Aerco Benchmark 1.5LN Page 39 Installation, Operation And Maintenance Manual Download

Page: 39 / 163

CHAPTER 3

OPERATION

PR1: 10/18//12 AERCO International Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

•

Ph: 800-526-0288

Page 39 of 166

GF-120

OMM-0041 0E

Benchmark 1.5LN Low NOx Boiler

Installation, Operation and Maintenance Manual

Table 3-4. Configuration Menu

Available Choices or Limits

Menu Item Display

Minimum

Maximum

Default

Internal Setpt

Lo Temp

Limit

Hi Temp Limit 130°F

Unit Type

KC Boiler, KC Boiler LN,

BMK Boiler Std, BMK Boiler

LN, BMK Boiler Dual, KC

Water Heater, KC Water

Heater LN, Innovation WH

BMK Boiler

Unit Size

(See

NOTE

at end

of Table 3-4)

750 MBH, 1000 MBH, 1500

MBH, 2000 MBTU, 3000

MBH, 6000 MBH

1500 MBH

(1.5 MBTU)

Fuel Type

Natural Gas, Propane

Natural Gas

Boiler Mode

Constant Setpoint,

Remote Setpoint,

Direct Drive

Combination

Outdoor Reset

Constant

Setpoint

Remote Signal

(If Mode = Remote

Setpoint, Direct

Drive or

Combination)

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (BMS)

Network

4 – 20 mA,

1-5V

Bldg Ref Temp

(If Mode = Outdoor

Reset)

40°F

230°F

70°F

Reset Ratio

(If Mode = Outdoor

Reset)

0.1

9.9

1.2

Outdoor Sensor

Enabled or Disabled

Disabled

System Start Tmp

(If Outdoor Sensor

= Enabled)

30°F

100°F

60°F

Setpt Lo Limit

40°F

Setpt Hi Limit

60°F

Setpt Hi Limit

Setpt Lo Limit

195°F

Temp Hi Limit

40°F

210°F

195°F

Max Valve Position

40%

100%

Pump Delay Timer

0 min.

30 min.

0 min.

Pump Delay Timer

0 min.

30 min.

0 min.

Aux Start On Dly

0 sec.

120 sec.

0 sec.

Summary of Contents for Benchmark 1.5LN

Page 1: ...oiler Installation Operation and Maintenance Manual OMM 0041_0E GF 120 USER MANUAL Modulating Condensing Forced Draft Hot Water Boiler 1 500 000 BTU H Input Applicable for Serial Numbers G 12 1953 and above Revised 10 18 2012 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Benchmark 1 5LN Low NOx Boiler ...

Page 2: ...out 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 m...

Page 3: ...IPING 18 2 7 1 Gas Supply Specifications 19 2 7 2 Manual Gas Shutoff Valve 19 2 7 3 External Gas Supply Regulator 19 2 7 4 IRI Gas Train Kit 20 2 8 AC ELECTRICAL POWER WIRING 20 2 8 1 Electrical Power Requirements 21 2 9 MODES OF OPERATION AND FIELD CONTROL WIRING 22 2 9 1 Constant Setpoint Mode 22 2 9 2 Indoor Outdoor Reset Mode 22 2 9 3 Boiler Management System Mode 23 2 9 4 Remote Setpoint and ...

Page 4: ...7 TUNING MENU 40 3 8 COMBUSTION CAL MENU 40 3 9 START SEQUENCE 41 3 10 START STOP LEVELS 45 CHAPTER 4 INITIAL START UP 47 4 1 INITIAL START UP REQUIREMENTS 47 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION 47 4 2 1 Tools Instrumentation 48 4 2 2 Installing Gas Supply Manometer 48 4 1 1Accessing the Vent Probe Port 49 4 3 RSI REGULATOR SAFE TEST 49 4 4 NATURAL GAS COMBUSTION CALIBRATION 5...

Page 5: ...ATER LEVEL FAULT TEST 71 6 5 WATER TEMPERATURE FAULT TEST 71 6 6 INTERLOCK TESTS 73 6 6 1 REMOTE INTERLOCK 73 6 6 2 DELAYED INTERLOCK 73 6 7 FLAME FAULT TESTS 73 6 8 AIR FLOW FAULT TESTS 75 6 9 SSOV PROOF OF CLOSURE SWITCH 76 6 10 PURGE SWITCH OPEN DURING PURGE 76 6 11 IGNITION SWITCH OPEN DURING IGNITION 77 6 12 SAFETY PRESSURE RELIEF VALVE TEST 78 CHAPTER 7 MAINTENANCE 79 7 1 MAINTENANCE SCHEDUL...

Page 6: ...SETUP 107 9 3 MENU PROCESSING UTILIZING RS232 COMMUNICATION 107 9 4 DATA LOGGING 108 9 4 1 Fault Log 108 9 4 2 Operation Time Log 108 9 4 3 Sensor Log 109 APPENDIX A MENU ITEM DESCRIPTIONS 111 APPENDIX B STARTUP STATUS AND FAULT MESSAGES 118 APPENDIX C SENSOR TEMPERATURE RESISTANCE 121 APPENDIX D INDOOR OUTDOOR RESET RATIO CHARTS 122 APPENDIX E BOILER DEFAULT SETTINGS 126 APPENDIX F PART AND DIMEN...

Page 7: ... inputs ranging from 75 000 BTU hr to 1 500 000 BTU hr The output of the boiler is a function of the unit s firing rate and return water temperature Output ranges from 74 250 BTU hr to 1 450 000 BTU hr depending on operating conditions When installed and operated in accordance with this Instruction Manual the Benchmark 1 5 Boiler complies with the NOx emission standards outlined in South Coast Air...

Page 8: ...AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E This page left intentionally blank ...

Page 9: ...lly followed in all cases Authorities having jurisdiction should be consulted before installations are made 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 WARNING MUST BE OBSERVED TO PREVENT SERIOUS INJURY WARNING BEFORE ATTEMPTING TO PER FOR...

Page 10: ...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 IMPORTANT The Installer must identify and indicate the location of the emergency shutdown manual gas valve to ...

Page 11: ...ll observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wal...

Page 12: ... 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...

Page 13: ...Note the information on the carrier s paperwork and request a freight claim and inspection by a claims adjuster before proceeding Any other visual damage to the packaging materials should also be made clear to the delivering carrier 2 3 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials A close inspection of the unit should be mad...

Page 14: ...equirements Minimum acceptable clearances required are Sides 24 inches Front 24 inches Rear 30 inches Top 18 inches All gas piping water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels or inhibit service or maintenance of the unit 24 4 HIGH PAD REAR FRONT 44 5 18 101 79 30 24 24 SEE NOTE IN PARAGRAPH 2 4 2 Figure 2 1 Benchmark 1 ...

Page 15: ...four 4 lag screws securing the unit to the shipping skid Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad required in the desired location NOTE When using the AERCO Condensate Neutralizer Tank for proper condensate drainage the Neutralizer Tank must be stored in a pit OR the boiler and AERCO Condensate Trap must be elevated higher than 4 above t...

Page 16: ... the supply and return piping connections are on the rear of the unit as shown in Figure 2 3 Refer to Appendix F Drawing AP A 832 for additional dimensional data BOILER SUPPLY 3 150 FLANGED CONNECTION BOILER RETURN 3 150 FLANGED CONNECTION 1 1 2 GAS INLET CONNECTION SHELL DRAIN VALVE EXHAUST MANIFOLD REAR VIEW Figure 2 3 Supply and Return Locations 2 6 CONDENSATE DRAIN The Benchmark 1 5 Boiler is ...

Page 17: ...threads are inside built in adapter on newer style Refer to Figure 2 5 and install the trap as follows Install 3 4 NPT nipples in the tapped inlet and outlet of the condensate trap part no 1 24060 Install a third 3 4 NPT nipple in the tapped condensate outlet of the exhaust manifold 2 Connect the exhaust manifold nipple to the condensate trap inlet using a female union 3 install a suitable support...

Page 18: ...s not interfere with removal of any covers inhibit service maintenance or restrict access between the unit and walls or another unit A 1 1 2 inch gas inlet connection is located on the rear 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 unappr...

Page 19: ...al shut off valve must be installed in the gas supply line upstream of the Boiler as shown in Figure 2 6 Maximum allowable gas pressure to the Boiler is 14 W C NOTE Paragraph 2 7 3 applies only to bolier installations within the Commonwealth of Massachusetts 2 7 3 External Gas Supply Regulator For Massachusetts installations a mandatory external gas supply regulator must be positioned as shown in ...

Page 20: ... factory pre piped and wired See Appendix F Drawing AP A 830 for details 2 8 AC ELECTRICAL POWER WIRING The AERCO Benchmark 1 5 Electrical Power Wiring Guide GF 4060 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 panel of the unit Remove the front door of the unit to access the Power Box mou...

Page 21: ...ULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BENCHMARK BOILER A double pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enclosures of the unit After placing the boiler in service the ignition safety shutoff device must be tested If an external electrical power sou...

Page 22: ...ed on the cover of the I O Box Figure 2 10 when making all wiring connections Brief descriptions of each mode of operation and their wiring requirements are provided in the following paragraphs Additional information concerning field wiring is provided in paragraphs 2 9 1 through 2 9 9 Refer to Chapter 5 for detailed information on the available modes of operation Figure 2 9 Input Output I O Box L...

Page 23: ...ons Guide 2 9 4 Remote Setpoint and Direct Drive Modes The Benchmark 1 5 Boiler can accept several types of signal formats from an Energy Management System EMS Building Automation System BAS or other source to control either the setpoint Remote Setpoint Mode or air fuel valve position Direct Drive Mode of the Boiler These formats are 4 to 20 mA 1 to 5 VDC 0 to 20 mA 0 to 5 VDC PWM Pulse Width Modu...

Page 24: ...damage 2 10 1 OUTDOOR SENSOR IN 1 An outdoor air temperature sensor AERCO Part No 122790 will be 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 sen...

Page 25: ...OG IN and terminals are used when an external signal is used to drive the air fuel valve position Direct Drive Mode or 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 setpoint or 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 ...

Page 26: ...output to control the rotational speed of the blower This function is enabled in the Configuration Menu Chapter 3 Table 3 4 2 10 10 EXHAUST SWITCH IN 11 These terminals permit an external exhaust switch to be connected to the exhaust manifold of the boiler The exhaust switch should be a normally open type switch such as AERCO Part No 123463 that closes trips at 500 F 2 10 11 INTERLOCKS 10 12 The u...

Page 27: ... 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 Boiler status indictor firing or not firing Its contacts are rated for 120 VAC 5 amps Refer to Figure 2 10 to locate the AUX RELAY terminals for wiring connections 2 11 FLUE GAS VENT INSTALLATION The mini...

Page 28: ...square inch for each 4000 BTU H boiler input 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 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 Eac...

Page 29: ...pump relay allows the user to turn a pump on off and open close a motorized valve as the boiler cycles on and off on demand The Pump Delay Timer feature allows the user to keep the pump running and keep the motorized valve open for up to 30 minutes after the boiler has shut down and the demand is satisfied The Benchmark pump relay SPDT contact is rated for 10 A Resistive 277 VAC 28 VDC 1 3 HP N O ...

Page 30: ...auvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E Figure 2 11b Schematic System Pump Start using a Separate Contact Relay Figure 2 12 Identifying the Presence of BMK Pump Relay Option 69102 ...

Page 31: ...at all times NOTE All of the installation procedures in Chapter 2 must be completed before attempting to start the unit ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460 208 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS WARNING DO NOT ATTEMPT TO DRY FIRE THE BOILER STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJU...

Page 32: ...national Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E 1 2 3 4 5 6 7 8 9 10 11 12 VALVE POSITION Figure 3 1 Control Panel Front View ...

Page 33: ...and Mode 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection 4 RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel 5 FAULT Indicator Red FAULT LED indicator lights wh...

Page 34: ... category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be c...

Page 35: ...ating 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 The Control Panel will normally be in the Operating Menu and the VFD will display the 1 current unit status Pressing the or arrow key will display the other available data i...

Page 36: ...s of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages 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 d...

Page 37: ...245 F Outdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Flame Strength 0 100 Run Cycles 0 999 999 999 Run Hours 0 999 999 999 Fault Log 0 19 0 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 ...

Page 38: ... 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 Available Choic...

Page 39: ... 2000 MBTU 3000 MBH 6000 MBH 1500 MBH 1 5 MBTU Fuel Type Natural Gas Propane Natural Gas Boiler Mode Constant Setpoint Remote Setpoint Direct Drive Combination Outdoor Reset Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V 0 20 mA 0 5V PWM Input BMS Network 4 20 mA 1 5V Bldg Ref Temp If Mode Outdoor Reset 40 F 230 F 70 F Reset Ratio If Mode Outdoor R...

Page 40: ...bled or Disabled Disabled Spark Current Display NOTE Only the Unit Sizes applicable to the selected Unit Type will be displayed CAUTION 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 T...

Page 41: ...lts Yes No Are You Sure No Table 3 6 Combustion Cal Menu Available Choices or Limits Menu Item Display Minimum Maximum Default CAL Voltage 16 25 8 20 1 80v CAL Voltage 30 25 8 20 3 20v CAL Voltage 45 25 8 20 3 70v CAL Voltage 60 25 8 20 3 80 CAL Voltage 80 25 8 20 4 60 CAL Voltage 100 25 8 20 6 00 SET Valve Position 0 100 0 Blower Output Monitor Blower Output Voltage 00 3 9 START SEQUENCE When the...

Page 42: ...e displayed throughout the start sequence if the required conditions are not observed The DEMAND LED status indicator will light 1 The unit checks to ensure that the Proof of Closure POC switch in the downstream 2 Safety Shut Off Valve SSOV is closed See Figure 3 3 for SSOV location With all required safety device switches closed a purge cycle will be initiated and the 3 following events will occu...

Page 43: ...pletion of the purge cycle the Control Box initiates an ignition cycle and the 5 following events occur a The Air Fuel Valve rotates to the low fire ignition position and closes the ignition switch The dial on the Air Fuel Valve Figure 3 6 will read between 25 and 35 to indicate that the valve is in the low fire position b The igniter relay is activated and provides ignition spark c The gas Safety...

Page 44: ...ration and Maintenance Manual GF 120 OMM 0041 0E AIR FUEL VALVE OUTLET TO BLOWER BLOWER PROOF SWITCH Figure 3 5 Blower Proof Switch 2 5 TO BLOWER AIR IN DIAL DETAIL A STEPPER MOTOR DETAIL A Figure 3 6 Air Fuel Valve In Ignition Position Up to 7 seconds will be allowed for ignition to be detected The igniter relay will be 6 turned off one second after flame is detected ...

Page 45: ...be deactivated and the Air Fuel Valve will be closed Standby will be displayed 3 10 START STOP LEVELS The start and stop levels are the Air Fuel Valve positions open that start and stop the unit based on load These levels are Factory preset as follows Start Level 20 Stop Level 16 Normally these settings should not require adjustment Note that the energy input of the boiler is not linearly related ...

Page 46: ... 46 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E This Page Is Intentionally Blank ...

Page 47: ...iciency with low flue gas emissions Initial unit start up is to 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 Mode of Operation settings in Chapter 5 and the Safety Device Testing procedures in Chapter 6 to complete all initial start up requirements AERCO Gas Fired Startup Sheet...

Page 48: ...ge flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to calibrate the gas pressure to be monitored on the downstream side of the SSOV during the Combustion Calibration procedures described in paragraph 4 4 The gas supply manometer is installed at the downstream location on the 1 4 NPT port shown in Figure 4 1 Note that...

Page 49: ...hown in Figure 4 1 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 6 W C manometer 4 1 1 Accessing the Vent Probe Port The unit contains a NPT plug on the exhaust manifold at the rear of the unit as shown in Figure 4 2 Prepare the port for the combustion analyzer probe as follows Remove the plug from...

Page 50: ...e boiler in MANUAL Mode 8 Look into the observation port in the top head see Figure 4 3 and ensure that you 9 observe the orange glow of the RSI flame during the ignition trial period Conduct at least three safe RSI ignitions while looking into the observation port in the top 10 head Assure the igniter lights immediately with a strong orange flame after the Staged Ignition Solenoid Valve opens and...

Page 51: ... s to the unit 2 Set the control panel ON OFF switch to the OFF position 3 Turn on external AC power to the unit The display will show LOSS OF POWER and the 4 time and date Set the unit to the Manual Mode by pressing the AUTO MAN key A flashing Manual 5 Valve Position message will be displayed with the present rate in Also the MANUAL LED will light Adjust the air fuel valve position to 0 by pressi...

Page 52: ...en range for the inlet air temperature 13 shown in Table 4 1 Also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown Table 4 1 Combustion Oxygen Levels for a 100 Air Fuel Valve Position Inlet Air Temp Oxygen 0 2 Carbon Monoxid e NOx 100 F 4 8 100 ppm 30 ppm 90 F 5 0 100 ppm 30 ppm 80 F 5 2 100 ppm 30 ppm 70 F 5 3 100 ppm 30 ppm If necessary adjust the...

Page 53: ...key and observe that CAL Voltage 80 is flashing 22 The oxygen level at the 80 valve position should be as shown below Also ensure that 23 the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown Table 4 2 Combustion Oxygen Levels for a 80 Air Fuel Valve Position Oxygen 0 2 Carbon Monoxide NOx 6 0 100 ppm 30 ppm If the oxygen level is not within the specified range adju...

Page 54: ...splay 34 Press the CHANGE key SET Valve Position will begin to flash 35 Press the arrow key until the SET Valve Position reads 45 then press the ENTER 36 key Press the arrow key until CAL Voltage 45 is displayed 37 Press the CHANGE key CAL Voltage 45 will begin to flash 38 The oxygen level at the 45 valve position should be as shown below Also ensure that 39 the carbon monoxide CO and nitrogen oxi...

Page 55: ...osition Press the arrow key until SET Valve Position appears on the C MORE display 50 Press the CHANGE key SET Valve Position will begin to flash 51 Press the arrow key until the SET Valve Position reads 16 then press the ENTER 52 key Press the arrow key until CAL Voltage 16 is displayed 53 Press the CHANGE key CAL Voltage 16 will begin to flash 54 The oxygen level at the 16 valve position should ...

Page 56: ... adjustable switch and a digital alarm switch These switches are mounted on a plate as shown in Figure 4 6 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 man...

Page 57: ... 0E Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual Figure 4 6 Over Temperature Limit Switch Locations 4 6 1 Digital Alarm Switch Checks and Adjustments FRONT VIEW ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH SEE DETAIL A DETAIL A F Alarm DIGITAL OVER TEMPERATURE ALARM SWITCH ...

Page 58: ...ON LED Display TEMP status Displays current water temperature or setpoint RST RESET Button Resets the unit after an alarm condition UP Button Increases the displayed temperature DOWN Button Decreases the displayed temperature SET SET Button Used to access and store parameters in the unit Perform the following steps to check or adjust the digital alarm switch settings 1 Set the ON OFF to the ON pos...

Page 59: ... the code set at 0 AERCO recommends that you do not change this code 7 Press the SET button again to enter the code The first parameter label SP will appear in the display 8 Using the and arrow keys select parameter P1 9 Press SET to view the value stored in memory 10 If the desired value is not displayed modify the setting using the and arrow keys The value can be changed from 10 to 10 offset Pre...

Page 60: ...Page 60 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E This Page Is Intentionally Blank ...

Page 61: ...rease by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 5 2 2 Building Reference Temperature This is a temperature from 40 F to 230 F Once selected it is the temperature that the system references to begin increasing ...

Page 62: ... keys to select the Reset Ratio determined in step 5 12 Press ENTER to save the change 13 Refer to paragraph 3 3 for detailed instructions on menu changing 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired Common uses of this mode of operation include water source heat pump loops and indirect heat exchangers for potable hot water systems or pr...

Page 63: ... 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 paragraph 3 3 for detailed instructions on changing menu options If the Network set...

Page 64: ... Building Automation System BAS The Direct Drive mode can be driven by a current or voltage signal within the following ranges 4 20 mA 1 5 Vdc 0 20 mA 0 5 Vdc The factory default setting for the Direct Drive mode is 4 20 mA 1 5 Vdc With this setting a 4 to 20 mA signal sent by an EMS or BAS is used to change the unit s valve position from 0 to 100 A 4 mA 1V signal is equal to a 0 valve position wh...

Page 65: ...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 BOILER MANAGEMENT SYSTEM BMS NOTE BMS Model 168 can utilize either pulse width modulation PWM or RS485 Modbus signaling to t...

Page 66: ...space heating and domestic hot water needs An AERCO Boiler Management System BMS Model 168 and a Combination Control Panel CCP or an ACS and an ACS Relay Panel optional depending on applications are necessary to configure this system Typically an adequate number of boilers are installed to cover the space heating load on the design day however one or more units are used for the domestic hot water ...

Page 67: ...onfiguration Menu for boiler mode remote signal type and setpoint The setpoint is adjustable from 40 F to 240 F Enter the following settings in the Configuration Menu MENU OPTION SETTING Boiler Mode Combination Remote Signal BMS PWM Input Internal Setpt 40 F to 240 F Refer to paragraph 3 3 for instructions on changing menu options While it is possible to change other temperature related functions ...

Page 68: ...Page 68 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation and Maintenance Manual GF 120 OMM 0041 0E This page is intentionally blank ...

Page 69: ...r 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 WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 120 AND 24 VOLTS AC Power MUST be Removed Prior to Performing Wire Removal OR OTHER Test Procedures that Can Result in Electrical Shock 6 2 LOW GAS PRESSURE FAULT TEST Refer to Fi...

Page 70: ... high gas pressure fault refer to Figure 6 1 and proceed as follows Remove the 1 4 plug from the leak detection ball valve shown in Figure 6 1 1 Install a 0 16 W C manometer or W C gauge where the 1 4 plug was removed 2 Slowly open the leak detection ball valve 3 Start the unit in Manual mode at a valve position firing rate between 25 and 30 4 Slowly increase the gas pressure using the adjustment ...

Page 71: ...sition above 30 5 Set the ON OFF switch to the ON position The READY light should remain off and the 6 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 7 Open the water shut off valve in the return piping to the unit 8 Open the water supply shut off valve to ...

Page 72: ...20 OMM 0041 0E Reset the adjustable over temperature switch to its original setting 4 The unit should start once the adjustable temperature limit switch setting is above the 5 actual outlet water temperature Figure 6 2 Temperature Limit Switch Setting FRONT VIEW ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH SEE DETAIL A DETAIL A F Alarm DIGITAL OVER TEMPERATU...

Page 73: ... operational 6 6 1 REMOTE INTERLOCK Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals 1 Start the unit in the Manual Mode and set the valve position between 25 and 30 2 If there is a jumper across the REMOTE INTL K IN terminals remove one side of the 3 jumper If the interlock is being controlled by an external device either open the interlock via the external device or di...

Page 74: ... Off Valve Location Set the ON OFF switch to the ON position to start the unit 4 The unit should shut down after reaching the Ignition cycle and display FLAME LOSS 5 DURING IGN Open the valve previously closed in step 3 and press the CLEAR button 6 Restart the unit and allow it to prove flame 7 Once flame is proven close the manual gas valve located between the SSOV Figure 6 8 3 and the Air Fuel V...

Page 75: ... will execute a 30 second re ignition delay and display WAIT RETRY PAUSE b The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY The unit should perform one IGNITION RETRY cycle and then shut down since the 4 blower is disabled The unit will then display AIRFLOW FAULT DURING PURGE Re enable the blower output drive voltage by performing the following steps 5 a Pres...

Page 76: ... loosening the screw shown in Figure 6 4 Lift off 4 the cover to access the terminal wiring connections Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 5 The unit should fault and display SSOV SWITCH OPEN 6 Replace wire 148 and press the CLEAR button 7 Set the ON OFF switch to ON to start the unit 8 Remove the wire again when the unit reaches the purge cycle and PURGI...

Page 77: ...Replace the wire on the Purge Switch and depress the CLEAR button The unit should 6 restart 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 Set the unit s ON OFF switch to the OFF position 1 Place the unit in Manual Mode and set the valve position between 25 and 30 2 Remove the Air Fuel Valve...

Page 78: ...lation Operation and Maintenance Manual GF 120 OMM 0041 0E STEPPER MOTOR DIAL 1 7 2 1 7 1 1 6 9 1 7 0 IGNITION POSITION SWITCH PURGE POSITION SWITCH AIR IN TO BLOWER Figure 6 6 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI ...

Page 79: ... also includes the items contained in the Annual Maintenance Kit Therefore only Kit Part No 58025 05 is required when performing the waterside fireside inspections Appendix K contains recommended spare parts lists for maintenance of the boiler WARNING TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE S...

Page 80: ...ts 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 AIR FUEL VALVE STAGED IGNITION ASSEMBLY FLAME DETECTOR IGNITOR INJECTOR BLOWER BURNER PLATE BURNER Figure 7 1 Benchmark 1 5LN Burner Assembly Shown Removed from Boiler To inspect replace the Igniter Set the ON O...

Page 81: ...ild 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 7 pound must be applied to the thr...

Page 82: ...ed to the burner plate with one 1 10 32 screw and one 1 8 32 screw Remove the flame detector and gasket from the burner plate 5 Thoroughly inspect the flame detector If eroded the detector should be replaced 6 Otherwise clean the detector with a fine emery cloth Reinstall the flame detector and flame detector gasket 7 Reconnect the flame detector lead wire 8 Reinstall the side and top panels on th...

Page 83: ...bserve the orange 11 glow of the RSI flame during the ignition trial period If the pressure is within specifications return the unit to service Make sure that the unit 12 is operating in AUTO Mode The MAN light in the upper left of the control box should NOT be lit when in AUTO Mode If the RSI regulator is NOT within specifications proceed to paragraph 7 4 1 2 RSI 13 Regulator Calibration and init...

Page 84: ...s between 3 0 w c and 4 0 w c conduct at least three safe 13 RSI ignitions while observing the observation port Assure the igniter lights immediately with a strong orange flame after the Staged Ignition Solenoid Valve opens NOTE Clear any Flame Loss During Ignition messages during the tests by pressing The CLEAR key on control panel Close the external gas supply and RSI Staged Ignition Gas Valves ...

Page 85: ...basis Test schedules must conform to local jurisdictions The results of the tests should be recorded in a log book See Chapter 6 Safety Device Testing Procedures 7 6 BURNER ASSEMBLY INSPECTION The burner assembly part no 24012 is located at the top of the unit s heat exchanger The burner assembly may be hot Therefore allow the unit to cool sufficiently before removing the burner assembly It should...

Page 86: ...curing the flame detector to the plate The flame detector 4 is secured to the burner plate with one 1 10 32 screw and one 1 8 32 screw Remove the flame detector and gasket from the burner plate 5 Disconnect the cable from the igniter injector 6 Using a 7 16 open end wrench disconnect the compression nut securing the gas 7 injector tube of the igniter injector to the elbow of the staged ignition as...

Page 87: ...ner flange Figure 7 4 using a 9 16 16 wrench NOTE The burner assembly is heavy weighing approximately 25 pounds Remove the burner assembly from burner flange by pulling straight up 17 Remove and replace the two 2 burner gaskets 18 NOTE During reassembly apply high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is pr...

Page 88: ...e from the exhaust manifold This trap should be inspected and if necessary cleaned to ensure proper operation NOTE There are two slightly different types of condensate traps that may be used in your configuration an older style without an inlet adapter and a newer style with a built in adapter see Figure 7 5 Maintenance is the same except that the newer style does not need an orifice gasket Step 6...

Page 89: ...condensate trap and replace the trap cover Reassemble all piping and hose connections to the condensate trap inlet and outlet 8 Reconnect trap to exhaust manifold drain Figure 7 5 External Condensate Trap 7 8 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...

Page 90: ...E BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed 1 Review installation requirements included in Chapter 2 2 Inspect all piping and connections to the unit 3 Inspect exhaust vent air duct if applicable 4 Perform initial startup per Chapter 4 5 Perform safety device testing and scheduled maintenance procedures p...

Page 91: ...device This RS232 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 RS232 communication set up and procedures When a fault occurs in the Benchmark Boiler proceed as follows to isolate and correct the fault Observe the fault messages displayed in the Control Box display 1 Refer to t...

Page 92: ...e Blower proof switch and inspect for signs of blockage clean or replace as necessary 4 Remove the blocked air inlet switch and inspect for signs of blockage clean or replace as necessary 5 Measure the Blower proof switch for continuity with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Measure the b...

Page 93: ...to the combustion blower for signs of blockage 5 Measure for 24 VAC during start sequence from each side of the switch to ground If 24VAC is not present refer to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 16 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 2 Blocked Blower inlet or inlet ductwork 3 Blocked ai...

Page 94: ...oiler 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration Menu FLAME LOSS DURING IGN 1 Burner Ground Screw not installed or loose 2 Worn flame detector 3 No spark from Spark Plug 4 Defective Ignition Transformer 5 Defective Ignition Stepper IGST Board 6 Defec...

Page 95: ... 5 Blocked condensate drain 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Check combustion calibration Adjust as necessary 4 Remove the burner and inspect for any carbon or debris Clean...

Page 96: ...h setpoint 6 Boiler Management System PID or other settings not correctly setup 7 No interlock to boiler or BMS to disable boiler s in event that system pumps have failed 8 System flow rate changes are occurring faster than boilers can respond 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against Menu Default settings in the Appendix ...

Page 97: ...h shows continuity when not in contact with the cam replace the switch 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If n...

Page 98: ...Incorrect supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is between 4 0 W C and 14 W C For IRI gas trains ensure it is between 4 2 W C and 14 W C see para 2 7 1 2 Measure gas pressure at the low gas pressure switch If it is greater than 2 6 W C measure continuity across the switch and r...

Page 99: ...he purge switch for continuity when closing Replace switch if continuity does not exist 2 Measure for 24 VAC from each side of the switch to ground If 24VAC is not present refer fault to qualified service personnel 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Pow...

Page 100: ...Board 2 The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two Normally this measurement should be near zero or no more than a few millivolts 3 Check SSOV power wiring SSOV SWITCH OPEN 1 Actuator not allowing for full closure of gas valve 2 SSOV powered when it should not be 3 Defective Switch or Actuator 4 Incorrectly wired switch 1 ...

Page 101: ...OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Staged Ignition Ball Valve closed 2 Clogged damaged Gas Injector Figure 8 2 3 Defective Staged Ignition Solenoid Figure 8 2 4 RSI regulator out of adjustment 1 Open the 1 4 Ball Valve downstream of the SSOV Fig 8 1 2 Remove and inspect Gas Injector to ensure it is not clogged or damaged 3 Close the 2 and the 1 4 Ball Valve downst...

Page 102: ... 0041_0E Page 102 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Figure 8 1 High Gas Pressure Switch Snubber Locations Figure 8 2 Staged Ignition Solenoid Location AIR FUEL VALVE STAGED IGNITION SOLENOID 1 FLAME DETECTOR IGNITOR INJECTOR BLOWER BURNER PLATE BURNER ...

Page 103: ...1_0E Installation Operation and Maintenance Manual Menu Items PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 103 of 166 SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT DAMPING ORIFICE Figure 8 3 Damping Orifice Location ...

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Page 105: ...your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it 9 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote machine bring up the PuTTY application by double cli...

Page 106: ...te 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 st...

Page 107: ... baud rate and data formats have been entered 2 Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS232 password jaguar in lower case letters and press Enter 4 Welcome to Aerco will appear in the laptop or dumb terminal display with a listing of the following available entry choices M Display next Menu D Display menu items N Display next menu items ...

Page 108: ...ciated with the boiler or water heater system Descriptions of these data logs are provided in the following paragraphs The basic procedure for accessing each data log is described in paragraph 9 3 step 7 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 RS232 port The Fault Log cannot be cl...

Page 109: ...ng in Constant Setpoint mode Table 9 1 Sample Fault Log Display No Fault Message Cycle Date Time 0 Direct Drive Signal Fault 609 1 10 02 8 42am 1 Low Gas Pressure 366 7 04 01 5 29pm 2 Loss of Power 0 1 01 01 11 50am 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...

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Page 111: ...tpoint 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 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 Displayed only if outdoor sensor is installed an...

Page 112: ...s C Default is F Comm Address For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The...

Page 113: ... Setpoint Direct Drive or Combination Mode The factory default is 4 20 mA 1 5V Bldg Ref Temp Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode Default is 70 F Reset Ratio 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 func...

Page 114: ... after ignition before going to the desired output Default is 2 sec 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 HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature When operating at a Valve Position below this value the effective Setpoint is equ...

Page 115: ...adband 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...

Page 116: ...rate will be 100 Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 0 10 Derivative Time This value 0 0 to 20 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 ...

Page 117: ...election of the Blower Motor output voltage at 30 CAL Voltage 45 Allows for the selection of the Blower Motor output voltage at 45 CAL Voltage 60 Allows for the selection of the Blower Motor output voltage at 60 CAL Voltage 80 Allows for the selection of the Blower Motor output voltage at 80 CAL Voltage 100 Allows for the selection of the Blower Motor output voltage at 100 Set Valve Position Allow...

Page 118: ...d date that the unit was disabled FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during the purge cycl...

Page 119: ...me signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switch is closed HIGH GAS PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP SWITCH OPEN T...

Page 120: ...NG IGNITION The Purge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN The SSOV switch opened d...

Page 121: ...r Resistance Voltage Chart Balco TEMP F RES OHMS VOLTS 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 1364 2 1391 0 1418 2 1445 7 1 93 1 96 1 99 2 02 2 05 2 07 2 10 2 12 2...

Page 122: ... 110 120 130 140 150 160 170 5F 83 94 105 116 127 138 149 160 171 182 10F 86 98 110 122 134 146 158 170 182 194 15F 89 102 115 128 141 154 167 180 193 206 20F 92 106 120 134 148 162 176 190 204 218 Table D 2 Header Temperature for a Building Reference Temperature of 60ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 60F 60 60 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72...

Page 123: ...49 161 173 185 197 209 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 D 4 Header Temperature for a Building Reference Temperature of 70ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70F 70 70 70 70 70 70 70 70 70 70 65F 73 74 75 76 77 78 79 80 81 82 60F 7...

Page 124: ...7 159 171 183 195 207 219 10F 114 127 140 153 166 179 192 205 218 5F 117 131 145 159 173 187 201 215 0F 120 135 150 165 180 195 210 5F 123 139 155 171 187 203 219 10F 126 143 160 177 194 211 15F 129 147 165 183 201 219 Table D 6 Header Temperature for a Building Reference Temperature of 80ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 80F 80 80 80 80 80 80 80 80 80 80 75F 83 84 85...

Page 125: ...02 80F 96 98 100 102 104 106 108 110 112 114 75F 99 102 105 108 111 114 117 120 123 126 70F 102 106 110 114 118 122 126 130 134 138 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126 132 138 144 150 156 162 55F 111 118 125 132 139 146 153 160 167 174 50F 114 122 130 138 146 154 162 170 178 186 45F 117 126 135 144 153 162 171 180 189 198 40F 120 130 140 150 160 170 180 190 200 210 35F ...

Page 126: ...e English Unit of Temp Fahrenheit ºF Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type BMK Boiler LN Unit Size 1500 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bldg Ref Temp If Boiler Mode Outdoor Reset 70 F Reset Ratio If Boiler Mode Outdoor Reset 1 2 Outdoor Sensor Disabled Sy...

Page 127: ...RY DEFAULT Configuration Menu Continued Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Position 0 10V CAUTION DO NOT Change Lo Fire Timer 2 sec 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 Spark Monitor Disabled Spark Current 0 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative T...

Page 128: ... International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 Table E 1 Boiler Default Settings Continued MENU OPTION FACTORY DEFAULT Combustion Cal Menu Cal Voltage 16 1 80 v Cal Voltage 30 3 20 v Cal Voltage 45 3 70 v Cal Voltage 60 3 80 v Cal Voltage 80 4 60 v Cal Voltage 100 6 00 v Set Valve Position 0 Blower Output 00 v ...

Page 129: ... Boiler APPENDIX F OMM 0041_0E Installation Operation and Maintenance Manual PARTS LISTS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 129 of 166 APPENDIX F PART AND DIMENSIONAL DRAWINGS ...

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Page 131: ...l Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 131 of 166 REAR REV AERCO INTERNATIONAL INC NORTHVALE NJ 07647 BENCHMARK 1 5 LOW NOx GAS FIRED BOILER ANCHOR BOLT LOCATION SD A 730 A DRWN BY SJD DATE 10 12 07 NOT TO SCALE FRONT NOTES 1 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2 ALL DIMENSIONS SHOWN ARE IN INCHES CENTIMETERS ...

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Page 133: ...nchmark 1 5LN Low NOx Boiler APPENDIX F OMM 0041_0E Installation Operation and Maintenance Manual PARTS LISTS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 133 of 166 ...

Page 134: ...F Benchmark 2 0LN Low NOx Boiler GF 120 PARTS LISTS Installation Operation and Maintenance Manual OMM 0041_0E Page 134 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 ...

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Page 136: ...F Benchmark 2 0LN Low NOx Boiler GF 120 PARTS LISTS Installation Operation and Maintenance Manual OMM 0041_0E Page 136 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 ...

Page 137: ...nchmark 1 5LN Low NOx Boiler APPENDIX F OMM 0041_0E Installation Operation and Maintenance Manual PARTS LISTS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 137 of 166 ...

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Page 142: ...F Benchmark 2 0LN Low NOx Boiler GF 120 PARTS LISTS Installation Operation and Maintenance Manual OMM 0041_0E Page 142 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 ...

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Page 145: ...w NOx Boiler APPENDIX G OMM 0041_0E Installation Operation and Maintenance Manual PIPING DRAWINGS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 145 of 166 APPENDIX G PIPING DRAWINGS ...

Page 146: ...Benchmark 2 0LN Low NOx Boiler GF 120 PIPING DRAWINGS Installation Operation and Maintenance Manual OMM 0041_0E Page 146 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 ...

Page 147: ...hmark 1 5LN Low NOx Boiler APPENDIX G OMM 0041_0E Installation Operation and Maintenance Manual PIPING DRAWINGS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 147 of 166 ...

Page 148: ...Benchmark 2 0LN Low NOx Boiler GF 120 PIPING DRAWINGS Installation Operation and Maintenance Manual OMM 0041_0E Page 148 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 ...

Page 149: ...hmark 1 5LN Low NOx Boiler APPENDIX G OMM 0041_0E Installation Operation and Maintenance Manual PIPING DRAWINGS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 149 of 166 ...

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Page 151: ...NOx Boiler APPENDIX H OMM 0041_0E Installation Operation and Maintenance Manual WIRING SCHEMATICS PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 151 of 166 APPENDIX H WIRING SCHEMATICS ...

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Page 154: ...154 of 166 PR1 10 18 12 Benchmark 1 5LN Low NOx Boiler Installation Operation Maintenance Manual OMM 0041_0E GF 120 APPENDIX H WIRING AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 ...

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Page 157: ...Chapter 4 Flue vent stack or intake air duct Monthly Operator Visually inspection condition and check for obstructions Spark Igniter Weekly Operator See paragraph 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial paragraph 3 9 SSOV Leakage test Annually Service Tech Check for leakage in accordance with the SSOV manufacturer s Siemens recommendations Flame failure Weekly Ope...

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Page 159: ... 0041_0E Installation Operation and Maintenance Manual CONTROL PANEL PR1 10 18 12 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 159 of 166 APPENDIX J BENCHMARK CONTROL PANEL FEATURES Figure J 1 Control Panel Exploded View ...

Page 160: ...Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 P1 P2 P3 P4 P5 P6 SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN SENSOR HARNESS CONNECTOR 7 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX Figure J 2 Control Panel Rear Panel ...

Page 161: ...LL FM gas train models Downstream SSOV of IRI gas train models 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset See Note 1 123552 Regulated Staged Ignition Solenoid Valve 124866 Table K 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside I...

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Page 163: ...Page 166 of 166 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 PR1 10 18 12 AERCO International Inc 2012 ...

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