS W C For IRI gas trains ensure it is between 4 5 W C and 14 W C PRESSURE see section 2 8 1 u 2 Defective Low Pressure Gas 2 Measure gas pressure at the low gas pressure switch If it is greater Switch than 3 6 W C for BMK 2500 and 2 6 W C for BMK 3000 measure continuity across the switch and replace if necessary 1 Insufficient water level in system 1 Check system for sufficient water level 2 Defective water level circuitry 2 Test wat
125. SURE SWITCH NATURAL HIGH GAS V GAS INLET SSOV lI se LOW GAS D PRESSURE AIR FUEL NN SWITCH 1 4 NPT PLUG And Ball Valve install manometer here for LOW GAS PRESSURE FAULT TEST MANUAL STOFF ski VALVE LOW GAS BALL VALVE Figure 6 1b BMK 3000 Low Gas Pressure Test Page 72 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING Low Gas Pressure Fault Test Remove the 1 4 plug from the ball valve at the low gas pressure switch shown in the lower portion of Figure 6 1a Install a 0 16 W C manometer or a W C gauge where the 1 4 plug was removed Slowly open the ball valve near the low gas pressure switch Place the unit in Manual Mode and adjust the Air Fuel Valve position 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 at approximately 3 6 W C for for BMK 2500 and 2 6 W C for BMK 3000 Fully open the external manual gas shut off valve and press the CLEAR button on the Control Box The fault message should clear and the FAULT indicator should go off The unit should restart Upon test completion close the ball valve and remove the manometer Replace the 1 4 plug removed in step 1 6 3 HIGH GAS PRESSU
126. TANVd 33108 4O WAOWSY HLIM 30N333JH31NI IN3A33d OL SONILLIJ YALVJH WOSJ 9 40 WNWININ v 513 SMOHT3 SNOIN Y9 SONILLIJ 131100 ANY LIINI N31VM 31V901 GaLINSNOOD 38 5 SJILIHOHLNY 53009 WOOT NIMVHQO NOILVTIVISNI 1VOIdAL V SI SIHL 1N3AdIHS NI ATSLVYVdSS GSGNIONI SW3ll TV Y00743 SHL 3AO8V 81 1H9I3H V Ol ATIVOILYSA Q3dld 38 GTQOHS 393vHOSId JAYA 33l134 JHL 318VlIVAv SI 30014 ON N3HM NOO14J LSSYVAN JHL 01 Q3dld 38 GINOHS 3ATVA 33l13M NIVMO NOO14 V OL ALIAVHO A133384 NIVMO 01 SAINTA JHL LINYSd OL GSONVYYV GINOHS 3SOH 31VSN3QNOO JAWA TI3HS T1VNOISN3AIQ 33S JHL Ol SNOILO3NNOO YSHLO Nidid JO SNOILVOO1 S3ZIS WNLOV X04 S310N Ee W31SAS 100 M3lVM LOH Q Q S YOSNIS N NMOI3M S V 53 xa 431V3H j9VHOIS Na OILS3NOGQ 1938IONI 1V1Svnov Alddfs S EN lt TI3H SN W3lSAS WovsHavid sx a NOILVNIBWOO C NG Ca 2m 31VSN30NOO T3NVd SOV 33l138 8 310N 55 SVD XVW YOLVINDSAY SVD OM Ov 1v 3890n0SS33d SVD 44OLNHS WOWINIW NIVLNIVIN SVO x YH NLE WOWIXVN 1v Page 195 of 204 03 20 2014 Ph 800 526 0288 Drawing Number SD A 96
127. TEM 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 DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 to 25 Default is 2 for both Deadband High and Deadband Low IGST Version Displays the version of the IGST Board installed IGN Time Setting Displays the MAX Ignition time of 4 Seconds or 7 Seconds as set in the Safety String Harness Slow Shutdown Enables or Disables the slow shutdown feature Default is Disabled Slow Sht Duration With the Slow Shutdown feature Enabled sets the time a boiler will continue to run at the Stop Level after running above the Slow Sht Threshold level for 60 Seco
128. Unit The unit must be installed on a concrete housekeeping pad a minimum of 4 inches and a maximum of 8 inches thick to ensure proper condensate drainage If anchoring the unit refer to Figure 2 1b for anchor locations Lg 1363 sD33 324 610 4X 0 75 919 27 686 H 24 O x O et0 Q lt LL O Y 9 O NOTES 1 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2 ALL DIMENSIONS SHOWN ARE IN INCHES MILIIMETERS Figure 2 1b Benchmark 2500 3000 Anchor Bolt Locations A total of 3 lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2 2 Remove the front top panel from the unit to provide access to the lifting tabs OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 17 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION Remove the four 4 lag screws securing the unit to the shipping skid Lift the unit off the shipping skid and position it on the 4 inch to 8 inch concrete housekeeping pad required in the desired location N WARNING N WHEN LIFTING OR MOVING THE BOILER DO NOT ATTEMPT TO MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER LIFTING LUGS 3 POSITIONS Figure 2 2 Boiler Lifting Provisions In multiple unit installations it is impor
129. WATTS 58048 W60 92016 10 69087 6 75 PSI KIT WATTS 58048 W75 92016 11 69087 6 100 PSI KIT WATTS 58048 W100 92016 12 69087 6 125 PSI KIT WATTS 58048 W125 92016 13 69087 7 150 PSI KIT WATTS 58048 W150 92016 14 69087 7 160 PSI KIT KUNKLE 58048 W160 Benchmark 2500 3000 Kits Available Part Description 24311 1 AIR FUEL VALVE KIT 58063 1 BLOWER REPLACEMENT KIT 460V 58063 2 BLOWER REPLACEMENT KIT 208V 27083 HEAT EXCHANGER REPLACEMENT KIT 24356 1 FLAME DETECTOR KIT 58023 IGNITOR INJECTOR REPLACEMENT KIT AERCO Benchmark 2500 3000 Part List 02 10 2014 International Inc Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 2 of 7 Page 156 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS AERCO Benchmark 2500 3000 Part List 02 10 2014 International Inc Blauvelt NY 10913 Whole Boiler 28536 1 28382 1 Sheet 3 of 7 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 157 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 amp 26014 AERCO Benchmark 2500 3000 Part List 02 10 2014 International Inc
130. X 1 4 NPT 6 3 94060 3 NIPPLE 1 1 2 NPT X 3 00 LG 7 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 8 1 9 323 ELBOW 90 DEGREE 1 1 2 9 1 69005 ACTUATOR SSOV W REGULATOR 10 1 94060 3 5 NIPPLE 1 1 2 NPT X 3 50 LG 11 1 93456 TEE REDUCING 2x1 5x2 12 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 13 1 93382 2 NPT CAP 14 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 15 1 93035 ELBOW STREET 1 4 NPT 16 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 17 1 97005 2 TUBING FLEXIBLE GAS 12 18 1 124084 ELBOW 1 4 NPT 150 M I 19 1 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 20 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 21 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 22 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 23 2 9 22 PIPE PLUG 1 4 NPT STEEL 24 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 25 4 12951 2 BUSHING CONTROL BOX 26 1 99017 SNUBBER PRESSURE 1 4 27 1 61002 3 HIGH GAS PRESSURE SWITCH 2 6 W C 28 1 63109 GAS TRAIN HARNESS BMK 3000 29 1 124862 RESISTOR ASSY 30 1 99015 DAMPING ORIFICE SSOV 31 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 32 2 95029 FLANGE SSOV 1 1 2 NPT 33 2 123533 NIPPLE CLOSE 1 8 34 2 93445 COUPLING REDUCING 1 4 x 1 8 NPT BLK MI 35 1 69038 ACTUATOR SSOV W O P O C SWITCH 36 1 122774 VALVE VENT 3 4 NPT 37 1 63043 HARNESS WIRING IRI 38 1 94061 11 00 NIPPLE 3 4 NPT 39 1 123148 BUSHING 1 NPT X 3 4 NPT 40 2 9 469 ELBOW 90 3 4 NPT 41 2 94061 3 00 NIPPLE 3 4 NPT X 3 00 LG 42 1 94061 18 00 NIPPLE 3 4 NPT X 18 00 LG AERCO
131. agement 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 lights to TEMPERATURE indicate whether the displayed temperature is in degrees 2 Displ Fahrenheit or degrees Celsius The F or C blinks when operating Isplay in the Deadband Mode On a BST Master display flashes amp shows header temperature Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes VED Disol e Startup Messages 3 eee e Fault Messages e Operating Status Messages e Menu Selection e BST Messages Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel AERCO offers for purchase the RS232 Adaptor Cable P N 124675 which is designed to 4 RS 232 Port work with this port This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports 5 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm condition occurs An alarm message will appear in the VFD Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid Lockout type alarms will be latched and 6 GLERIEREY cannot be cleared by simply pressing this key Troubleshooting may be required to clear these types of alarms 7
132. al Vertical Conventional Sidewall Conventional Direct Vent Vertical Sealed Direct Vent Horizontal These boilers are capable of being vented utilizing Polypropylene and AL29 4C vent systems The Benchmark s advanced electronics are available in several selectable modes of operation offering the most efficient operating methods and energy management system integration IMPORTANT Unless otherwise specified all descriptions and procedures provided in this Installation Operation amp Maintenance Manual apply to the Benchmark series of boiler OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 137 Ph 800 526 0288 Page 7 of 204 03 20 2014 Benchmark 2500 3000 Boilers FORWARD Phrases Abbreviations and Acronyms Phrase Abbreviation or Acronym Meaning A Amp Ampere ACS AERCO Control System ADDR Address AGND Analog Ground ALRM Alarm ASME American Society of Mechanical Engineers AUX Auxiliary BAS Building Automation System often used interchangeably with EMS see below Baud Rate Symbol rate or simply the number of distinct symbol changes 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 Thermal Unit A unit
133. alent gauge and plastic tubing e 1 4 inch NPT to barbed fittings for use with gas supply manometer or gauge e Small and large flat blade screwdrivers e Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to monitor the gas pressure on the 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 1a BMK 2500 and 4 1b BMK 3000 NATURAL HIGH GAS V GAS INLET 1 4 NPT PLUG P E Install manometer L here for Combustion j Calibration e SSOV LEAK DETECTION To BALL VALVE AIRIFUEL LOW GAS MANUAL PRESSURE SHUT OFF SWITCH VALVE Figure 4 1a BMK 2500 1 4 Inch Gas Plug Location for Combustion Calibration Page 52 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP NATURAL GAS INLET SSOV AIR FUEL MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWITCH PRESSURE 1 4 PLUG LEAK DETECTION Install manometer BALL VALVE here for Combustion Calibration Figure 4 1b BMK 3000 1 4 Inch Gas Plug Location for Combustion Calibration Install the 16 W C manometer s as described in the following steps Installing Gas Supply Manomete
134. alue or setting for the option and press lt Rtn gt Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning Menus The Calibration and Diagnostic Menus should only be used by Factory Trained service personnel 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 Rtn gt 10 To display the Fault F Log Sensor S Log or Time T Line Log press F S or T followed by Rtn Refer to section 9 4 for descriptions and samples of these data logs 11 To log off and terminate the RS 232 communication link press L followed by lt Rtn gt 9 4 DATA LOGGING During operation the C More Control Panel continuously monitors and logs data associated with operational events faults and sensor readings associated with the boiler system Descriptions of these data logs are provided in the following sections The procedure for accessing specific data log is described in section 9 3 step 10 Page 116 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 9 RS232 COMMUNICATION 9 4 1 Fault Log The C More Control Panel logs the last 20 faults 0 19 starting with the most recent 0 They can be viewed in the front panel display or via the RS 232 po
135. an air filter in place of a Combustion Air Duct not shown remove the air filter Page 80 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers 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 Flame Detector Connector Boot TO WIRE HARNESS Flame Signal Generator Figure 6 4a 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 t
136. ani3s NW31SAS ONILV3H JAVA TT3HS 8 310N WNolvin93H SV9 N S SON OM vi 34nSS3Hd SVD XV OM O v LV JYNSS3Yd SVD WOWININ NIVLNIVA YH NLE WOWIXVW 1v 33O1nHS SVD lt Drawing Number SD A 957 rev A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 0E Page 191 of 204 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS 896 7 05 A38 215021 5 LINN Z 3ONVHV3IO 3015 0532 LLINW MO H8N 000 00072 HVWHON3H IVNOLLVNH3INI D Alddn s W3LSAS SNILV3H JAYA d l3A3133 3000 192071 Q3MInO34 SSFINN TVNOldO SI MOlVIn939 SVD MOISE MO vt IV s STIVL30 Od 00 1 SNOILONYLSNI MNVL 31VSN3QNOO 33S JOO014 JHL 3AO8V NVHL M3H9IH G31VA313 ISNW 31VSN3QNOO OOM3V Y31108 3HL V NI Q3T VISNI 1SNW MNVL M3ZIIVMIQ3N JHL 39VNIVHO 31VSN3QNOO M3dOBd 4NVL NAZNVYLNSN 31VSN3QNOO O23N3V JHL ONISN N3HM SS3 HO 1 01 NMOG 553 SVD JHL SNING Ol 3ATA 44O1nHS TWOANVW JHL 3O WVv3sHlsSNMOG LSNW MOlv1n93H 3 7ALS dn 5201 V atl 1 SI 330SS33d SV9 318V1NAV N3HM 9 STANVd 3015 AVMV 9 38 3SIM3MI GINOHS S3XO8 LINGNOD S3HOIIMS 30l M3S SNOLLO3NNOO 21419313 ONY S9NIdld TIY SH3AOO ST3Nvd 4343108 30 TW
137. ark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5 1 INTRODUCTION The boiler is capable of being operated in any one of six different modes The following sections in this Chapter provide descriptions of each of these operating modes Each boiler is shipped from the factory tested and configured for the ordered mode of operation All temperature related parameters are at their factory default values which work well in most applications However it may be necessary to change certain parameters to customize the unit to the system environment A complete listing and descriptions of the temperature related parameters are included in Appendix A Factory defaults are listed in Appendix D After reading this chapter parameters can be customized to suit the needs of the specific application 5 2 INDOOR 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 an adjustable number from 0 1 to 9 9 Once adjusted the supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreas
138. at 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 carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the ex
139. ate 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 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 2 3 0 2 W C If gas pressure adjustment is required remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make gas pressure adjustments using a flat tip screwdriver to obtain a gas pressure within the range of 2 3 W C 0 2 W C Using the A arrow key increase the valve open position to 10096 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2 1 0 2 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
140. ater 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 IGN SWTCH OPEN DURING IGNITION The Ignition Position Limit switch on the Air Fuel Valve closed DURING PURGE during purge The Ignition Position Limit switch on the Air Fuel Valve opened during ignition INTERLOCK OPEN The Remote Interlock is open LINE VOLTAGE OUT OF PHASE The Line Hot and Neutral wires are reversed LOW GAS The Low Gas Pressure Limit Switch is open PRESSURE LOW WATER The Low Water Cutoff board is indicating low water level LEVEL NETWORK COMM The RS 485 network information is not present or is FAULT corrupted O5 96 OUT OF RANGE The has gone below 3 or above 8 Page 140 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 2 Fault Messages Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range OUTLET TEMP SENSOR FAULT The temperature measured by the Outlet Sensor is out of range e OUTLET TEMPERATURE display SHt Indicates sensor is shorted e OUTLET TEMPERATURE display Opn indicates sensor is open circu
141. ature is expected The sensor must be shielded from direct sunlight as well as impingement by the elements The outdoor sensor may be wired up to 200 feet from the boiler OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 125 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 4 Continued e There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded dez qeu uere aad GND 12VDC Power Supply Temp Sensor PN 61043 Modbus Transmitter I O Box Step 3 Configure ALL C More Units On ALL Boilers 1 Goto 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 Outdoo
142. be replaced Otherwise clean the detector with a fine emery cloth Reinstall the flame detector and flame detector gasket Reconnect the flame detector lead wire Reinstall the shroud on the unit 7 4 O SENSOR The sensor part no 61026 is located on the burner plate at the top of the unit see Figures 7 1 and 7 2 The sensor may be hot Allow the unit to cool sufficiently before removing or replacing the O sensor O Sensor Maintenance Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Disconnect the O sensor lead wire by pushing in on the release tab and pulling apart the connector Next loosen and remove the O sensor and crush washer from the burner plate using a 15 16 open end wrench Thoroughly inspect the O sensor If eroded the sensor should be replaced Otherwise clean the sensor with a fine emery cloth Reinstall the O sensor and crush washer on the burner plate Reconnect the sensor lead wire Reinstall the shroud on the unit 7 5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed Certain code requirements such as ASME CSD 1 require that these tests be performed on a
143. bes the existing conditions Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication Perform the checks and procedures listed in the Corrective Action column for the first Probable Cause candidate Continue checking each additional Probable Cause for the existing fault until the fault is corrected Section 8 2 and Table 8 2 contain additional troubleshooting information which may apply when a no fault message is displayed If the fault cannot be corrected using the information provided in the Troubleshooting Tables contact your local AERCO Representative OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 99 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE This page left intentionally blank Page 100 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION T Blower stopped running due to thermal or current overload Blocked Blower inlet or inlet air filter Blockage in Blower Proof switch Blockage in Blocked Inlet switch Defective Blower Proof switch Defective Blocked Inlet switch L
144. bled or Disabled Disabled Setpt Limit Band O F 10 F 0 Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt EN 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 A CAUTION N DO NOT CHANGE the Analog Output Menu Item from its Default setting Valve Position 0 10V 3 7 TUNING MENU The Tuning Menu items in Table 3 5 are Factory set for each individual unit Do not change these menu entries unless specifically requested to do so by factory trained personnel Table 3 5 Tuning Menu Menu Item Display Choices eii S Lucis Default 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 0 F 120 F 95 F Warmup Int Gain 0 2 00 0 50 Warmup PID timer 0 sec 240 sec 20 sec Reset Defaults Yes No Are You Sure No Page 42 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION 3 8 COMBUSTION CAL MENU The Combustion Cal Calibration Menu is protected by the level 2 password 6817 which must be entered to view or change the menu items shown in Table 3 6 These menu items are used to vary the speed of the unit s blower motor based on air temperature and air density at prescribed Air Fuel Valve positions 96 open This is accomplished by providing a DC driv
145. 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 A FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED BE SURE TO SHUT OFF ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE N WARNING 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 N WARNING N ELECTRICAL VOLTAGES UP TO 480 VAC MAY BE USED IN THIS EQUIPMENT THEREFORE THE COVER ON THE UNIT S POWER BOX LOCATED BEHIND THE FRONT PANEL DOOR MUST BE INSTALLED AT ALL TIMES EXCEPT DURING MAINTENANCE AND SERVICING OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 11 of 204 GF 137 Ph 800 526 0288 03 20 2
146. chieving maximum operational efficiency BST is designed to ensure that all Boilers in the system operate at maximum efficiency This is accomplished by lighting off boilers only if all ignited boilers reach or exceed a defined Valve Position Fire Rate Operating all boilers below the defined Fire Rate Next on VP for Next Turn on Valve Position insures that they are firing at their most efficient Fire Rate One C More unit is defined as the MASTER unit and all other C More units on the BST Modbus Network are defined as SLAVE units The Master unit will monitor the system Header Temperature monitor all Slave units status information and efficiently control all units in order to achieve and maintain the required BST Setpoint Temperature When there is a demand the Master unit will light off one of the boilers based on the BST Sequencing selection in the BST menu As system load increases and the valve position of the ignited units reach the Next On VP valve position the BST master will light off the next available unit A simplified block diagram of multiple Boilers connected to a BST is shown in Figure 9 1 below Note Use either FFWD Header sensor or Modbus Header Sensor Modbus FFWD Header Header Sensor Sensor OUTLET Optional av 9 Loss _ Note Modous Header sensor amp a Sequencing o can be connected to any I Vale ri boiler on the Modbus Network Boiler Boiler Boiler 1 2 8 Not
147. ctions 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 96 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 e 4 20 mA 1 5 0 20 0 5 The factory default setting for the Direct Drive mode is 4 20 mA 1 5 With this setting 4 to 20 mA signal sent by an EMS or BAS is used to change the unit s valve position from 0 to 100 A 4 mA 1V signal is equal to a 0 valve position while a 20 mA 5V signal is equal to a 10096 valve position When a 0 20 mA 0 5 Vdc signal is used zero is equal to a 096 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
148. displayed in UPPER CASE letters and are bounded by an asterisk in order to readily identify them within the item list OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 GF 137 Ph 800 526 0288 Page 43 of 204 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION The Items contained in group 1 BST Monitor Items are ALWAYS displayed within the menu as these items are critical for proper system operation Therefore the BST Monitor Items Header itself is NOT displayed The Items contained in groups 2 5 are NOT DISPLAYED unless that particular item group has been enabled from the C More keypad Table 3 7 BST Menu Available Choices or Limits Menu Item Display Default Minimum Maximum BST Mode Off BST Slave BST Master Off BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130 F Header Temp NA Header Temp CF BST Fire Rate 0 10096 Fire rate 96 BST Ave Fire Rate 0 100 Avg Fire Rate 96 BST Outdoor Temp NA ip TUR Units Available 0 8 Units Present Units Ignited 0 8 Units firing BST Valve State 0 CLOSED 1 OPEN 0 1 Comm Errors 8 0 9 0 1 BST Units 8 0 see table 0 see table 0 BST SETUP MENU Disabled Enabled Disabled BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header T
149. e FFWD Header Sensor SSE SRE Master must be connected to a Master INLET Figure 10 1 Simplified BST Block Diagram OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 119 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 2 AERCO BST Quick Start Chart Select the single option that suites your installation and then complete the instructions in the corresponding sub sections of section 10 3 BST Implementation Instructions Constant Setpoint choose option 1 or 2 Option 1 Direct Wired Header Complete section 10 3 1 OR Option 2 Modbus Header Complete section 10 3 2 Outdoor Reset choose option 3 or 4 Option 3 Direct Wired Header AND Direct Wired Outdoor Air Complete section 10 3 3 OR Option 4 Modbus Header AND Modbus Outdoor Air Complete section 10 3 4 Remote Setpoint choose option 5 through 8 Option 5 4 20ma Drive AND Direct Wired Header Complete section 10 3 5 OR Option 6 Modbus Drive AND Direct Wired Header Complete section 10 3 6 OR Option 7 4 20ma Drive AND Modbus Header Complete section 10 3 7 OR Option 8 Modbus Drive AND Modbus Header Complete section 10 3 8 Page 120 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 BST Implem
150. e 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 are listed in Table 3 6 Table 3 6 Combustion Cal Menu Menu Item Display BMK 2500 BMK 3000 CAL Voltage 16 CAL Voltage 1496 CAL Voltage 3096 CAL Voltage 3096 CAL Voltage 4096 CAL Voltage 4096 CAL Voltage 5096 CAL Voltage 5096 CAL Voltage 70 CAL Voltage 70 CAL Voltage 100 CAL Voltage 100 SET Valve Position SET Valve Position Blower Output Set Stdby Volt Oxygen Level Blower Output Set Stdby Volt Oxygen Level 3 9 BST Boiler Sequencing Technology Menu The BST Menu must be Enabled in order to be displayed and accessed The BST Enable item is located at the end of the Configuration Menu The Boiler Sequencing Technology BST Menu contains all of the items required to Configure Operate and Monitor the functionality of the BST System There are over 50 items in this menu and selecting any particular item from the list for inspection or modification could be time consuming As a result the BST Menu has been segmented into FIVE logical groups based on functionality The five Item groups are 1 BST Monitor Items BST SETUP MENU OPERATE MENU TEMP CTRL MENU BST COMM MENU Oc RON These displayed item groups are
151. e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE 7 8 AIR FILTER CLEANING amp REPLACEMENT The Benchmark boiler is equipped with an air filter part no 88014 which should be cleaned and re oiled every 12 months and replaced every 24 months The air filter is located at the inlet of the air fuel valve at the top of the boiler as shown in Figure 7 7 To inspect replace the air filter proceed as follows Air Filter Cleaning amp Replacement Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Refer to Figure 7 7 and locate the air filter attached to the air fuel valve inlet Using 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
152. e 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 GND amp The RS 485 communication terminals are used when the boiler plant is being controlled by an Energy Management System EMS or an AERCO Control System ACS using Modbus RS 485 communication 2 10 10 RS 232 Comm TxD amp RxD The RS 232 communication terminals permit a laptop computer or other suitable terminal to be connected to the boiler The RS 232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing fault and sensor log displays 2 10 11 VFD Blower 0 10 amp AGND These terminals 0 10 amp AGND send an analog signal to control the blower speed When any of the 4 20mA options is selected for the Analog Outputs Section 2 10 8 the output from the VFD Blower terminals is disabled 2 10 12 Interlocks The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers or other accessories These interlocks are called the Remote Interlock and Delayed Interlock REMOTE INTL K IN and DELAYED INTL K IN in Figure 2 12 Both interlocks described below are factory wired in the closed position using jumpers NOTE Both the Delayed Interlock and Remote Interlock must be in the cl
153. e Procedures Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit and turn off the gas supply Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels Disconnect the lead wire from the flame detector installed on the burner plate See Figure 7 2 Remove the two 2 screws securing the flame detector to the plate The flame detector is secured to the burner plate with 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 from the igniter injector Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench Retrieve the blower support rig and attach it to the blower and unit as described in the instructions provided with the rig Loosen and remove the four 5 16x1 3 4 bolts washers and nuts from the burner plenum where it is attached to the blower see Figure 7 4a amp 7 4b Page 92 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000
154. e User Manual OMM 0080 GF 129 for more information Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit Connect the Header Temperature Sensor AERCO PN 61040 to the Feed Forward FFWD terminals on the P 1 Harness Via the terminal block labeled Header Temp sensor in the I O Box NOTES e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded xe ol Temp Sensor PN 61040 Header Temp Sensor Box Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF 129 Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Go to the BST Menu and set the BST Mode item to BST Slave for now On Master only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint Goto the BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Go to the Head Temp Source item and select FFWD Temp Go to the BST Remote Signal item and select Network NO Of When ALL C More units have been configured 8 Go to the BST Menu of the des
155. e modulating and condensing units They represent a true industry advance that meets the needs of today s energy and environmental concerns Designed for application in any closed loop hydronic system the Benchmark s modulating capability relates energy input directly to fluctuating system loads The turn down ratios for these boilers is 15 1 These BMK models provide extremely high efficiency operation and are ideally suited for modern low temperature as well as conventional heating systems The Benchmark Model BMK 2500 and BMK 3000 operate within the following input and output ranges Benchmark Model Input Range BTU hr Output Range BTU hr Minimum Maximum Minimum Maximum BMK 2500 167 000 2 500 000 144 000 2 150 000 BMK 3000 200 000 3 000 000 186 000 2 790 000 The output of the boiler 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 these boilers comply with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the BMK 2500 and BMK 3000 offer the maximum venting flexibility with minimum installation space requirements These Boilers are Category 11 III and IV positive pressure appliances Single and or multiple breeched units are capable of operation in the following vent configurations Convention
156. ection switches not set for correct signal type voltage or current Co 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 0094 0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 103 of 204 03 20 2014 Benchmark 2500 3000 B
157. ed in Chapter 6 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Benchmark must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at AERCO International Inc 100 Oritani Drive Blauvelt 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 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 51 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP 4 2 1 Required Tools amp Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit e Digital Combustion Analyzer Oxygen accuracy to 0 496 Carbon Monoxide CO and Nitrogen Oxide NOx resolution to 1PPM 16 inch W C manometer or equiv
158. eet vue dee cos 22 2 8 2 Manual Gas Sli toff Valve I u terre nere ee heres e tera age eere EE eed iE eran nne 22 2 8 3 External Gas Supply R gu lat r u L uD u q uQ am N enne Q tenent entente terrens sententia 23 2 9 AC ELECTRICAL POWER WIRING U u u 24 2 9 1 Electrical Power Req lrem nts ra e eo ee Pee pape ve erae etate a P pipu 25 2 10 FIELD CONTROL WIRING uu uu us aaa reser ern a oe RR INNER teeta 26 2 10 1 Outdoor Air In OUT amp Air Sensor Common COM nennen enne nnn n s enne enne 27 2 10 2 COMBUSTION AIR Terminal enn 27 2 10 30 SENSOR O21 8 02 Siva de Foe eese a eevee learns 28 2 10 4 SPARK SIGNAL FLW amp FLW 28 210 5 Analog ees asc ease LG 28 2 10 6 5 PWM In BMS amp 28 2 10 7 Shield SHED amp SHLD ee eet tnt Sn a Dee Rd qa eA u hua h uma det 28 2 10 8 Analog OUTPUT E R 28 2 10 9 RS 485 Comni F GND amp eere evene ete eres e oe A egg ee eee ease dena S epa opas u en eaae 29 2 10 10 RS 232 Commr TXD 8SCRXD EO hn ie BG Ne De etn eee Sea RU pa eee inse uere 29 2 10 11 V
159. emp 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 Network Network Yes BST Auto Mstr No NOTELA 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 ipud Shutdown One Boiler Mode Off Oise On Avg Temp Off Temp 1 Bir Threshold 10 35 25 Setpoint Setback Disable Enable Disable Page 44 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER OPERATION Available Choices or Limits Menu Item Display Default Minimum Maximum Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130 F Setback Start 12 00am 11 59pm 12 00am Setback End 12 00am 11 59pm 12 00am Rate Threshold 1 F 30 F 15 F Disabled Enabled Disabled BST Next On VP 1696 10096 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
160. entation Instruction 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit Connect the Header Temperature Sensor AERCO PN 61040 to the Feed Forward FFWD terminals on the P 1 Harness Via the terminal block labeled Header Temp sensor in the I O Box NOTES e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header e Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded ol 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 Goto the BST Setup Menu item and set to Enabled 5 Goto the BST Setpoint Mode item and select Constant Setpoint to the Head Temp Source item and select FFWD Temp When ALL C More units have been configured 7 Goto the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 121 of
161. er level circuitry using the Control Box front panel LOW LOW WATER WATER TEST and RESET buttons Replace water level circuitry if LEVEL it does not respond 3 Defective water level probe 3 Check continuity of probe end to the shell change probe if there is no continuity MODBUS Unit not seeing information from Check network connections If fault persists contact qualified COMMFAULT Modbus network Service Personnel PRG SWTCH CLOSED DURING IGNITION 1 A F Valve rotated open to purge and did not rotate to ignition position Start the unit The Air Fuel Valve should rotate to the purge open position then back to ignition position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fuel Valve or the Control Box Refer fault to qualified service personnel OMM 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 107 of 204 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PRG SWTCH CLOSED DURING IGNITION continued PROBABLE CAUSES 2 Defective or shorted switch 3 Switch wired incorrectly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 2 CORRECTIVE ACTION If t
162. es 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 I O Box Use shielded 18 to 22 AWG wire for connections A wiring diagram is provided on the cover of the I O Box Refer to Chapter 2 section 2 9 1 for additional wiring information 5 2 4 Indoor Outdoor Startup Startup in the Indoor Outdoor Reset Mode is accomplished as follows NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data OMM 009
163. fety devices before during and after the start sequence The following tests check to ensure that the system is operating as designed SAFETY DEVICE TESTING Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Chapter 3 NOTE It will be necessary to remove the front door and side panels from the unit to perform the following tests N WARNING N ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 208 230 OR 460 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK OMM 0094 0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 71 of 204 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 2 LOW GAS PRESSURE FAULT TEST Refer to Figure 6 1a and 6 1b then ensure that the leak detection ball valve located at the low gas pressure switch is closed V NATURAL GAS INLET HIGH GAS ie PRESSURE SWITCH SSOV LOW GAS PRESSURE SWITCH MANUAL And Ball Valve SHUT OFF install manometer here for LOW GAS PRESSURE FAULT TEST VALVE LOW GAS BALL VALVE Figure 6 1a BMK 2500 Low Gas Pressure Test PRES
164. for your PuTTY session B Session Options controlling local serial lines Logging Specify the destination you want to connect to Tu Logging Select a serial line B Terminal al l 4 Terminal i i Keyboard Serial line _ Speed i Keyboard Serial line to connect to COM1 Bell COMI p Configure the serial Features Connection type Features DESERUIT E Window Tenet Rogn SSH Seral B Window Speed baud 9600 f Appearance Load save or delete a stored session i z ee Data bits 8 i Translation Saved Sessions Translation Stop bits 1 i Selection Selection Paty i Colours Default Settings Load i Colours Connection B Connection Flow control XON XOFF Y i Data Save i Data Ms Telnet Telnet j gt Rlogin Rlogin SSH 6 SSH Sea Close window on exit Always Never Only on clean ext Figure 9 1 PuTTY GUI Basic Serial Session L and Serial Options In Serial mode text typed into the PuTTY window will be sent straight out of your computer s serial port and data received through that port will be displayed in the PuTTY window To create a Serial connection click the radio button labeled Serial The Serial line and Speed fields will then be automatically filled in as shown in left image of Figure 9 1 but will allow you to specify the serial line to use if your computer has more than one and what speed baud
165. g is designed or installed Suitable U L approved positive pressure watertight vent materials MUST be used for safety and UL certification Because the unit is capable of discharging low temperature exhaust gases the flue must be pitched back towards the unit a minimum of 1 4 per foot to avoid any condensate pooling and to allow for proper drainage While there is a positive flue pressure during operation the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet or 0 8 W C Fittings as well as pipe lengths must be calculated as part of the equivalent length For a natural draft installation the draft must not exceed 0 25 W C These factors must be planned into the vent installation If the maximum allowable equivalent lengths of piping are exceeded the unit will not operate properly or reliably For Massachusetts installations the following companies provide vent systems which conform to all applicable requirements for installations within the Commonwealth of Massachusetts Contact information is as follows Selkirk Corporation Heatfab Division Watertown Supply 130 Industrial Blvd 33Grove St Turners Falls MA 01376 Watertown MA 02472 Phone 1 800 772 0739 Phone 617 924 2840 www heat fab com http www watertownsupply com M A Peacard Glover Sheet Meatal Inc 1250 Massachusetts Ave 44 Riverdale Ave Boston MA 02125 1689 Newton MA 02485 Phone 617 288 0629 Phone 617 527 8178 ww
166. he unit should not start If the unit does start shut the unit off immediately and refer fault to qualified service personnel Close the drain and pressure relief valve used in draining the unit Open the water shut off valve in the return piping to the unit Open the water supply shut off valve to the unit to refill After the shell is full press the LOW WATER LEVEL RESET button to reset the low water cutoff Press the CLEAR button to reset the FAULT LED and clear the displayed error message 12 Set the ON OFF switch to the ON position The unit is now ready for operation OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 75 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic over temperature switch This switch is accessible from the front of the unit as shown in Figure 6 3 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 s
167. he Air Fuel Valve does rotate to the ignition position check the purge switch for continuity between the N O and COM terminals If the switch shows continuity when not in contact with the cam check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch Check DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED 051 and verify it is blinking ON amp OFF every second If not replace IGST Board PRG SWTCH OPEN DURING PURGE 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 DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED 051 and verify it is blinking ON amp OFF every second If not replace IGST Board OUTDOOR TEMP SENSOR FAULT 1 Loose or broken wiring 2 Defective Sensor
168. he alligator clip see Figure 6 4a to any bare metal surface or ground The C More display should now show FLAME PROVEN and begin to ramp up to 100 fire rate Note that no gas or flame is present in the boiler at this time 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 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 81 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING ii AIR INLET Combustion Air Duct removed PRIMARY EXHAST WATER INLET MANIFOLD ANALYZER PORT DRAIN VALVE CONDENSATE DRAIN Figure 6 5 Boiler Rear View Showing Air Inlet Location 6 9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6 1a and 6 1b 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
169. he installer must identify the emergency shut off device Page 12 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 1 SAFETY PRECAUTIONS IMPORTANT FOR MASSACHUSETTS INSTALLATIONS Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements e Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts e Prior to unit operation the complete gas train and all connections must be leak tested using a non corrosive soap e The vent termination must be located a minimum of 4 feet above grade level If side wall venting is used the installation must conform to the following requirements extracted from 248 CMR 5 08 2 a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe th
170. he 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 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 V 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
171. he source When driving multiple units each unit s wiring must conform to the above 5 5 2 Direct Drive Startup Since this mode of operation is factory preset and the valve position is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the signal is present To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Direct Drive mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 6 AERCO CONTROL SYSTEM ACS NOTE ACS is for installations with 9 or more boilers It utilizes only RS 485 signaling to the boiler Installations with 1 to 8 boilers can use BST see Chapter 10 The ACS mode of operation is used in conjunction with an AERCO Control System The ACS mode is used when it is desired to operate multiple units in the most efficient manner possible For this mode of operation an ACS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant s supply water header The ACS can control up to 40 boilers Up to 32 via Modbus RS 485 network communication For ACS programming operation and Header Sensor installation details see ACS Operations Guide GF 131 For operation via an RS 485 Modbus network refer to Modbus Communication Manual GF 114 To enable the ACS Mode the following menu settings
172. hield must be left free and ungrounded GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 Direct Wired 0 20ma or 4 20ma Wirin 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master NOTES 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 v pre SERS ERAS a i Remote Signal OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 129 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 7 Continued Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Go to the BST Menu and set the BST Mode item to BST Slave for now On MASTER only Go to the BST Setpoint item and enter the Failsafe Setpoint Gotothe BST Setup Menu item and set to Enabled Go to the BST Setpoint Mode item and select Remote Setpoint Goto the BST Remote Signal and select either 4 20ma or 0 20ma Goto the Head Temp Source item and select Network Goto 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
173. hould 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 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 8 The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature OVER TEMPERATURE LIMIT DIGITAL CONTROLLER ADJUSTABLE TEMPERATURE LIMIT SWITCH MANUAL SWITCH RESET BUTTON TEMPERATURE LIMIT SWITCH Figure 6 3 Temperature Limit Switch Location Page 76 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock Terminal connections for these circuits are located in the I O Box Figure 2 12 and are labeled REMOTE INTL K IN and DELAYED INTL K IN These circuits can s
174. hut 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 an emergency cut off or to prove that a device such as a pump gas booster or louver is operational 6 6 1 Remote Interlock Test Remote Interlock Test Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals Start the unit in the Manual Mode and set the valve position between 25 and 30 If there is a jumper across the REMOTE 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 Once the interlock connection is reconnected the INTERLOCK OPEN message should automatically clear and the unit should restart 6 6 2 Delayed Interlock Test Delayed Interlock Test Remove the cover from the I O Box and locate the DELAYED INTL K IN terminals Start the unit in the Manual Mode at a valve position between 2596 and 30 If there is a jumper across the DELAYED INTL K IN terminals remove one side of the jumper If the interlock is connected to a proving switch of an external device disconnect one of the wires leading to the proving switch The unit should shut down and display a DELAY
175. igure 6 7 Air Fuel Valve Cover Location Page 84 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING TO BLOWER Ignition f Position 3 Switch 170 VALVE Wy POSITION AIR FUEL VALVE K DIAL SWITCH WIRING BREAKOUT L Purge Position Switch AIR IN Figure 6 8 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 85 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING This Page Is Intentionally Blank Page 86 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE CHAPTER 7 MAINTENANCE 7 1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability For best operation and life of the unit the following routine maintenance procedures should be performed in the time periods specified in Table 7 1 For a complete inspection check list see ASME CSD 1 chart In order to perform the maintenance
176. iler The Operation Time Log can only be accessed through the RS 232 interface using a laptop or other terminal device Ten operation time records are displayed for each T command entry The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu Table 9 2 Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time Off Direct Drive 0 0 8 1 15 02 2 35pm Run Direct Drive 38 100 34 1 15 02 2 27pm Run Direct Drive 31 100 30 1 15 02 1 53am Run Direct Drive 35 100 2 1 15 02 1 23pm Run Direct Drive 29 100 0 1 15 02 1 21pm Ignition 0 0 0 1 15 02 1 20pm Off Switch 0 0 35 1 15 02 12 30pm Run Manual 40 100 0 1 15 02 11 55am Ignition 0 0 0 1 15 02 11 55am Power up 0 0 0 1 15 02 11 50am OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 117 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 9 RS232 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 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
177. iler plant containing up to eight combination boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers e OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler plant containing up to eight combination boilers that are divided up into Building Priority BLDG PRIORITY boilers and Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and using two hydronic isolation valves in the main header one between the BLDG HEAT and BLDG PRIORITY boilers and the other between the BLDG PRIORITY and the DHW PRIORITY boilers 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 Page 68 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION satisfied the combo boiler s remain on the domestic hot water load If the
178. ill read 100 to indicate that it is full open 100 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 47 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION c The VALVE POSITION bargraph will show 100 N TO BLOWER PURGE VALVE POSITION DIAL AT 100 Figure 3 4 Air Fuel Valve In Purge Position 4 Next the blower proof switch on the Air Fuel Valve Figure 3 5 closes The display will show Purging and indicate the elapsed time of the purge cycle in seconds AIR FUEL VALVE OUTLET TO BLOWER BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR FUEL VALVE INLET FROM GAS TRAIN Figure 3 5 Blower Proof Switch 5 Upon completion of the purge cycle the Control Box initiates an ignition cycle and the following events occur a The Air Fuel Valve rotates to the low fire Ignition Position position and closes the ignition switch The Dial on the Air Fuel Valve Figure 3 6 will read between 25 and 35 to indicate that the valve is in the low fire position Page 48 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION b The Spark Cycle Time item in the Factory menu can be set to either 0 Sec 2 Sec or 7 Sec to define the duration of the Spark Element Cleaning Cycle This cycle turns on the spark transfor
179. in line must be removable for routine maintenance N CAUTION N Use PVC stainless steel aluminum or polypropylene for condensate drain piping Figure 2 6 DO NOT use carbon or copper components TRAP INLET COMBUTION Assis ADAPTOR AND ANA FECI THUMBSCREW PROBE PORT TOP FLUE STARTER COVER CONDENSATE SECTION THUMB TRAP P N 24060 SREWS BOILER I 3 4 NPT EXHAUST 27 BEP NIPPLES HOSE MANIFOLD EE un 5 1 DIAM HOSE NOTE 4 HOUSKEEPING PApMUsrNor HOUSE _ gt I KEEPING s MAXIMUM EXHAUST TO os MANIFOLD CONDENSATE PAD DRAIN PORT SUPPORT DRAIN ASSEMBLY Figure 2 6 Sample Condensate Trap Installation Right Side View OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 21 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide GF 2030 must be consulted prior to designing or installing any gas supply piping N WARNING N NEVER USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS CAUTION Many of the soaps used for gas pipe leak testing are corrosive to metals Therefore piping must be rinsed thoroughly with clean water after leak checks have been completed NOTE All gas piping must be arranged so that it does not interfere with removal of any covers inhibit service mainte
180. ination Control System CCS is one that uses multiple boilers to cover both space heating and domestic hot water needs The theory behind this type of system is that the maximum space heating load and the maximum domestic hot water load do not occur simultaneously Therefore boilers used for domestic hot water are capable of switching between constant setpoint and ACS control For a typical CCS an adequate number of boilers are installed to cover the space heating load on the design day However one or more units are used for the domestic hot water load as well These boilers are the combination units and are referred to as the combo boilers The combo boilers heat water to a constant setpoint temperature That water is then circulated through a heat exchanger in a domestic hot water storage tank Only the AERCO Control System ACS is necessary to configure this system if only a single valve is 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 bo
181. ing Orifice is installed in the SSOV Actuator shown in Figure 8 2 For IRI DBB Gas Trains the Damping Orifice is installed in the downstream SSOV Actuator Air Fuel Valve hunting at the 80 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 0094 0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 111 of 204 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE BLOWER PLENUM STAGED IGNITION STAGED IGNITION SOEENOIE COMPRESSION FITTING amp ELBOW FLAME DETECTOR HARNESS TERMINAL FLAME DETECTOR amp GASKET O2 SENSOR CABLE TERMINAL O2 SENSOR amp WASHER IGNITOR CABLE TERMINAL STAGED IGNITION FLEX GAS HOSE NIPPLE INJECTOR IGNITOR FLAME ASSEMBLY OBSERVATION PORT INDEXING CLOCKING BURNER PLATE FLANGE WASHERS 0 3 as needed GAS INJECTOR TUBE Figure 8 1 Staged Ignition Connection to Gas Injector Tube DAMPING ORIFICE BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw Figure 8 2 SSOV Actuator With Gas Pressure Adjustment Page 112 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 9 RS232 COMMUNICATION CHAPTER 9 RS 232 COMMU
182. ired Master unit and set the BST Mode item to BST MASTER Page 128 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive NOTE Both Header Sensor AND 4 20ma Direct Drive must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode User Manual OMM 0080 GF 129 for more information Step 1 MODbus Header Sensor 1 Using Shielded pair 18 22 AWG cable Connect the Temperature Transmitter AERCO P N 65169 terminal Pin 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 downstream of the LAST boiler in the plant s supply water header e There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the s
183. is manual Page 98 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE CHAPTER 8 TROUBLESHOOTING GUIDE 8 1 INTRODUCTION This troubleshooting guide is intended to aid service maintenance personnel in isolating the cause of a fault in a Benchmark 2500 MBH and 3000 MBH boilers The troubleshooting procedures contained herein are presented in tabular form on the following pages These tables are comprised of three columns labeled Fault Indication Probable Cause and Corrective Action The numbered items in the Probable Cause and Corrective Action columns correspond to each other For example Probable Cause No 1 corresponds to Corrective Action No 1 etc NOTE The front panel of the C More Control Box contains an RS 232 port which can be interfaced to a laptop computer or other suitable device This RS 232 communication feature permits service personnel to 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 Fault Correction Observe the fault messages displayed in the Control Box display Refer to the Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best descri
184. 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 A or Y arrow key The first option in the selected menu will be displayed Continue to press the A 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 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 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 37 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION OPERATIHG LEVEL 1 PWD SETUP COHFIGURATIOH Y CALIBRATIOH HOT USED IH THIS 0 amp M SEE GF 112 FOR MEHU ITEM DESCRIPTIOHS wv DIAGHOSTICS HOT USED IH THIS 0 amp M SEE GF 112 FOR MEHU ITEM DESCRI
185. iscontinued code used to define gas trains containing two SSOVs and a solenoid operated vent valve ISO Isolated LED Light Emitting Diode LN Low NOx MA mA Milliampere 0 001 Amp one thousandth of an amp MAX Max Maximum MIN Min Minimum Modbus A serial half duplex data transmission protocol developed by AEG Modicon NC N C Normally Closed NO N O Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen O D Outside Diameter PMC 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 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 9 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers FORWARD Phrases Abbreviations and Acronyms Cont Phrase Abbreviation or Acronym Meaning SSOV Safety Shut Off Valve TEMP Temp
186. it 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 e Sides 24 inches e Front 24 inches e Rear 24 inches e Top 18 inches All gas piping water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels or inhibit service or maintenance of the unit NOTE Ensure that condensate assembly is not located over the housekeeping pad Figure 2 1a Benchmark Boiler Model 2500 Clearances Page 16 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION N WARNING N KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS CAUTION N 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 2 4 2 Setting the
187. ited PRG SWTCH CLOSED DURING IGNITION The Purge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE REMOTE SETPT SIGNAL FAULT The Purge Position Limit Switch on the Air Fuel Valve opened during purge The Remote Setpoint signal is not present or is out of range 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 GF 137 SSOV FAULT i MET DURING IGN The SSOV switch closed or failed to open during ignition SSOV FAULT The SSOV switch closed for more than 15 seconds during DURING RUN run SSOV RELAY A failure has been detected in one of the relays that control FAILURE the SSOV STEPPER MOTOR The Stepper Motor failed to move the Air Fuel Valve to the FAILURE desired position OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 141 of 204 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES This Page Is Intentionally Blank Page 142 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Tempera
188. kage 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 104 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS PRESSURE Incorrect supply gas pressure Defective SSOV Actuator Defective High Gas Pressure Switch Check to ensure gas pressure at inlet of SSOV does not exceed 14 W C If gas supply pressure downstream of SSOV Actuator cannot be lowered to the range of 2 0 0 1 W C for BMK2500 or 2 1 0 2 W C for BMK3000 using the gas pressure adjustment screw see section 4 3 1 or 4 3 2 step 10 the SSOV Actuator may be defective Remove the leads from the high gas pressure switch Measure continuity across the common C and normally closed NC terminals with the unit
189. le pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any joint compound into the valve body The relief valve must be piped to within 12 inches of the floor to prevent injury in the event of a discharge are allowed in the discharge line In multiple unit installations the discharge lines must not be manifolded together Each must be individually run to a suitable discharge location OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 19 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION PRESSURE RELIEF VALVE 4 HOT BOILER WATER OUTLET Figure 2 4 P amp T Relief Valve Location 2 7 CONDENSATE DRAIN amp PIPING The Benchmark Boiler is designed to condense water vapor from the flue products Therefore the installation must have provisions for suitable condensate drainage or collection The condensate drain port located on the exhaust manifold Figure 2 5 must be connected to the condensate trap P N 24060 which is packed separately within the unit s shipping container The condensate trap inlet features two integral O rings and a thumbscrew to allow direct connection of the drain port into the trap inlet See the Condensate trap Installation instructions and Figure 2 6 on the next page e AIR INLET EXHAST MANIFOLD PRIMARY WATER INLET 1 4 ANALYZER NPT PORT DRAIN VA
190. lity if such item has been improperly installed operated or maintained as defined in the applicable AERCO O amp M manual or if the buyer 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 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 or 12 months from startup whichever comes first Rev 11 22 2013 OMM 0094 OE AERCO In
191. ll Capacity 1496 Stop Level 200 000 6 7 20 320 000 11 30 690 000 23 40 1 110 000 37 50 1 530 000 51 60 1 820 000 61 70 2 210 000 74 80 2 490 000 83 90 2 780 000 93 100 3 000 000 100 50 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP CHAPTER 4 INITIAL START UP 4 1 INITIAL START UP REQUIREMENTS The requirements for the initial start up of the Benchmark boiler consists of the following Complete installation Chapter 2 Set proper controls and limits Chapter 3 Perform combustion calibration Chapter 4 Test safety devices Chapter 6 All applicable installation procedures in Chapter 2 must be fully completed prior to performing the initial start up of the unit The initial start up must be successfully completed prior to putting the unit into service Starting a unit without the proper piping venting or electrical systems can be dangerous and may void the product warranty The following start up instructions should be followed precisely in order to operate the unit safely and at a high thermal efficiency with low flue gas emissions Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this Chapter it will be necessary to perform the Safety Device Testing procedures specifi
192. ll increment the selected setting 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 Permits a setting to be changed edited When the CHANGE key is pressed the displayed menu item will begin to flash Y DOWN Arrow CHANGE Pressing the 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 This switch toggles the boiler between the Automatic and Manual modes of operation When in the Manual MAN mode the front panel controls are enabled and the MANUAL status LED lights 11 AUTO MAN Switch 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 20 segment red LED bargraph continuously shows the Air Fuel 12 VALVE POSITION Valve position in 5 increments from 0 to 100 Bargraph Page 36 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION 3 3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up and configure the unit T
193. lockwise to unlock it see Figure 6 7 Remove one of the two wires 171 or 172 from the Purge Switch Figure 6 7 Initiate a unit start sequence 5 The unit should begin its start sequence then shut down and display PRG SWITCH OPEN DURING PURGE Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 83 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch and the Purge Switch is located on the Air Fuel Valve To check the switch proceed as follows Ignition Switch Open During Ignition 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 7 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 8 Initiate a unit start sequence 6 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 BLOWER PROOF SWITCH AIR FUEL VALVE COVER Rotate Counter Clock Wise to Remove AIR FUEL VALVE BLOCKED INLET SWITCH F
194. mer to produce a spark with no gas flowing to clean the spark element of moisture or carbon buildup For the duration of this cycle the C More will display the CLEANING IGNITER message c Following the Spark Element Cleaning Cycle power is applied to the Gas Safety Shut off Valve SSOV and the C More displays the PRE IGNITION message When the SSOV indicates the Gas Valve is OPEN the C More displays the IGNITION TRIAL message d If no spark is present 3 seconds into the IGNITION TRIAL the C More will abort the Ignition Cycle and shut down the boiler Refer to Chapter 8 Troubleshooting for guidance if this occurs TO BLOWER A STEPPER IGNITION VALVE POSITION DIAL AT 25 to 35 Figure 3 6 Air Fuel Valve In Ignition Position 6 Up to 4 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 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 cl
195. n 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 Menu Option Setting Boiler Mode Constant Setpoint Internal Setpt Select desired setpoint using A and Y arrow keys 40 F to 240 F Refer to section 3 3 for detailed instructions on changing menu options Page 64 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION 5 4 REMOTE SETPOINT MODES The unit s setpoint can be remotely controlled by an Energy Management System EMS or Building Automation System BAS The Remote Setpoint can be dri
196. n section 4 5 1 DIGITAL OVER TEMPERATURE ALARM SWITCH ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH MANUAL TEMPERATURE LIMIT SWITCH Figure 4 5 Over Temperature Limit Switch Locations 4 5 1 Digital Alarm Switch Checks and Adjustments The digital alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4 6 and Table 4 1 Alarm SE ILI I d LI 7 Limit Control Figure 4 6 Digital Over Temperature Alarm Switch Front Panel OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 61 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP Table 4 1 Digital Alarm Switch Controls and Display bt MEANING FUNCTION LED Display TEMP status E current water temperature or RST RESET Button Resets the unit after an alarm condition ZX UP Button Increases the displayed temperature V DOWN Button Decreases the displayed temperature SET SET Button peg to access and store parameters in the Perform the following steps to check or adjust the digital alarm switch settings Digital Alarm Settings Set the ON OFF to the ON position Press the SET button on the Digital Alarm Switch SP will appear in the display Press the SET button again The curren
197. nance or restrict access between the unit and walls or another unit Benchmark 2500 MBH and 3000 MBH units contain a 2 inch NPT gas inlet connection on the top of the unit 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 for Natural Gas are as follows e The maximum static pressure to the unit must not exceed 14 W C e The gas supply piping and pressure to the unit must be of sufficient capacity to provide 3000 cfh while maintaining the gas pressure at 7 inches W C for FM gas trains operating at maximum capacity 2 8 2 Manual Gas Shutoff Valve A manual shut off valve must be installed in the gas supply line upstream of the boiler
198. nd warm up period 2 10 4 SPARK SIGNAL FLW amp FLW The two SPARK SIGNAL terminals permit an external current sensor to be connected for ignition spark monitoring purposes If no spark is present during the ignition sequence the controller will shut down and display a fault message 2 10 5 Analog In amp The two ANALOG IN terminals are used when an external signal is used to change the setpoint Remote Setpoint Mode of the boiler Either a 4 to 20 mA 1 to 5 VDC or a 0 to 20 mA 0 to 5 VDC signal may be used to vary the set point or air fuel valve position The factory default setting is for 4 to 20 mA 1 to 5 VDC however this may be changed to 0 to 20 mA 0 to 5 VDC using the Configuration Menu described in Chapter 3 If voltage rather than current is selected as the drive signal a DIP switch must be set on the PMC Board located inside the C More Control Box Contact the AERCO factory for information on setting DIP switches All supplied signals must be floating ungrounded signals Connections between the source and the boiler s I O PCB Figure 2 12 must be made using twisted shielded pair of 18 22 AWG wire such as Belden 9841 Polarity must be maintained and the shield must be connected only at the source end and must be left floating not connected at the Boiler s I O PCB Whether using voltage or current for the drive signal they are linearly mapped to a 40 F to 240 F setpoint or a 096 to 100 air fuel valve po
199. nds 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 4096 to 10096 Default is 6096 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 137 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU 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 greater than the proportional band setting the fire rate will be 10096 Integral Gain Derivative Time 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 This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output WARMUP The feature embodied in the next three menu items eliminates Temperature Overshoots during the Warmup period of a cold ignition cycle on all boilers by temporarily modifying the PID Gain parameter during warm
200. nit should restart and fire Page 78 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING IGNITER INJECTOR GAS INLET ASSEMBLY BLOWER PLENUM BLOWER VALVE HEAT PLENUM EXCHANGER BLOWER PROOF SWITCH MANUAL SHUT OFF AIR FUEL YALVE VALVE SSOV BLOCKED INLET SWITCH AIR FILTER Figure 6 4 Bare Boiler Partial View BMK 2500 Shown NOTE The BMK 2500 bare boiler image in Figure 6 4 may be used to refer to the BMK 3000 model as well Both units are virtually identical except for the position of the High Gas Pressure Switch on the gas train and the burner size OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 79 of 204 03 20 2014 GF 137 Ph 800 526 0288 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING 6 8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6 4 6 8 1 Blower Proof Switch Test Blower Proof Switch Test Disable the blower output drive voltage as follows a Press the MENU key until CONFIGURATION MENU is displayed b Press the A arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the Y arrow key until OFF is displayed then press the ENTER key 2 Start the unit in the Manual M
201. nition Stepper IGST board OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 105 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION IGN SWTCH CLOSED DURING PURGE 1 PROBABLE CAUSES Air Fuel Valve not rotating 2 Defective or shorted switch 3 Switch wired incorrectly Defective Power Supply Board or fuse Defective IGST Board CORRECTIVE ACTION 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 personnel 2 If the Air Fuel Valve does rotate to purge check the ignition switch for continuity between the N O and COM terminals If the switch shows continuity when not in contact with the cam replace the switch Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 amp DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board Check Heartbeat LED DS1 and verify it is blinking ON amp OFF every second If not replace IGST Board Co
202. nt 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 the boiler will fire at the 29 Valve Position level or below for a period of one minute When this entry is set to zero the unit will turn on again as soon as the Valve Position in reaches the Start Level value There will not be a one minute delay when firing at the 29 Valve Position level Setting range is 0 to 25 Default is 10 Page 136 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU I
203. o Limit to 210 F Default is 140 F Temp Hi Limit This is the maximum allowable outlet temperature 40 to 210 F Any temperature above this setting will turn off the unit The temperature must then drop 5 below this setting to allow the unit to run Default Hi Limit is 160 F Max Valve Position Sets the maximum allowable valve position for the unit 40 to 100 Default is 100 Pump Delay Timer Specifies the amount of time 0 to 30 min to keep the pump running after the unit turns off Default is zero OMM 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 135 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS APPENDIX A BOILER MENU ITEM DESCRIPTIONS Continued MENU LEVEL amp OPTION DESCRIPTION CONFIGURATION MENU Cont Aux Start On Dly Specifies the amount of time to wait 0 to 120 sec between activating the Aux Relay due to a demand and checking the pre purge string to start the boiler Default is 0 sec Failsafe Mode Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown Default is Shutdown Analog Output Must be set to Valve Pos 0 10V for BMK 2500 amp 3000 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 Setpoi
204. observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded GND 12VDC Power Supply Temp Sensor PN 24410 Modbus Transmitter Box Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Goto 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 Gotothe 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 Goto the Header Temp Addr item and enter the Modbus Address 240 Goto the Header Temp Point item and enter the Modbus Point 14 O 000 When ALL C More units have been configured 10 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 131 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY This Page Is Intentionally Blank Page 132 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OM
205. ode at a valve position between 2596 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 and 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 CONFIGUR ATION MENU is displayed b Press the A arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the A arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key d Press the CLEAR button to clear the airflow fault Once the unit has proved flame turn off the blower again by going to the Configuration Menu Analog Output menu item and select OFF The Blower Proof Switch will open and the blower should stop The unit should shut down and display AIRFLOW FAULT DURING RUN Goto the Configuration Menu Analog Output item and select VALVE POSITION 0 10v 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 5 below For units that have
206. of energy approximately equal to the heat required to raise 1 pound of water 1 F CCP Combustion Control Panel C More Controller or Control Box A control system developed by AERCO and currently used in all Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide COMM Comm Communication Cal Calibration CNTL Control DBB Double Block and Bleed Used to define boiler gas trains containing 2 Safety Shutoff Valves SSOVs and a solenoid operated vent valve Also known as IRI gas trains see below DIP Dual In Line Package EMS Energy Management System often used interchangeably with BAS FM Factory Mutual Used to define boiler gas trains GND Ground HDR Header HX Heat Exchanger Hz Hertz Cycles Per Second I D Inside Diameter IGN Ignition Page 8 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers FORWARD Phrases Abbreviations and Acronyms Cont Phrase Abbreviation or Acronym Meaning IGST Board Ignition Stepper Board contained in C More Control Box INTLK INTL K Interlock Input Output I O Box Input Output I O Box currently used on Benchmark Innovation and KC1000 Series products IP Internet Protocol IRI Industrial Risk Insurers A now d
207. oilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION FLAME LOSS DURING IGN continued PROBABLE CAUSES 6 Carbon or other debris on Burner 7 Staged ignition solenoid valve doesn t open 8 Clogged staged ignition piece CORRECTIVE ACTION 6 Remove View Port and inspect Burner with Boroscope If it is fouled or black with soot remove the Burner 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 staged ignition piece 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 FLAME LOSS that the gas 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 Debris on burner 4 Remove the burner and inspect for any carbon build up or debris Clean and reinstall 5 Blocked condensate drain 5 Remove bloc
208. ompts the operator to wait WARMUP um XX sec Displayed for 2 minutes during the initial warm up only OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 139 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 2 Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge or air inlet is blocked AIRFLOW FAULT The Blower Proof Switch opened during ignition DURING IGN AIRFLOW FAULT The Blower Proof Switch opened during run DURING RUN DELAYED The Delayed Interlock is open INTERLOCK OPEN DIRECT DRIVE The direct drive signal is not present or is out of range SIGNAL FAULT 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 The Flame signal was lost during run DURING RUN HEAT DEMAND The Heat Demand Relays on the Ignition board failed to FAILURE activate when commanded HIGH EXHAUST The Exhaust Temperature has exceeded 200 F TEMPERATURE HIGH GAS The High Gas Pressure Limit Switch is open PRESSURE HIGH WATER The temperature measured by the Outlet Sensor exceeded TEMPERATURE the Temp Hi Limit setting HIGH WATER TEMP The High W
209. oose temperature to AUX connection in I O Box 1 2 3 4 5 T Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices Inspect the inlet to the combustion blower including the air filter at the air fuel valve for signs of blockage Remove the Blower Proof switch and inspect for signs of blockage clean or replace as necessary Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary Check the continuity of the Blower Proof switch with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch Turn off unit and check the continuity of the Blocked Inlet switch If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch Check the actual inlet air temperature and measure voltage at AUX input in the I O Box Verify that the voltage conforms to the values shown in the tabular listing provided in Appendix C 8 Defective temperature sensor 8 Refer to CORRECTIVE ACTION 7 and verify that the voltage conforms to the values shown in Appendix C 9 Loose wire connection between the 0 9 Check wire connection from I O Box 0 10V signal to the 10V signal from I O box to the Blower Blower Motor input 10 Measure voltage at the I O box 0 10V output A voltage of 10
210. osed Standby will be displayed OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 49 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION 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 BMK 2500 BMK 3000 Start Level 24 20 Stop Level 16 14 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 2500 MBH boiler running on natural gas Table 3 8a BMK 2500 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas Air Fuel Valve Energy Input Boiler Energy Input Position Open BTU Hr 9o of Full Capacity 1496 Stop Level 200 000 6 7 20 320 000 11 30 690 000 23 40 1 110 000 37 50 1 530 000 51 60 1 820 000 61 70 2 210 000 74 80 2 490 000 83 90 2 780 000 93 100 3 000 000 100 Table 3 8b BMK 3000 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas Air Fuel Valve Energy Input Boiler Energy Input Position Open BTU Hr 9o of Fu
211. osed position for the unit to fire 2 10 12 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 Delayed Interlock In OUT amp IN The Delayed Interlock terminals can be used in one of two ways e 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 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 29 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 300
212. peration 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 upper left portion on the front of the unit as shown in Figure 2 11 The I O board terminal strip connections are shown in Figure 2 12 All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided on the sides of the I O board Refer to the wiring diagram provided below the I O Box Figure 2 12 when making all wiring connections TERMINAL STRIPS JODO OOOSO OOODOOOGOOODOOOOS Figure 2 11 Input Output 1 0 Box Location NOTE Use Figure 2 12 to determine the functions of the I O PCB connections Do not use the silkscreened labels on the PCB itself as these may not match the function names There is a diagram of the connection functions on the cover of the I O Box as well Z CAUTION DO NOT make any connections to the I O Box terminals labeled NOT USED Attempting to do so may cause equipment damage Page 26 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION
213. position Place the unit in Manual Mode and set the valve position between 25 and 30 Refer to Figure 6 1a or 6 1b and locate the SSOV Remove the cover from the SSOV by loosening the screw shown in Figure 6 6 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 Setthe ON OFF switch to the ON position to start the unit Remove the wire again when the unit reaches the purge cycle and PURGING is displayed 10 The unit should shut down and display SSOV FAULT DURING PURGE 11 Replace the wire on the SSOV and press the CLEAR button The unit should restart Page 82 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING SSOV ACTUATOR ACTUATOR COVER COVER SCREW l gt Figure 6 6 SSOV Actuator Cover Location 6 10 PURGE SWITCH OPEN DURING PURGE The Purge Switch and Ignition Switch is located on the Air Fuel Valve To check the switch proceed as follows Purge Switch Open During Purge Set the 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 by rotating the cover counterc
214. 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 102 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE TABLE 8 1 BOILER TROUBLESHOOTING Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Delayed Interlock Jumper not properly installed or missing Check to insure jumper is properly installed across the delayed interlock terminals the I O Box DELAYED 2 Device proving switch hooked to 2 If there are 2 external wires on these terminals check to see if INTERLOCK OPEN interlocks is not closed an end switch for a proving device such as a pump louver etc is tied these interlocks Ensure that the device and or its end switch is functional A jumper may be temporarily installed to test the interlock 1 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 wiring Signal is not isolated floating Control Box signal type sel
215. r 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 3 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 1a or 4 1b depending on the model being calibrated Install a NPT to barbed fitting into the tapped plug port Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 53 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP 4 2 3 Accessing the Analyzer Probe Port The unit contains a 1 4 NPT port on the side of the exhaust manifold as shown in Figure 4 2 Prepare the port for the combustion analyzer probe as follows Accessing the Analyzer Probe Port 1 Refer to Figure 4 2 and remove the 1 4 NPT plug from the exhaust manifold 2 If necessary adjust the stop on the combustion analyzer probe so it will extend mid way into the flue gas flow DO NOT install the probe at this time AIR INLET PRIMARY HOT WATER INLET DRAIN VALVE EXHAST MANIFOLD ANALYZER PORT CONDENSATE DRAIN Figure 4 2 Analyzer Probe Port Location Right Side Partial View 4 3 NATURA
216. r Temp Point item and enter the Modbus Point 15 OND oO W When ALL C More units have been configured 13 Go to the BST Menu of the desired Master unit and set the BST Mode item to BST MASTER Page 126 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive NOTE Both Header Sensor AND 4 20ma Direct Drive must be wired See the C More Controller User Manual OMM 0032 GF 112 and ProtoNode User Manual OMM 0080 GF 129 for more information Step 1 Direct Wired Header Sensor Wiring 1 On the MASTER Unit Connect the Header Temperature Sensor AERCO PN 61040 to the Feed Forward FFWD terminals on the P 1 Harness Via the terminal block labeled Header Temp sensor in the I O Box NOTES e The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler 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 6 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
217. rating procedures and menu descriptions provided in this Chapter OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 33 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION o 20 COGO O Figure 3 1 Control Panel Front View NOTE If there is a requirement to use the RS232 port Item 4 on the C More controller front panel contact AERCO to purchase the RS232 Adaptor Cable P N 124675 which is designed for this purpose This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports Page 34 of 204 03 20 2014 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0094 OE GF 137 Benchmark 2500 3000 Boilers CHAPTER 3 OPERATION Table 3 1 Operating Controls Indicators and Displays ITEM CONTROL NO INDICATOR OR FUNCTION E DISPLAY LED Status Indicators Four Status LEDs indicate the current operating status as follows COMM Lights when RS 232 communication is occurring Lights when the valve position fire rate is being controlled using 1 MANUAL the front panel keypad This mode of operation is for service technician use only REMOTE Lights when the unit is being controlled by an external signal from an Energy Man
218. rbon Monoxide CO 5096 6 096 0 5 20 ppm 100 ppm 40 6 3 0 5 lt 20 ppm lt 100 ppm 30 6 3 0 5 lt 20 ppm lt 100 ppm 16 6 0 0 5 lt 20 ppm lt 100 ppm 29 If the oxygen level at the 16 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 5 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the to the specified level Recalibration MUST be performed again from 5096 down to 16 after making a change to the idle screw TAC valve 30 This completes the BMK 2500 Natural Gas combustion calibration procedures BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw ESTE Figure 4 3 Gas Pressure Adjustment Screw Location TAC VALVE IDLE SCREW Figure 4 4 TAC Valve Adjust Idle Screw OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 57 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 4 INITIAL START UP BMK 3000 Natural Gas Combustion Calibration Open the water supply and return valves to the unit and ensure that the system pumps are running Open the natural gas supply valve to the unit Set the control panel ON OFF switch to the OFF position 4 Turn on external ac power to the unit The display will show loss of power and the time and d
219. re Disconnect the external condensate trap by loosening the union pipe connection between the trap and the exhaust manifold drain pipe Remove the connections on the inlet and outlet sides of the condensate trap shown in Figure 7 6 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover Remove the float from the condensate trap Remove the O ring and orifice gaskets from the trap AERCO recommends that these items be replaced annually Thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thoroughly cleaned replace the trap After the above items have been inspected and thoroughly cleaned replace the O ring 84017 and orifice gasket 81092 with new parts Reassemble all piping and hose connections to the condensate trap inlet and outlet Reconnect trap to exhaust manifold drain NOTE There are two slightly different types of condensate traps that may be used in your configuration an older style with a separate inlet adapter and a newer style with a built in adapter Maintenance is the same except that the newer style does not need an orifice gasket Step 5 gasket Step 6 THUMB m SCREWS OVER Thumb Screws e GASKET GUIDE Condensate Trap O Ring f Float Guide Float CONDENSATE 3 4 NPT Port Figure 7 6 External Condensate Trap Cutaway and Exploded Views Page 96 of 204 AERCO International Inc
220. rees to the first two and a fourth opposite the third and then repeat this pattern with the remaining four nuts Repeat the entire pattern a second time to partially tighten all eight nuts and then repeat a third time until all eight nuts are fully torqued to 22 ft Ibs Ensure that the igniter injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange OMM 0094 0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 93 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE Burner Assembly Inspection and Maintenance Procedure Cont 5 16 x 1 3 4 BOLTS 5 16 WASHERS amp gt NYLOCK NUTS 1 4 each BLOWER PLENUM IGNITER d 5975 BLOWER INJECTOR CE A ASSEMBLY s AIF VALVE PLENUM AIR FUEL 3 8 16 VALVE HEX NUTS s fg FILTER 8 each 1 2 NUTS amp BOLTS 4 each GAS TRAIN Figure 7 4a Burner Assembly Mounting Details BMK 2500 Shown NOTE The BMK 2500 bare boiler image in Figure 7 4a and 7 4b may be used to refer to the BMK 3000 as well Both units are virtually identical except for the position of the High Gas Pressure Switch on the gas train and the burner size Page 94 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENAN
221. rt 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 1 01 01 11 50am NOTE The Operation Time T Log can store thousands of records Therefore to view the most recently logged record enter T 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 42 Operation Time Log The Operation Time Log consists of a string of ASCII records stored in non volatile memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate or flame strength must change by more than 5 or the run mode must change At steady state the run length is allowed to reach a maximum of 30 minutes before the record is logged This means that no more than 30 minutes of data can be lost if the unit loses power Table 9 2 shows a sample Operation Time Log for a bo
222. sition No scaling for these signals is provided 2 10 6 B M S PWM In BMS amp BMS These terminals are only used to connect to legacy AERCO Boiler Management Systems BMS which utilize a 12 millisecond ON OFF duty cycle and is Pulse Width Modulated PWM to control valve position A 0 valve position a 5 ON pulse and a 100 valve position a 95 ON pulse Note that these connections cannot be used with the AERCO Control System ACS 2 10 7 Shield SHLD amp SHLD The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit Shields must only be connected to these terminals 2 10 8 Analog Output amp The ANALOG OUT terminals amp output from 0 to 20 mA and may be used to monitor Setpoint Outlet Temperature Valve Position 4 20 mA Valve Position 0 10v or be set to OFF Default setting in the C More controller is Valve Position 0 10v and settings behave as follows 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 Page 28 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION e When th
223. sor 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 xe ST Temp Sensor PN 61040 Header Temp Sensor Box Step 2 Direct Wired Outdoor Sensor 1 On the MASTER Unit Connect the Outdoor Temperature Sensor AERCO PN 123525 to the OUT and terminals in the I O Box NOTES e Twisted shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded e When mounting the Outdoor sensor it must be located on the North side of the building where an average outside air temperature is expected The sensor must be shielded from direct sunlight as well as impingement by the elements The outdoor sensor may be wired up to 200 feet from the boiler Temp Sensor PN 123525 OMM 0094_0E AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 123 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Option 3 Continued Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Goto the BST Menu and set the BST Mode item to BST Slave for now On MASTER only
224. t indicated by the Tip N Tell indicator The freight carrier should be notified immediately if any damage is detected The following accessories come standard with each unit and are either packed separately within the unit s shipping container or are factory installed on the unit e Pressure Temperature Gauge e ASME Pressure Relief Valve e Condensate Drain Trap part no 24060 e 2 Gas Supply Shutoff Valve When optional accessories are ordered they may be packed within the unit s shipping container factory installed on the unit or packed and shipped in a separate container Any standard or optional accessories shipped loose should be identified and stored in a safe place until ready for installation or use OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 15 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark 2500 3000 Boiler includes e Access to AC Input Power at 208 VAC Three Phase 60 Hz 10 Amps OR 460 VAC Three Phase 60 Hz 5 Amps e Access to Natural Gas line at a minimum pressure of 8 inches W C at gas flow for 2 500 000 BTU hr energy input for the BMK 2500 OR 3 000 000 BTU hr energy input for the BMK 3000 2 4 1 Installation Clearances The Benchmark Model 2500 and 3000 are packaged in an enclosure having identical exterior dimensions The un
225. t over temperature limit value stored in memory will be displayed default 210 F If the display does not show the required over temperature alarm setting press the A or V arrow button to change the display to the desired temperature setting Once the desired over temperature alarm setting 210 F is displayed press the SET button to store the setting in memory To calibrate the offset P1 press and hold the SET button for 8 seconds on the Digital Alarm Switch Access code value 0 should appear in the display The switch comes from the factory with the code set at 0 AERCO recommends that you do not change this code Press the SET button again to enter the code The first parameter label SP will appear in the display Using the A and Y arrow keys select parameter P1 Press SET to view the value stored in memory If the desired value is not displayed modify the setting using the A and Y arrow keys The value can be changed from 10 to 10 offset Press SET to enter the value and exit to the text parameter To exit the programming mode press the SET and Y buttons simultaneously or simply wait one minute and the display will automatically exit the programming mode Once the programming mode has been exited the display will show the current outlet water temperature of the boiler Page 62 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchm
226. tal Alarm Switch Checks and Adjustments eterne rna 61 CHAPTER 5 MODE OF OPERATION 63 5 INTROBDUGTIGJ l t b room Rn p RENE 63 5 2 INDOOR OUTDOOR RESET MODE sees nennt 63 D2 AM IRESOE RAT o c LT M M ERE 63 5 2 2 Building kapuni asuaka ayau a 63 5 2 3 Outdoor Air Temperature Sensor Installation 63 532 A Indoor Outdoor Startup ctr ertet dp eee e teen th o eb Ra eee red re atre Eie e e RS 63 5 3 CONSTANT SETPOINT MODE 64 53d Setting eere etre E NH MR eR POUR EROS Qali de sepe aae ede 64 5 4 REMOTE SETPOINT MODES aa T nissan sa sara sa sa sa sa 65 5 4 1 Remote Setpoint Field WirIng uy n rero reet Re tonta Pee 65 5 4 2 Remote Setpoint Startup 66 5 5 DIRECT DRIVE MODES ceci ate utet tede d cet incu obe et edite da 66 5 5 1 Direct Drive Field Wiring ern e eee ee ne nere eae ene 67 5 5 2 DIFECt Drive ROC 67 5 6 AER
227. tant to plan the position of each unit in advance Sufficient space for piping connections and future service maintenance requirements must also be taken into consideration All piping must include ample provisions for expansion If installing a Combination Control Panel CCP system it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location Refer to Chapter 5 for information on Combination Mode Boilers Page 18 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 5 SUPPLY AND RETURN PIPING The Benchmark Boiler utilizes 4 150 flanges for the water system supply and return piping connections The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2 3 2 GAS INLET BOILER HOT WATER OUTLET SUPPLY AIR INLET PRIMARY WATER INLET RETURN EXHAUST MANIFOLD CONDENSATE DRAIN DRAIN VALVE Figure 2 3 Supply and Return Locations 2 6 PRESSURE RELIEF VALVE INSTALLATION An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler The pressure rating for the 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 suitab
228. tasks specified in Table 7 1 the following maintenance kits are available through your local AERCO Sales Representative e 12 Month Maintenance Kit Part No 58025 01 e 24 Month Waterside Fireside Inspection Kit Part No 58025 10 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 10 is required when performing the waterside fireside inspections Refer to Appendix M for recommended spare N WARNING N TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED e DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER e SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF VALVE PROVIDED WITH THE UNIT e ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO PREVENT BURNING OR SCALDING Table 7 1 Maintenance Schedule Labor Time Igniter Injector iut Detector EE RES Sensor EM Combustion H 7 5 Testing of Safety See ASME CSD 1 abs mne Devices Chart 76 Bumer j 7 7 Condensate ne pabi Inspect Clean amp Inspect Clean amp Sine Drain Trap P Replace Gaskets Ec Gaskets Air Filter 88014 Replace 15 mins Only performed after initial 6 month period after initial startup OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 8
229. terior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 13 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 1 SAFETY PRECAUTIONS 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or
230. ternational Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 203 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers Change Log Date Description Changed By Rev D 11 27 2013 03 20 2014 934 5 Revised the regulator requirements 934 2 revised Analog Output amp VFD Blower terminal descriptions 934 2 changed sealed combustion to ducted combustion 934 5 added AERCO RS 232 cable info to C More section 934 8 changed p n 122790 to GM 123525 in section 2 10 1 Misc Updated graphics and format Rev E PIR 780 replaced mechanical latch with magnetic PIR 934 14 Corrected labels of Blower Proof and Blocked Inlet switches in diagrams in chapter 7 PIR 942 Replaced 460 V Power Box label in section 2 9 PIR 934 24 Increased max height of housekeeping pad to 8 inch Chapter 2 PIR 981 Modified formatting of Table A in Appendix F Part List PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Valve Installation addition of section 3 9 BST Menu addition of Chapter 10 Boiler Sequencing Technology replaced all wiring schematics in Appendix J addition of 24V Sequencing Valve PIR 934 33 Modified step 13 in Combustion Calibration regarding defective O Sensor PIR 934 37 Modified Blocked Inlet Switch Test instructions section 6 8 2 PIR 1005 Changed 12 Month Maintenance Kit part number to 58025 01 Curtis Harvey Curtis Harvey amp
231. th using the Control Panel Flame signal strength Weekly Operator Operating Menu See section 3 4 Low water level cut off Weekly Operator See section 6 4 and alarm Perform a slow drain test in accordance with ASME Slow drain test Semi Annually Operator Boiler and Pressure Vessel Code Section IV High water temperature Annually Service Technician See section 6 5 safety control test Operating controls Annually Operator See section 3 2 Low air flow Monthly Operator See section 6 8 High ang OW gas Monthly Operator See sections 6 2 and 6 3 pressure interlocks AFURI Valve purge Annually Service Technician See section 6 10 position switch ae VAWE nition Annually Service Technician See section 6 11 position switch Safety valves As required Operator Check per A S M E Boiler and Pressure Vessel Code Section IV Inspect burner Semi Annually Service Technician See section 7 6 components Semi Condensate Trap Operator See section 7 7 Annually Oxygen O Level Monthly Operator Verify oxygen level is between 3 and 8 during OMM 0094_0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 147 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING boiler operation This page intentionally blank Page 148 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY
232. the equipment or 750 square inches of free area The free area must take into account restrictions such as louvers and bird screens For Canada installations refer to the requirements specified in CSA B149 1 10 sections 8 4 1 and 8 4 3 2 12 2 Combustion Air from Inside the Building When combustion air is provided from within the building it must be supplied through two permanent openings in an interior wall Each opening must have a free area of not less than one square inch per 1000 BTUH of total input or 3000 square inches of free area The free area must take into account any restrictions such as louvers 2 13 DUCTED COMBUSTION AIR For ducted combustion air installations the air ductwork must then be attached directly to the air inlet connection on the sheet metal enclosure In a ducted combustion air application the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run See the AERCO Benchmark Venting and Combustion Air Guide GF 2050 When using the heater in a ducted combustion air configuration each unit must have a minimum 8 inch diameter connection at the unit 2 14 SEQUENCING VALVE INSTALLATION All Benchmark units are shipped with a connection for an optional motorized external sequencing valve p n 92084 TAB included in the shipping container This valve is an integral component of the AERCO s on board Boiler Sequencing Technology BST solution BST allo
233. the valve position to 70 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 7096 5096 4096 30 and 14 as described in the following steps These steps assume that the inlet air temperature is within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O level up to 196 higher than the listed calibration range Record the increased value on the Combustion Calibration sheet Press the MENU key on the front panel of the C MORE and access the Setup menu Enter password 6817 and then press the ENTER key Press the MENU key on the front panel of the C MORE until Combustion Cal Menu appears on the display Press the A arrow key until SET Valve Position appears on the display Press the CHANGE key SET Valve Position will begin to flash Press the A arrow key until the SET Valve Position reads 70 Press the ENTER key Next press the down Y arrow key until CAL Voltage 70 is displayed Press the CHANGE key and observe that CAL Voltage 70 is flashing The oxygen level at the 7096 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the following values Combustion Calibration Readings 2
234. ting of the supply gas regulator GAS PRESSURE REGULATOR NATURAL GAS SUPPLY NATURAL GAS INLET 2 MANUAL SHUT OFF VALVE Figure 2 7 Manual Gas Shut Off Valve Location NOTE It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above However AERCO offers for sale an appropriate regulator which may be ordered at the time of unit purchase or separately Contact AERCO for more information OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 23 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 9 AC ELECTRICAL POWER WIRING The AERCO Benchmark Electrical Power Wiring Guide GF 2060 must be consulted prior to connecting any AC power wiring to the unit External AC power connections are made to the unit inside the Power Box on the front of the unit Remove the front panel to access the Power Box which is mounted in the upper right corner of the unit as shown in Figure 2 8 Loosen the two upper screws of the Power Box cover and remove cover to access the internal connections shown in Figure 2 9 Figure 2 8 Power Box Location with Cover Closed N WARNING THE POWER BREAKER SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS WIRE CONDUITS POWER BREAKER TRANSFORMER 24V POWER SUPPLY
235. to 170 180 in Ibs DO NOT over tighten 11 Connect the staged ignition assembly to the gas injector tube of the igniter injector by securing the compression nut to the elbow of the staged ignition assembly 12 Reconnect the igniter injector cable 13 Reinstall the shroud on the unit 7 3 FLAME DETECTOR The flame detector part no 66020 is located on the burner plate at the top of the unit see Figures 7 1 and 7 2 The flame detector may be hot Allow the unit to cool sufficiently before removing the flame detector Inspect or replace the flame detector as follows Flame Detector Maintenance Set the control panel ON OFF switch to the OFF position 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 gt gt gt Page 90 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 7 MAINTENANCE Flame Detector Maintenance Cont Disconnect the flame detector lead wire Remove the two 2 screws securing the flame detector to the plate Figure 7 2 The flame detector is secured to the burner plate with one 10 32 screw and one 88 32 screw Remove the flame detector and gasket from the burner plate 6 Thoroughly inspect the flame detector If eroded the detector should
236. ture 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 34 130 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 0094 0E GF 137 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 Page 143 of 204 03 20 2014 Benchmark 2500 3000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART This Page Is Intentionally Blank Page 144 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 250 0 3000 Boilers APPENDIX D BOILER DEFAULT SETTINGS APPENDIX D BOILER DEFAULT SETTINGS Appendix D Boiler Default Settings MENU amp OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type BMK Boiler LN Unit Size 2500 MBH or 3000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode
237. turn off unit and check the Blocked Inlet switch for continuity Replace the switch if continuity does not exist Remove the air filter and Blocked Inlet switch and inspect for signs of blockage Clean or replace as necessary Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN Blower stopped running due to thermal or current overload Blocked Blower inlet or inlet ductwork Blockage in air filter or Blocked Inlet switch Defective Blocked Inlet switch Combustion oscillations Probable causes from 3 to 16 for AIRFLOW FAULT DURING IGNITION applies for this fault Check combustion blower for signs of 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 switch and ground If 24 VAC is not
238. 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 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 2 0 0 2 W C If gas pressure adjustment is required remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make gas pressure adjustments using a flat tip screwdriver to obtain a gas pressure within the range of 2 0 W C 0 2 W C Using the A arrow key increase the valve open position to 10096 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2 0 0 1 W C Readjust the gas pressure if necessary With the valve position at 10096 insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer reading to stabilize 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
239. up 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 138 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES APPENDIX B STARTUP STATUS amp DISPLAY MESSAGES Table B 1 Startup And Status Messages MESSAGE DESCRIPTION DEMNE DELAT Displayed if Demand Delay is active XX sec DISABLED Displayed if ON OFF switch is set to OFF The display also HH MM pm pm shows the time am or pm and date that the unit was MM DD YY disabled Displayed after flame has been detected for a period of 2 FLAME PROVEN seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL Displayed during ignition trial of startup sequence The XX sec duration of cycle counts up in seconds PURGING Displayed during the purge cycle during startup The XX sec duration of the purge cycle counts up in seconds Displayed when ON OFF switch is in the ON position but STANDBY there is no demand for heat The time and date are also displayed WAIT Pr
240. ven by a current or voltage signal within the following ranges e 4 20 mA 1 5 0 20 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 to 5 signal is used 0 mA is equal to a 40 F setpoint In addition to the current and voltage signals described above the Remote Setpoint mode can also driven by a RS 485 Modbus Network signal from an EMS or BAS The Remote Setpoint modes of operation can be used to drive single as well as multiple units NOTE If a voltage rather than current signal is used to control the remote setpoint a DIP switch adjustment must be made on the PMC Board located in the Control Panel Assembly Contact your local AERCO representative for details In order to enable the Remote Setpoint Mode the following menu setting must be made in the Configuration Menu Menu Option Setting Boiler Mode Remote Setpoint Remote Signal 4 20mA 1 5V 0 20mA 0 5V or Network Refer to section 3 3 for detailed instructions on changing menu options If the Network setting is selected for RS 485 Modbus operation a valid Comm Address must be entered in the Setup Menu Refer to Modbus Communication Manual GF 114 for additional information
241. w mapeacard com www gloversheetmetal com Page 30 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0094 OE 03 20 2014 Ph 800 526 0288 GF 137 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 2 12 COMBUSTION AIR The AERCO Benchmark Boiler Venting and Combustion Air Guide GF 2050 MUST be consulted before any flue or inlet air venting is designed or installed Air supply is a direct requirement of ANSI 223 1 NFPA 54 CSA B149 1 and local codes These codes should be consulted before a permanent design is determined The combustion air must be free of chlorine halogenated hydrocarbons or other chemicals that can become hazardous when used in gas fired equipment Common sources of these compounds are swimming pools degreasing compounds plastic processing and refrigerants Whenever the environment contains these types of chemicals combustion air MUST be supplied from a clean area outdoors for the protection and longevity of the equipment and warranty validation The more common methods of combustion air supply are outlined in the following sections For combustion air supply from ducting consult the AERCO GF 2050 Gas Fired Venting and Combustion Air Guide 2 12 1 Combustion From Outside the Building Air supplied from outside the building must be provided through two permanent openings For each unit these two openings must have a free area of not less than one square inch for each 4000 BTUs input of
242. ws 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 The implementation of BST and the installation and use of this valve is optional The boiler IS pre wired to accept the sequencing valve Installation consists of installing the sequencing valve in the hot water outlet pipe and then connecting it into the shell harness as described below OMM 0094 OE AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 31 of 204 GF 137 Ph 800 526 0288 03 20 2014 Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION 1 Install the sequencing valve in the boiler s hot water outlet pipe SEQUENCING VALVE HOT WATER OUTLET ah Figure 2 13 Sequencing Valve Installed 2 The boilers shell harness has one unused cable One end of this cable is connected to the DELAYED INTERLOCK IN terminals in the I O board see Figure 2 14 while the other end contains a Molex connector with a jumper wire inserted in it this jumper wire allows units that do not have a sequencing valve to operate normally Find the free end of this cable inside the unit s enclosure E Figure 2 14 Sequencing Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing valve s connector Page 32 of 204 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 1091

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