Aerco Benchmark 1500 User Manual Download

Page: 104 / 186

Benchmark 1500 - 2000 Boilers

CHAPTER 8 – TROUBLESHOOTING GUIDE

Page

104

188

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0097_0D

Ph.: 800-526-0288

GF-142

TABLE 8-1: BOILER TROUBLESHOOTING – Continued

FAULT INDICATION

PROBABLE CAUSES

CORRECTIVE ACTION

IGN SWTCH CLOSED

DURING PURGE

Air/Fuel Valve not rotating.

Defective or shorted switch.

Switch wired incorrectly.

Defective Power Supply Board

or fuse.

Defective IGST Board.

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.

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.

Check DS1 & 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 &

OFF every second. If not, replace IGST Board.

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.

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 & 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 &

OFF every second. If not, replace IGST Board.

Summary of Contents for Benchmark 1500

Page 1: ...c 100 Oritani Dr Blauvelt NY 10913 Page 1 of 188 GF 142 Ph 800 526 0288 USER MANUAL Installation Operation and Maintenance BENCHMARK 1500 2000 Gas Fired Boilers Natural Gas Modulating Condensing Hot Water Boiler Models BMK 1500 BMK 2000 Applicable to Serial Numbers G 14 0304 and Above Latest Update 03 20 2014 ...

Page 2: ...formation 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...

Page 3: ...or 23 2 9 AC ELECTRICAL POWER WIRING 24 2 9 1 Electrical Power Requirements 25 2 10 FIELD CONTROL WIRING 26 2 10 1 Outdoor Air In OUT Air Sensor Common COM 27 2 10 2 COMBUSTION AIR Terminal 28 2 10 3 O2 SENSOR O2 O2 28 2 10 4 SPARK SIGNAL FLW FLW 28 2 10 5 Analog In 28 2 10 6 B M S PWM In BMS BMS 28 2 10 7 Shield SHLD SHLD 28 2 10 8 Analog Output 28 2 10 9 RS 485 Comm GND 29 2 10 10 RS 232 Comm Tx...

Page 4: ...UTDOOR RESET MODE 63 5 2 1 Reset Ratio 63 5 2 2 Building Reference Temperature 63 5 2 3 Outdoor Air Temperature Sensor Installation 63 5 2 4 Indoor Outdoor Startup 63 5 3 CONSTANT SETPOINT MODE 64 5 3 1 Setting the Setpoint 64 5 4 REMOTE SETPOINT MODES 65 5 4 1 Remote Setpoint Field Wiring 65 5 4 2 Remote Setpoint Startup 66 5 5 DIRECT DRIVE MODES 66 5 5 1 Direct Drive Field Wiring 67 5 5 2 Direct...

Page 5: ...SETUP 113 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION 113 9 4 DATA LOGGING 114 9 4 1 Fault Log 115 9 4 2 Operation Time Log 115 9 4 3 Sensor Log 116 CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 117 10 1 INTRODUCTION 117 10 2 AERCO BST QUICK START CHART 118 10 3 BST IMPLEMENTATION INSTRUCTION 119 10 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor 119 10 3 2 Option 2 Constant Setpoi...

Page 6: ...M Page 6 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 APPENDIX H PART DRAWINGS 155 APPENDIX I WIRING DIAGRAMS 167 APPENDIX J PIPING DRAWINGS 175 APPENDIX K C MORE CONTROL PANEL VIEWS 181 APPENDIX L RECOMMENDED SPARES 183 ...

Page 7: ... 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 1500 and BMK 2000 offer the maximum ve...

Page 8: ...er Management Systems BLDG Bldg Building BST AERCO on board Boiler Management Technology BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound of water 1 F CCP Combustion Control Panel C More Controller or Control Box A control system developed by AERCO and currently used in all Benchmark Innovation and KC1000 Series product lines CO Carbon Monoxide CO...

Page 9: ...ndth 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...

Page 10: ... Meaning SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each end of a daisy chain or multi drop network in order to prevent reflections that may cause invalid data in the communication uA Microamp 0 000001 amp one millionth of an amp VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W...

Page 11: ...uld 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 DO NOT USE MATCHES CANDLES FL...

Page 12: ...pect 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 Figure 1 1 Manual Gas Shutoff Valve 1 3 PROLONGED SHUTDOWN After pr...

Page 13: ...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 sp...

Page 14: ... 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 b...

Page 15: ...ion on the carrier s paperwork and request a freight claim and inspection by a claims adjuster before proceeding Any other visual damage to the packaging materials should also be made clear to the delivering carrier 2 3 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials After unpacking a close inspection of the unit should be made...

Page 16: ...cribed clearances for service as shown in Figure 2 1a The minimum clearance dimensions required by AERCO are listed below However if Local Building Codes require additional clearances these codes shall supersede AERCO s requirements Minimum acceptable clearances required are as follows Sides 24 inches Front 24 inches Rear 24 inches Top 18 inches All gas piping water piping and electrical conduit o...

Page 17: ... 4 2 Setting the Unit The unit must be installed on a 4 inch to 8 inch thick housekeeping pad to ensure proper condensate drainage If anchoring the unit refer to Figure 2 1b for anchor locations Figure 2 1b Benchmark 1500 2000 Anchor Bolt Locations A total of 3 lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2 2 Remove the front top panel from the unit to prov...

Page 18: ... 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 informatio...

Page 19: ... the relief valve must be specified on the sales order Available pressure ratings range from 30 psi to 160 psi The relief valve is installed on the hot water outlet of the boiler as shown in Figure 2 4 A suitable pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any joint compound into the valve body The relief valve must be piped to wit...

Page 20: ...e 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 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 conden...

Page 21: ...utlet and secure with a hose clamp 4 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 drain line must be removable for routine maintenance Use PVC stainless steel aluminum or polypropylene for condens...

Page 22: ...t install any flexible connectors or unapproved gas fittings Piping must be supported from the floor ceiling or walls only and must not be supported by the unit A suitable piping compound approved for use with natural gas should be used Any excess must be wiped off to prevent clogging of components To avoid unit damage when pressure testing gas piping the unit must be isolated from the gas supply ...

Page 23: ...hown in Figure 2 7 The gas supply regulator must be properly vented to outdoors Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator 2 8 3 2 All Installations Except Massachusetts For multi unit installations other than Massachusetts that EXCEED 7 W C gas pressure a mandatory external gas supply regulator as shown in Figure 2 7 is highly recommende...

Page 24: ...el 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 THE POWER BREAKER SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS Figure 2 9 Power Box Internal Component...

Page 25: ...igure 2 10 Power Box Cover Labels 120VAC Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A three pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enclosures of the unit After pla...

Page 26: ... 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 Figure 2 11 Input O...

Page 27: ...sensor is DISABLED To enable the sensor and or select an enable disable outdoor temperature see the Configuration Menu in Chapter 3 The outdoor sensor may be wired up to 200 feet from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O PCB Figure 2 12 Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG There is no polarity to observe when te...

Page 28: ...e 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...

Page 29: ...uts 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 be...

Page 30: ...ntacts are rated for 120 VAC 5 amps Refer to Figure 2 12 to locate the AUXILLIARY RELAY terminals for wiring connections 2 11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide GF 2050 must be consulted before any flue or combustion air venting is designed or installed Suitable U L approved positive pressure watertight vent materials MUST be used for safety and UL certific...

Page 31: ...r 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 fr...

Page 32: ...ble 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 Figure 2 14 Sequencing Valve Installed 3 Remove the jumper wire...

Page 33: ...ND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS 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 All of the installation procedures in Chapter 2 must be completed before attempting to start the unit 3 2 CONTROL...

Page 34: ...w 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 3 1 8 9 10 11 7 6 5 4 12 2 ...

Page 35: ...o 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection BST Messages 4 RS 232 Port 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 work with this port This cable features a DB9 connector for c...

Page 36: ...tem 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 changed edited When the CHANGE key is pressed the displ...

Page 37: ... 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 1 The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status Pressing the or arrow key will display the other available data items in the Oper...

Page 38: ...00 526 0288 GF 142 Only if BST is enabled see Chapter 10 Figure 3 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages ...

Page 39: ...tdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Out 0 100 Exhaust Temp F F Flame Strength 0 100 Oxygen Level 0 21 Run Cycles 0 999 999 999 Run Hours 0 999 999 999 Fault Log 0 19 0 NOTE The Outdoor Temp and Valve Position Out display 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 ...

Page 40: ...0 C More Alpha A Z A 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 en...

Page 41: ...1500 MBH 2000 MBH 2500 MBH 3000 MBH 6000 MBH 1500 MBH or 2000 MBH Fuel Type Natural Gas or 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 Legacy BMS Network 4 20 mA 1 5V Outdoor Sensor Enabled or Disabled Disabled Bldg Ref...

Page 42: ...ork 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 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...

Page 43: ...AL Voltage 14 CAL Voltage 30 CAL Voltage 30 CAL Voltage 45 CAL Voltage 45 CAL Voltage 60 CAL Voltage 60 CAL Voltage 80 CAL Voltage 80 CAL Voltage 100 CAL Voltage 100 SET Valve Position SET Valve Position Blower Output Blower Output Set Stdby Volt Set Stdby Volt Oxygen Level Oxygen Level 3 9 BST Boiler Sequencing Technology Menu The BST Menu must be Enabled in order to be displayed and accessed The...

Page 44: ...ate BST Outdoor Temp NA Outdoor Temp F Units Available 0 8 Units Present Units Ignited 0 8 Units firing BST Valve State 0 CLOSED 1 OPEN 0 1 Comm Errors 8 0 9 0 1 BST Units 8 0 see table 0 see table 0 BST SETUP MENU Disabled Enabled Disabled BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr 0 255 240 Header...

Page 45: ...elay 0 15 min 1 min BST Sequencing Run Hours Unit Size Select Lead Run Hours Select Lead Unit 0 127 0 Select Lag Unit 0 127 0 Lead Lag Hours 25 hours 225 hours 72 hours BST TEMP CTRL MENU 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 1 F 120 F 100 F BST Intgral Gain 0 00 2...

Page 46: ...l switch High Water Temperature switch High Gas Pressure switch Low Gas Pressure switch Blower Proof switch Blocked 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 appropriat...

Page 47: ...tches closed a purge cycle will be initiated and the following events will occur a The Blower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 NATURAL GAS INLET TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS PRESSURE SWIT...

Page 48: ... of the purge cycle in seconds 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 positio...

Page 49: ...ent 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 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 w...

Page 50: ...nd Air Fuel Valve position for a BMK 1500 MBH boiler running on natural gas Table 3 8a BMK 1500 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 16 Stop Level 76 000 5 0 20 127 000 8 5 30 366 000 24 4 40 629 000 41 9 50 822 000 54 7 60 977 000 65 0 70 1 119 000 74 5 80 1 255 00...

Page 51: ...ons Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this Chapter it will be necessary to perform the Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Benchmark must be completed for each unit f...

Page 52: ...s for use with gas supply manometer or gauge Small and large flat blade screwdrivers 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 loca...

Page 53: ...SOV as shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 4 2 3 Accessing the Analyzer Probe Port The unit contains a 1 4 NPT port 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 An...

Page 54: ... the natural gas supply valve to the unit 3 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 5 Set the unit to the manual mode by pressing the AUTO MAN key A flashing manual valve position message will be displayed with the present position in Also the MANUAL LED will light 6 Adjust the air fue...

Page 55: ... adjustment Clockwise rotation reduces the oxygen level while counterclockwise rotation increases the oxygen level 16 Once the oxygen level is within the specified range at 100 record the O2 NOx and CO readings on the Combustion Calibration Data Sheets provided with the unit 17 Lower the valve position to 80 using the arrow key NOTE The remaining combustion calibration steps are performed using th...

Page 56: ...all readings on the Combustion Calibration Sheets provided 28 Repeat steps 20 through 27 for valve positions of 60 45 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 O2 level up to 1 higher than the listed calibration...

Page 57: ...ERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 57 of 188 GF 142 Ph 800 526 0288 Figure 4 3 Gas Pressure Adjustment Screw Location Figure 4 4 TAC Valve Adjust Idle Screw BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw TAC VALVE IDLE SCREW ...

Page 58: ...s 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 3 9 W C 0 2 W C 11 Using the arrow key increase the valve open position to 100 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 3 9 0 2 W C Readjust the gas pressure i...

Page 59: ...s within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O2 level up to 1 higher than the listed calibration range Record the increased O2 value on the Combustion Calibration sheet 18 Press the MENU key on the front panel of the C MORE and access the Setup menu Enter password 6817 and then press the ENTER key 19 Press the MENU key on the front panel of the C ...

Page 60: ...6 3 0 5 20 ppm 100 ppm 30 6 3 0 5 20 ppm 100 ppm 16 6 0 0 5 20 ppm 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 4 Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the O2 to the specified level Recalibration MUST b...

Page 61: ...able from xxx to yyy ºF 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 210ºF and should not be changed If an over temperature condition is detected this switch automatically shut...

Page 62: ...larm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210ºF is displayed press the SET button to store the setting in memory 6 To calibrate the offset P1 press and hold the SET button for 8 seconds on the Digital Alarm Switch Access code value 0 should appear in the display The switch comes from the factory...

Page 63: ... number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 5 2 2 Building Reference Temperature This is a temperature from 40 F to 230 F Once selected it is the temperature that the system references to begin increasing its temperatu...

Page 64: ...e CHANGE key The display will begin to flash 12 Use the and arrow keys to select the Reset Ratio determined in step 5 13 Press ENTER to save the change This completes 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired Common uses of this mode of operation include water source heat pump loops and indirect heat exchangers for potable hot water sy...

Page 65: ...lowing 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 additi...

Page 66: ...ng 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 while a 20 mA 5V signal is equal to a 100 valve position When a 0 20 mA 0 5 Vdc signal is used zero is equal to a 0 valve position In addition to the current and voltage signals described above the Direct Drive mode can also driven by a RS 485 Modbu...

Page 67: ...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 A...

Page 68: ...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...

Page 69: ... the ACS Relay Box see section 2 14 in the same manual 5 7 1 Combination Control System Field Wiring Wiring for this system is between the ACS the ACS Relay Box and the terminals in the I O Box Wire the units 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 Com...

Page 70: ...Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION Page 70 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 71: ...ng tests check to ensure that the system is operating as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Chapter 3 NOTE It will be necessary...

Page 72: ...lowly open the ball valve near the low gas pressure switch 5 Place the unit in Manual Mode and adjust the Air Fuel Valve position open between 25 and 30 6 While the unit is firing slowly close the external manual gas shut off valve 7 The unit should shut down and display a GAS PRESSURE fault message at approximately 3 6 W C for both BMK 1500 and BMK 2000 8 Fully open the external manual gas shut o...

Page 73: ...e manometer installed in step 2 and record the gas pressure reading 7 Slowly increase the gas pressure using the adjustment screw on the SSOV see Figure 4 3 8 The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 4 7 W C for both BMK 1500 and BMK 2000 The FAULT indicator should also start flashing 9 Reduce the gas pressure back to the value recorded ...

Page 74: ...ge is displayed and the FAULT indicator flashes 5 Place the unit in the Manual Mode and raise the valve position above 30 6 Set the ON OFF switch to the ON position The READY light should remain off and the unit should not start If the unit does start shut the unit off immediately and refer fault to qualified service personnel 7 Close the drain and pressure relief valve used in draining the unit 8...

Page 75: ... a HIGH WATER TEMP SWITCH OPEN fault message should be displayed It should not be possible to restart the unit 4 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 6 Once the adjustable over temperature switch setting is approximately at or just below the actu...

Page 76: ...etween 25 and 30 3 If there is a jumper across the REMOTE INTL K IN terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock via the external device or disconnect one of the wires leading to the external device 4 The unit should shut down and display INTERLOCK OPEN 5 Once the interlock connection is reconnected the INTERLOCK OPEN ...

Page 77: ...ve located between the Safety Shut Off Valve SSOV and the Air Fuel Valve see Figure 6 3 4 Set the 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 7 Restart the unit and a...

Page 78: ...ritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Figure 6 3 Bare Boiler Partial View BMK 1500 2000 BLOWER HEAT EXCHANGER BLOWER PROOF SWITCH AIR FUEL VALVE BLOCKED INLET SWITCH AIR FILTER SSOV IGNITER INJECTOR ASSEMBLY BLOWER PLENUM GAS INLET MANUAL SHUT OFF VALVE GAS TRAIN A F VALVE PLENUM ...

Page 79: ...ut drive voltage by performing the following steps a Press the MENU key until CONFIGURATION MENU is displayed b Press the arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key d Press the CLEAR button to clear the airflow fault 6 Once the unit has proved flame turn off the blower agai...

Page 80: ...0 fire rate and then turn on the main ON OFF switch on the front of the Control Panel b Push the BACK button three 3 times to return to the upper level menu c When the Controller gets into the ignition phase the Control Panel will show IGNITION TRIAL At that point attach the alligator clip see Figure 6 3a to any bare metal surface or ground The C More display should now show FLAME PROVEN and begin...

Page 81: ...e 6 1 and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 5 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 6 The unit should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press the CLEAR button 8 Set the ON OFF switch to the ON position to start the un...

Page 82: ...ing Purge 1 Set the unit s ON OFF switch to the OFF position Place the unit in manual mode and set the valve position between 25 and 30 2 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 6 6 3 Remove one of the two wires 171 or 172 from the Purge Switch Figure 6 6 4 Initiate a unit start sequence 5 The unit should begin its start sequence then shut dow...

Page 83: ...nual Mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 6 6 by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove one of the two wires 169 or 170 from the Ignition Switch Figure 6 7 5 Initiate a unit start sequence 6 The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION 7 Replace the...

Page 84: ... 0288 GF 142 Figure 6 7 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI 172 171 170 169 Ignition Position Switch Purge Position Switch AIR IN TO BLOWER VALVE POSITION DIAL AIR FUEL VALVE SWITCH WIRING BREAKOUT ...

Page 85: ...t 58025 01 Therefore only Kit Part No 58025 13 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF VALVE PRO...

Page 86: ...1 Benchmark 1500 2000 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 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power ...

Page 87: ...s an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion calibration procedures Figure 7 2 Igniter Injector Flame Detector Mounting Details 7 Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench 8 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosio...

Page 88: ...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 detec...

Page 89: ...Maintenance Procedures 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 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 3 Disconnect the O2 sensor lead wire by pushing in on the release tab and pulling apart the connector 4 Next loosen an...

Page 90: ... the burner assembly proceed as follows Burner Assembly Inspection and Maintenance Procedures 1 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 2 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 3 Disconnect the le...

Page 91: ... 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 lbs 15 Beginning with the burner assembly reinstall all the components...

Page 92: ...800 526 0288 GF 142 Burner Assembly Inspection and Maintenance Procedure Cont Figure 7 4a Burner Assembly Mounting Details 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each BLOWER PLENUM GAS TRAIN AIR FILTER A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 each AIR FUEL VALVE FILTER IGNITER INJECTOR ASSEMBLY 1 2 NUTS BOLTS 4 each ...

Page 93: ... 16 HEX NUTS 8 each 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each A F VALVE PLENUM AIR FILTER AIR FUEL VALVE GAS TRAIN BLOWER PLENUM GAS INLET PIPE BLOCKED INLET SWITCH BLOWER PROOF SWITCH BLOWER MANUAL SHUT OFF VALVE 81183 UPPER RELEASE GASKET 81166 MIDDLE BURNER GASKET 81186 LOWER RELEASE GASKET BARE BURNER INSTALLED IN HEAT EXCHANGER ASSY IMPORTANT Use ALL THREE gaskets provided even if th...

Page 94: ...e the cover 4 Remove the float from the condensate trap 5 Remove the O ring and orifice gaskets from the trap AERCO recommends that these items be replaced annually 6 Thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thoroughly cleaned replace the trap 7 After the above items have been inspected and thoroughly cleaned replace the O ring 84017 and ...

Page 95: ...ing straight up This will disengage the shroud from the four 4 pins in the side panels 3 Refer to Figure 7 7 and locate the air filter attached to the air fuel valve inlet 4 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 5 The filter may be cleaned in hot soapy water to remove oil and dirt T...

Page 96: ...ontrols 2 Disconnect AC power from the unit 3 Close the water supply and return valves to isolate boiler 4 Close external gas supply valve 5 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 1 Review installati...

Page 97: ...mmunication 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 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Ind...

Page 98: ...Benchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE Page 98 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This page left intentionally blank ...

Page 99: ...cessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 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 6 Turn off unit and check the continuity of the Blocked Inlet switch If there is an erratic resi...

Page 100: ...leading up to the combustion blower for signs of blockage 5 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 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 2 Blocked Blower...

Page 101: ... Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Check signal at source to ensure it is isolated 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 Worn Flame ...

Page 102: ...burner 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 using procedures in Chapter 4 4 Remove the burner and inspect for any carbon...

Page 103: ...e 5 Unit setpoint is greater than Over Temperature Switch setpoint 6 System flow rate changes are occurring faster than units 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 Appendix D If the settings have been changed record the current readings then reset them to the default values 3 Using ...

Page 104: ...ct 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 not replace IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 2 Defective ignition swit...

Page 105: ... 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 6 0 W C and 14 W C For DBB gas trains ensure it is between 6 5 W C and 14 W C see section 4 3 2 Measure gas pressure at the low gas pressure switch If it is greater than 4 7 W C for both BMK 1500 and BMK 2000 measure continuity across the switch and replace if...

Page 106: ...tive purge switch 2 No voltage present at switch 3 Switch wired incorrectly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 1 If the air fuel valve does rotate check 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 ...

Page 107: ...heck control signal type set in Configuration Menu RESIDUAL FLAME 1 Defective Flame Detector 2 SSOV not fully closed 1 Replace Flame Detector 2 Check open close indicator window of Safety Shut Off Valve SSOV and ensure that the SSOV is fully closed If not fully closed replace the valve and or actuator Close the 2 Gas Shut Off Valve downstream of SSOV Figure 2 7 Install a manometer or gauge at the ...

Page 108: ...lectrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator 4 Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE 1 Air Fuel Valve out of calibration 2 Air Fuel Valve unplugged 3 Loose wiring connection to the stepper motor 4 Defective Air Fuel Valve step...

Page 109: ...re 8 1 and inspect Gas Injector to ensure it is not clogged or damaged 2 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 Ori...

Page 110: ...8 1 Igniter Injector Flame Detector Mounting Details Figure 8 2 SSOV Actuator with Gas Pressure Adjustment BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw DAMPING ORIFICE STAGED IGNITION SOLENOID FLAME DETECTOR GASKET FLAME OBSER VATION PORT INJECTOR IGNITOR ASSY WITH INDEXING CLOCKING WASHERS 0 3 as needed O2 SENSOR WASHER BURNER PLATE FLANGE BLOWER PLENUM ...

Page 111: ...he putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it 9 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote machine bring up the PuTTY a...

Page 112: ...e 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 Runni...

Page 113: ...600 Default o 19 2K Data Format The program must be set for o 8 data bits o 1 stop bit o no parity o either Xon Xoff or No flow control 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS 232 communication is accomplished as follows Menu Processing Utilizing Rs 232 Communication 1 Start the emulator software program and e...

Page 114: ...Diagnostic Menu 8 To change a value or setting for a displayed menu option proceed as follows d Enter C followed by the number to the right of the displayed option to be changed and then press Rtn e Enter the desired value or setting for the option and press Rtn Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning Menus ...

Page 115: ...y 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 maximu...

Page 116: ...s Menu The log interval can vary from once every minute to once every day Table 9 3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN...

Page 117: ...ed 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 ...

Page 118: ...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 secti...

Page 119: ...ielded 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 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 t...

Page 120: ...s at the SHLD terminal in the I O the Box 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 Step 2 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu a...

Page 121: ...er 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 Step 2 Direct Wired Outdoor Sensor 1 On the MASTER Unit Connect the Outdoor Temperature Sensor AERCO PN 123525 to the OUT and COM terminals in the I O Box NOTES...

Page 122: ...and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Outdoor Reset 6 Go to the Head Temp Source item and select FFWD Temp 7 Go to the BST Outdoor Sens item and select Enabled 8 Go to the Outdoor Temp Source item and select Outdoor T...

Page 123: ...st 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 Step 2 Modbus Outdoor Sensor Wiring 1 If you have not already done so when installing the Modbus Header Sensor use Shielded pair 18 22 AWG cabl...

Page 124: ...Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Outdoor Reset 6 Go to the Head Temp Source item and select Network 7 Go to the Header Temp Addr item and enter the Modbus Address 240 8 Go to the Header Temp Point item and enter the Modbus Point 14 9 Go to the BST Outdoor Sens item and select Enabled 10 Go...

Page 125: ...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 Step 2 Direct Wired 0 20ma or 4 20ma Wiring 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master Unit s I O Box NOTE Shielded pair 18 22 AWG cable is recommended for this connection Polarity must be observed The ground f...

Page 126: ...r 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 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 ...

Page 127: ...cable connect the Modbus Header Temperature Sensor AERCO PN 24410 to pins 2 and 3 of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet downstream of the LAST boi...

Page 128: ... now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Remote Setpoint 6 Go to the BST Remote Signal and select either 4 20ma or 0 20ma 7 Go to the Head Temp Source item and select Network 8 Go to the Header Temp Addr item and enter the Modbus Address 240 9 Go to the Header T...

Page 129: ...the shield is at the SHLD terminal in the I O the Box 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 Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD D...

Page 130: ...chmark 1500 2000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Page 130 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 131: ...ndix F Inlet Water Temp Displays the inlet water temperature in ºF or ºC Default is ºF 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 ºF default or ºC only if outdoor sensor is installed and enabled Valve Position In Desired input valve position...

Page 132: ...unications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The COMM LED will light during the upload Unit A...

Page 133: ...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 s...

Page 134: ...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 permi...

Page 135: ...utlet 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 v...

Page 136: ...al Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 1 0 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output WARMUP The feature embodied in the next three menu items...

Page 137: ...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 cycle during startup The dura...

Page 138: ...ILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F 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 The High Water Temperature Limit Switch is open IGN BO...

Page 139: ...sition 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 during standby SSOV FAULT...

Page 140: ...mark 1500 2000 Boilers APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 140 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 141: ...alco 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 15 2 17 2 20 2 23 2 25 2 27...

Page 142: ...mark 1500 2000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 142 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 143: ...Setpt 130 F Unit Type BMK Boiler LN Unit Size 1500 MBH or 2000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bldg Ref Temp If Boiler Mode Outdoor Reset 70 F Reset Ratio If Boiler Mode Outdoor Reset 1 2 Outdoor Sensor Disabled System Start Tmp If Outdoor Sensor Enabled 60 F Setpt Lo Limit 60 F Setpt Hi Limit 19...

Page 144: ...13 OMM 0097_0D Ph 800 526 0288 GF 142 Appendix D Boiler Default Settings MENU OPTION FACTORY DEFAULT Configuration Menu Cont Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min ...

Page 145: ...dition and check for 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 Check for leakage in accordance with the SSOV manufacturer s Siemens recommendations Flame failure Weekly Operator Close manual gas shutoff valve and check safety shutdown See sectio...

Page 146: ...chmark 1500 2000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING Page 146 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 147: ... 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 F 2 Header Temperature for a Building Reference Temperature of 60F 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 50F 66 68 70 72 74 76 78...

Page 148: ...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 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 76 78 80 82 84 86 88 90 9...

Page 149: ...19 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 F 6 Header Temperature for a Building Reference Temperature of 80F 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 86 87 88 89 90 91 92 70...

Page 150: ... 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 123 134 145 156 167 178 ...

Page 151: ...APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 151 of 188 GF 142 Ph 800 526 0288 Appendix G DIMENSIONAL AND CLEARANCE DRAWINGS Drawing Number AP A 936 rev A ...

Page 152: ...mark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS Page 152 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Drawing Number AP A 995 rev A ...

Page 153: ...mark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 188 GF 142 Ph 800 526 0288 Drawing Number AP A 898 rev C ...

Page 154: ...ark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS Page 154 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 155: ...1183 BURNER RELEASE GASKET 51 1 63104 I O INTERLOCK HARNESS 14 1 43090 AIR FUEL VALVE PLENUM 52 1 63090 HARNESS ASSY TEMP LIM CONT PWR 15 1 24220 3 AIR FUEL VALVE ASSY BMK 1500 53 1 63150 HARNESS FLAME ROD 1 24220 10 AIR FUEL VALVE ASSY BMK 2000 54 1 33170 MOUNTING PANEL 55 1 124324 GROUND BAR HOSES INSULATION 56 1 63156 POWER CABLE 24V SEQUENCE VALVE 16 1 97005 9 FLEX GAS TUBE 48 57 1 63103 SHELL...

Page 156: ... 69087 3 58088 W150 150 PSI KIT WATTS 92023 14 69087 4 58088 W160 160 PSI KIT KUNKLE 92023 15 69087 4 Benchmark 1500 2000 Kits Available Part Description 24311 4 AIR FUEL VALVE KIT BMK 2000 24311 3 AIR FUEL VALVE KIT BMK 1500 24356 1 FLAME DETECTOR KIT 58023 IGNITOR INJECTOR REPLACEMENT KIT Benchmark 1500 2000 Part List Continued Item Qty Part Description Item Qty Part Description SHEET METAL PANE...

Page 157: ...T DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 188 GF 142 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 3 of 7 ...

Page 158: ... Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Benchmark 1500 2000 Burner Air Fuel Valve Assembly P N 24378 24388 See full part lists below AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 4 of 7 ...

Page 159: ...age 159 of 188 GF 142 Ph 800 526 0288 Benchmark 1500 2000 Standard FM Gas Train P N 22188 See full part lists below Benchmark 1500 2000 Double Block Bleed Gas Train P N 22199 See full part lists below AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 5 of 7 ...

Page 160: ... DRAWINGS Page 160 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 76 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 6 of 7 ...

Page 161: ...O International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 188 GF 142 Ph 800 526 0288 Power I O Box P N 24386 97 29 54 31 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 02 01 2014 Whole Boiler 29313 1 29337 1 Sheet 7 of 7 PARTIAL FRONT VIEW ...

Page 162: ...PPLE 1 1 2 NPT X 8 00 LG 8 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 25 2 9 323 ELBOW 90 DEGREE 1 1 2 9 3 92077 1 4 NPT MXF BRASS BALL VALVE 26 1 124150 VALVE SSOV 1 1 2 NPT 10 3 9 22 PIPE PLUG 1 4 NPT STEEL 27 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 11 1 99017 SNUBBER PRESSURE 1 4 28 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 12 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 29 1 93382 2 NPT CAP 13 2 123536 BUS...

Page 163: ...1 63109 GAS TRAIN HARNESS BMK 3000 35 1 124024 HARNESS WIRING IRI 12 1 124862 RESISTOR ASSY 36 2 95029 FLANGE SSOV 1 1 2 NPT 13 3 93035 ELBOW STREET 1 4 NPT 37 2 123533 NIPPLE CLOSE 1 8 14 1 9 420 TEE REDUCING 1 1 2 X 1 2 X 1 1 2 38 2 93445 COUPLING REDUCING 1 4 x 1 8 NPT BLK MI 15 1 94060 3 NIPPLE 1 1 2 NPT X 3 00 LG 39 1 93290 TEE MXFXF BLACK IRON 1 4 NPT 16 2 94060 6 NIPPLE 1 1 2 NPT X 6 00 LG ...

Page 164: ...X H PART DRAWINGS Page 164 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 DBB Gas Train 10 31 2013 22199 rev A Sheet 2 of 2 ...

Page 165: ... GASKET BLOWER 23 1 81048 GASKET FLAME ROD LOW NOX 6 1 43095 BLOWER PLENUM 24 1 66020 FLAME DETECTOR 7 10 55025 BOLT LOCKING 1 4 20 X 1 00 LG 25 1 59104 OBSERVATION PORT 8 1 59138 FILTER AIR 6 26 1 81183 RELEASE GASKET 9 5 9 21 PLUG HEX HD 1 8 NPT 27 1 24277 STAGED IGNITION ASSY 10 2 123535 TEE 1 8 NPT 28 1 81184 GASKET BLOWER 11 1 124008 NIPPLE 1 8 NPT X 3 00 LG 29 2 123626 1 4 BOLT SIZE FLAT WAS...

Page 166: ...tional Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Burner Assembly 10 18 2013 24378 24388 rev A Sheet 2 of 1 24 20 25 21 27 5 15 16 26 19 27 28 7 9 9 10 13 11 14 17 18 22 23 30 29 31 32 12 2 33 ...

Page 167: ...0 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 167 of 188 GF 142 Ph 800 526 0288 Appendix I WIRING DIAGRAMS Drawing Number 68050 rev B page 1 of 2 ...

Page 168: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 168 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This page intentionally blank ...

Page 169: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 188 GF 142 Ph 800 526 0288 Drawing Number 68050 rev B page 2 of 2 ...

Page 170: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 170 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This page intentionally blank ...

Page 171: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 188 GF 142 Ph 800 526 0288 Drawing Number 68071 rev B page 1 of 2 ...

Page 172: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 172 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This page intentionally blank ...

Page 173: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 188 GF 142 Ph 800 526 0288 Drawing Number 68071 rev B page 2 of 2 ...

Page 174: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 174 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This Page Is Intentionally Blank ...

Page 175: ... 1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 188 GF 142 Ph 800 526 0288 Appendix J PIPING DRAWINGS Drawing Number SD A 989 rev A ...

Page 176: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 176 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Drawing Number SD A 990 rev A ...

Page 177: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 188 GF 142 Ph 800 526 0288 Drawing Number SD A 991 rev A ...

Page 178: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 178 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Drawing Number SD A 992 rev A ...

Page 179: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 188 GF 142 Ph 800 526 0288 Drawing Number SD A 993 rev A ...

Page 180: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 180 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 Drawing Number SD A 994 rev A ...

Page 181: ...NT FACE PLATE BENCHMARK P N 124949 FISH PAPER INSULATOR P N 124960 ENCLOSURE P N 124951 V F D DISPLAY MODULE P N 124527 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW WATER CUTOFF BOARD P N 124363 CONNECTOR BOARD P N 124366 IGNITION STEPPER BOARD P N 124361 POWER SUPPLY BOARD P N 124362 GREEN LED P N 124948 ROCKER SWITCH P N 124947 PUSH BUTTON SWITCHES P N 124954 BENCHMARK CONTROL PANEL EXPLODE...

Page 182: ...97_0D Ph 800 526 0288 GF 142 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 K 2 Benchmark Control Panel Rear View ...

Page 183: ... Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of IRI gas train models 69005 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset 123552 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 13 N...

Page 184: ...Benchmark 1500 2000 Boilers APPENDIX L RECOMMENDED SPARES Page 184 of 188 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0D Ph 800 526 0288 GF 142 This page left intentionally blank ...

Page 185: ...Benchmark 1500 2000 Boilers OMM 0097_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 187 of 188 GF 142 Ph 800 526 0288 NOTES ...

Page 186: ...format updated Warranty to version 11 22 13 Curtis Harvey 03 20 2014 Rev D PIR 780 replaced mechanical latch with magnetic PIR 934 14 Corrected labels of Blower Proof and Blocked Inlet switches in diagrams in chapter 7 PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Valve Installation addition of section 3 9 _BST Menu addition of Chapter 10 Boiler Sequencing Tec...

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