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Benchmark 2.0 LN Installation, Operation & Maintenance Manual

CHAPTER 2 – INSTALLATION

OMM-0046_0J

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

Page

168

GF-123

Ph.: 800-526-0288

06/18/2015

Diagram 2-1b: Schematic – System Pump Start using a Separate Contact Relay

Figure 2-12: Identifying the Presence of BMK Pump Relay Option 69102

Summary of Contents for Benchmark 2.0 LN

Page 1: ...r Blauvelt NY 10913 Page 1 of 168 GF 123 Ph 800 526 0288 06 18 2015 USER MANUAL Installation Operation and Maintenance Natural Gas Fired Modulating Condensing Forced Draft Hot Water Boiler 2 000 000 BTU H Input Applicable to Serial Numbers G 12 0800 and above Latest Update DRAFT Benchmark 2 0LN Low NOx Boiler ...

Page 2: ...ormation 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: ...Requirements 23 2 9 MODES OF OPERATION AND FIELD CONTROL WIRING 24 2 9 1 Constant Setpoint Mode 25 2 9 2 Indoor Outdoor Reset Mode 25 2 9 3 Boiler Management System Mode 25 2 9 4 Remote Setpoint and Direct Drive Modes 25 2 9 5 Combination Mode 26 2 10 I O BOX CONNECTIONS 26 2 10 1 Outdoor Sensor In 1 27 2 10 2 Air temp Sensor 2 27 2 10 3 Analog In 3 27 2 10 4 B M S PWM IN 4 28 2 10 5 Shield 5 28 2...

Page 4: ...63 5 1 INTRODUCTION 63 5 2 INDOOR OUTDOOR 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...

Page 5: ...OUT SPECIFIC FAULT MESSAGES 104 CHAPTER 9 RS232 COMMUNICATION 107 9 1 INTRODUCTION 107 9 1 1 Aquiring the PuTTY Application 107 9 1 2 Logging on to a Remote Machine Using PuTTY 107 9 1 3 Running a Command on a Remote Machine Using PuTTY 108 9 2 RS232 COMMUNICATION SETUP 109 9 3 MENU PROCESSING UTILIZING RS232 COMMUNICATION 109 9 4 DATA LOGGING 110 9 4 1 Fault Log 110 9 4 2 Operation Time Log 110 9...

Page 6: ...ark 2 0 LN Installation Operation Maintenance Manual Page 6 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 7: ...om 100 000 BTU hr to 2 000 000 BTU hr The output of the boiler is a function of the unit s firing rate and return water temperature Output ranges from 99 000 BTU hr to 1 933 000 BTU hr depending on operating conditions When installed and operated on natural gas in accordance with this Instruction Manual the Benchmark 2 0LN Boiler complies with the NOx emission standards outlined in South Coast Air...

Page 8: ...2 0 LN Installation Operation Maintenance Manual FORWARD Page 8 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 9: ...liances and Equipment CSA B149 1 and applicable Provincial regulations for the class which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made 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 f...

Page 10: ...iping must be rinsed thoroughly with clean water after leak checks have been completed CAUTION DO NOT use this boiler if any part has been under water Call a qualified service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the manual gas shutoff valve Figure 1 1 located external to the unit...

Page 11: ...side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirement...

Page 12: ...lly vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the mos...

Page 13: ...d by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled equipment and all the venting instructions parts lists and or design instructions for the venting system shall remain with the appliance or equipment at the completion of the...

Page 14: ...tallation Operation Maintenance Manual CHAPTER 1 SAFETY PRECAUTIONS Page 14 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page is intentionally blank ...

Page 15: ...do not sign for the shipment 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 inspect...

Page 16: ...ances for service as shown in Figure 2 1 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 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...

Page 17: ...ix F for anchor locations Two lifting tabs are provided at the top of the heat exchanger Figure 2 2 shows the location of the tab on the top left side The second tab is located on the top right side of the heat exchanger USE THESE TWO TABS TO LIFT AND MOVE THE UNIT Remove the top panel from the unit to provide access to the lifting tabs Remove the four 4 lag screws securing the unit to the shippin...

Page 18: ...ts must also be taken into consideration All piping must include ample provisions for expansion If installing a Combination Control Panel CCP system it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location Refer to Chapter 5 for information on Combination Mode Boilers 2 5 SUPPLY AND RETURN PIPING The Benchmark 2 0LN Boiler utilizes 4 150 fl...

Page 19: ... VALVE REAR VIEW Figure 2 3 Supply and Return Locations 2 6 CONDENSATE DRAIN AND PIPING The Benchmark 2 0LN Boiler is designed to condense water vapor from the flue products Therefore the installation must have provisions for suitable condensate drainage or collection The condensate drain pipe located on the exhaust manifold Figure 2 4 must be connected to a condensate trap which is packed separat...

Page 20: ... 5 must be level with or lower than the exhaust manifold drain port The condensate trap must be supported to ensure that its base is level horizontal The trap must be removable for routine maintenance AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port While observing the above guidelines connect the condensate trap inlet to the exha...

Page 21: ...gas piping must be arranged so that it does not interfere with removal of any covers inhibit service maintenance or restrict access between the unit and walls or another unit A 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 ins...

Page 22: ... 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 boiler 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 Figure 2 6 The gas supply regulator must b...

Page 23: ... be installed so that it does not interfere with the removal of any unit covers inhibit service maintenance or prevent access between the unit and walls or another unit UPPER RIGHT CORNER OF FRONT PANEL TERMINAL BLOCK Figure 2 7 AC Input Terminal Block Location 2 8 1 Electrical Power Requirements The AERCO Benchmark 2 0LN Boiler accepts 120 VAC single phase 60 Hz 20A The Power Box contains a termi...

Page 24: ...ts intended mode some additional field wiring may be required to complete the installation This wiring is typically connected to the Input Output I O Box located on the lower portion of the unit front panel Figure 2 9 behind the removable front door To access the I O Box terminal strips shown in Figure 2 10 loosen the four cover screws and remove the cover All field wiring is installed from the re...

Page 25: ...The BMS Mode can utilize either pulse width modulation PWM signaling or RS485 Modbus signaling For PWM signaling connections are made from the AERCO Boiler Management System to the B M S PWM IN terminals on the I O Box terminal strip For RS485 Modus signaling connections are made from the BMS BMS II ACS to the RS485 COMM terminals on the I O Box terminal strip Polarity must be maintained and the s...

Page 26: ...tions and the RS 485 Comm terminals in the I O box The wiring must be accomplished using twisted shielded pair wire from 18 to 22 AWG Polarity must be maintained For further instructions and wiring diagrams refer to the GF 108 Boiler Management System Operations Guide and the CCP 1 data sheet BMS 168 applications GF 131 and TAG 0050 ACS applications Figure 2 10 I O Box Terminal Locations and Funct...

Page 27: ...r input to the Air Fuel Valve This temperature reading is one of the components used to calculate the rotational speed of the blower used in the combustion Calibration process Chapter 4 The AIR TEMP SENSOR terminals can be used to add an additional temperature sensor for monitoring purposes This input is always enabled and is a view only input that can be seen in the Operating Menu The sensor must...

Page 28: ...al communication between the unit and an external Master such as a Boiler Management System BMS AERCO Control System ACS Energy Management System EMS Building Automation System BAS or other suitable device 2 10 8 TxD RxD 8 These terminals provide a parallel connection to the connector on the C More Controller front panel for connecting a computer or laptop 2 10 9 VFD Blower 9 These terminals provi...

Page 29: ...2 Fault Relay 13 The fault relay is a single pole double throw SPDT relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed The fault relay connections are shown in Figure 2 10 2 10 13 Auxilia...

Page 30: ...vity of the equipment The AERCO Benchmark 2 0LN Boiler is UL listed for 100 sealed combustion It can also be installed using room air provided there is an adequate supply See para 2 13 3 for more information concerning sealed combustion air If the sealed combustion air option is not being used an inlet screen will be attached at the air inlet on the top of the unit The more common methods of suppl...

Page 31: ...minimum 8 inch diameter connection at the unit In order to implement this option you must remove the internal flex hose between the air inlet iris and the air fuel valve and install an air filter AERCO part number 59138 on the air fuel valve s inlet as shown in the right hand image in Figure 2 11 Once the hose has been replaced with the air filter you must now repeat the combustion calibration pro...

Page 32: ...er for dust accumulation and replace it when the accumulation becomes noticeable 2 13 BENCHMARK PUMP RELAY OPTION An optional Benchmark 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 boile...

Page 33: ...INSTALLATION OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 33 of 168 GF 123 Ph 800 526 0288 06 18 2015 Diagram 2 1b Schematic System Pump Start using a Separate Contact Relay Figure 2 12 Identifying the Presence of BMK Pump Relay Option 69102 ...

Page 34: ...Installation Operation Maintenance Manual CHAPTER 2 INSTALLATION Page 34 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 35: ...ll of the installation procedures in Chapter 2 must be completed before attempting to start the unit WARNING 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 INJURY TO PERSO...

Page 36: ...n Maintenance Manual CHAPTER 3 OPERATION Page 36 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 1 2 3 4 5 6 7 8 9 10 11 12 VALVE POSITION Figure 3 1 Control Panel Front View ...

Page 37: ... 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 when a boile...

Page 38: ... 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 changed ed...

Page 39: ... 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 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 th...

Page 40: ...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 displayed ...

Page 41: ...nter the unit password 159 which is required to change the menu options To prevent unauthorized use the password will time out after 1 hour Therefore the correct password must be reentered when required In addition to permitting password entries the Setup Menu is also used to enter date and time units of temperature measurements and entries required for external communication and control of the un...

Page 42: ...ith the requirements specified for each individual order Therefore under normal operating conditions no changes will be required 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 Wtr Heater LN Innovation W...

Page 43: ...tart On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown Analog Output See CAUTION at end of Table 3 4 Off Setpoint Outlet Temp Valve Position 4 20 mA Valve Position 0 10V Valve Position 0 10V Low Fire Timer 2 sec 600 sec 2 sec Setpt Limiting Enabled or Disabled Disabled Setpt Limit Band 0 F 10 F 5 F Network Timeout 5 Sec 999 Sec 30 Sec HI DB Setpt EN 0 100 30 Demand Offse...

Page 44: ... 1 240 20 Reset Defaults Yes No Are You Sure No 3 8 COMBUSTION CAL MENU The Combustion Cal Calibration Menu items are used to vary the speed of the unit s blower motor based on air temperature and air density at prescribed Air Fuel Valve positions open This is accomplished by providing a DC drive voltage to the motor which adjusts the rotational speed of the blower to maximize combustion efficienc...

Page 45: ... to ensure they are closed These switches include Safety Shut Off Valve Proof of Closure POC switch Low Water Level 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 fo...

Page 46: ... POSITION bargraph will show 100 4 Next the blower proof switch on the Air Fuel Valve Figure 3 5 closes The display will show Purging and indicate the elapsed time of the purge cycle in seconds 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 and closes the ignition switch ...

Page 47: ...ER 3 OPERATION OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 47 of 168 GF 123 Ph 800 526 0288 06 18 2015 100 DETAIL A TO BLOWER AIR IN DIAL DETAIL A STEPPER MOTOR Figure 3 4 Air Fuel Valve In Purge Position Figure 3 5 Blower Proof Switch ...

Page 48: ...e unit firing properly it will be controlled by the temperature controller circuitry The boiler s VALVE POSITION will be continuously displayed on the front panel bargraph Once the demand for heat has been satisfied the Control Box will turn off the dual SSOV gas valves The blower relay will be deactivated and the Air Fuel Valve will be closed Standby will be displayed 3 10 START STOP LEVELS The s...

Page 49: ... 0288 06 18 2015 Table 3 7 Relationship Between Air Fuel Valve Position and Energy Input For Unit Running On Natural Gas Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 0 0 0 10 0 0 18 Stop Level 100 000 5 0 20 134 000 7 30 349 000 17 40 631 000 32 50 893 000 45 60 1 150 000 58 70 1 410 000 71 80 1 610 000 81 90 1 830000 92 100 2 000 000 100 ...

Page 50: ...N Installation Operation Maintenance Manual CHAPTER 3 OPERATION Page 50 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 51: ...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 Sheets included wi...

Page 52: ...bustion 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 a 1 4 plug must be removed from the port in order to install the manometer Figure 4 1 Manometer Installation Location Install the 16 W C manometer s as described in the following steps 1 Turn off the main gas supply upstream of...

Page 53: ... the port for the combustion analyzer probe as follows 1 Remove the plug from the probe port on the left or right side of the exhaust manifold 2 If necessary adjust the stop on the combustion analyzer probe so that it will extend mid way into the flue gas flow DO NOT install the probe at this time EXHAUST MANIFOLD 1 2 NPT CONDENSATE DRAIN CONNECTION BOILER RETURN ANALYZER PROBE PORT Figure 4 2 Ana...

Page 54: ...al 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 rate in Also the MANUAL LED will light 6 Adjust the air fuel valve position to 0 by pressing the arrow key 7 Ensure that the leak detection ball valve down stream of the SSOV is o...

Page 55: ...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 Monoxide 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 14 If necessary adjust the iris air damper shown in Figure 4 5 until the oxygen level is within the range specified in Table 4 1 15 Once the oxygen level is wit...

Page 56: ...own Table 4 2 Combustion Oxygen Levels for a 80 Air Fuel Valve Position Oxygen 0 2 Carbon Monoxide NOx 5 2 100 ppm 30 ppm 24 If the oxygen level is not within the specified range adjust the level using the and arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the arrow key increases the oxygen level and pressing the down arrow key decreases the...

Page 57: ...lve position should be as shown below Also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown Table 4 4 Combustion Oxygen Levels for a 45 Air Fuel Valve Position Oxygen 0 2 Carbon Monoxide NOx 7 2 50 ppm 30 ppm 40 If the oxygen level is not within the specified range adjust the level using the and arrow keys This will adjust the output voltage to the ...

Page 58: ...gs do not exceed the values shown Table 4 6 Combustion Oxygen Levels for a 18 Air Fuel Valve Position Oxygen 0 2 Carbon Monoxide NOx 8 0 50 ppm 30 ppm 56 If the oxygen level is not within the specified range adjust the level using the and arrow keys This will adjust the output voltage to the blower motor as indicated on the display Pressing the arrow key increases the oxygen level and pressing the...

Page 59: ...ust be manually reset by pressing the manual reset button shown in Figurer 4 6 before the boiler can be restarted The rotary dial temperature limit switch is manually adjustable from 32ºF 212ºF 0ºC 100ºC 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 digit...

Page 60: ...ature 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 position 2 Press the SET button on the Digital Alarm Switch SP will appear in the display 3 Press the SET button again The current over temperature limit value stored in memor...

Page 61: ...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 Press SET to enter the value and exit to the text parameter 11 To exit the programming mode press the SET and buttons simultaneously or simply wait one minute and the display will automatically exit the...

Page 62: ...stallation Operation Maintenance Manual CHAPTER 4 INITIAL START UP Page 62 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

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

Page 64: ...gin to flash 9 Use the and arrow keys to select the Reset Ratio determined in step 5 10 Press ENTER to save the change 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 po...

Page 65: ...anual GF 112 or 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 setting is selected for RS485 Modbus...

Page 66: ...an 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 while a 20 mA 5V signal is equal to a 100 valve position ...

Page 67: ...ssary In this mode the REMOTE LED will light when the signal is present To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Direct Drive mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 6 BOILER MANAGEMENT SYSTEM BMS NOTE BMS Model 168 can utilize either pul...

Page 68: ...tup This mode of operation is factory preset and the AERCO BMS BMS II ACS controls the firing rate air fuel valve open position There are no setup instructions for each individual unit To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the BMS mode simply press the AUTO MAN switch The REMOTE LED will again light a...

Page 69: ...el the ACS Relay Panel optional depending on application and the RS485 Comm 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 For a complete CCP system wiring diagram see the AERCO CCP 1 literature BMS 168 applications and TAG 0050 ACS 5 7 2 Combination Control System Setup and Startup ...

Page 70: ...stallation Operation Maintenance Manual CHAPTER 5 MODE OF OPERATION Page 70 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 71: ...te 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 Figure 6 1 a...

Page 72: ...the leak detection ball valve shown in Figure 6 1 2 Install a 0 16 W C manometer or W C gauge where the 1 4 plug was removed 3 Slowly open the leak detection ball valve 4 Start the unit in Manual mode at a valve position firing rate between 25 and 30 5 Slowly increase the gas pressure using the adjustment screw on the SSOV see Figure 4 3 6 The unit should shut down and display a HIGH GAS PRESSURE ...

Page 73: ...rain and pressure relief valve used in draining the unit 8 Open the water shut off valve in the return piping to the unit 9 Open the water supply shut off valve to the unit to refill 10 After the shell is full press the LOW WATER LEVEL RESET button to reset the low water cutoff 11 Press the CLEAR button to reset the FAULT LED and clear the displayed error message 12 Set the ON OFF switch to the ON...

Page 74: ...Limit Switch Setting 6 6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock Terminal connections for these circuits are located in the I O Box Figure 2 9 and are labeled REMOTE INTL K IN and DELAYED INTL K IN These circuits can shut down the unit in the event that an interlock is opened These interlocks are shipped from the factory ju...

Page 75: ... proving switch of an external device disconnect one of the wires leading to the proving switch 4 The unit should shut down and display a DELAYED INTERLOCK OPEN fault message The FAULT LED should be flashing 5 Reconnect the wire or jumper removed in step 3 to restore the interlock 6 Press the CLEAR button to reset the fault 7 The unit should start 6 7 FLAME FAULT TESTS Flame faults can occur durin...

Page 76: ...ly closed in step 8 12 Press the CLEAR button The unit should restart and fire SSOV BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR INLET AIR FUEL VALVE MANUAL GAS SHUT OFF VALVE PARTIAL LEFT SIDE VIEW Figure 6 3 Manual Gas Shut Off Valve Location 6 8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6 3 1 Disable the blower outpu...

Page 77: ...RING RUN 8 Go to the Configuration Menu Analog Output item and select VALVE POSITION 0 10v 9 Press the CLEAR button The unit should restart 10 Next check the Blocked Inlet Switch by first noting the current position of the Iris Air Damper and then closing the Damper to position 8 11 The unit should shut down and again display AIRFLOW FAULT DURING RUN 12 Return the Iris Air Damper to its previous s...

Page 78: ...otating the cover counterclockwise to unlock it and then lift up see Figure 6 5 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 it s start sequence then shut down and display PRG SWITCH OPEN DURING PURGE 6 Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart 6 11 IGNITION SWITCH ...

Page 79: ...gin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION 7 Replace the wire on the Ignition Switch and press the CLEAR button The unit should restart AIR FUEL VALVE COVER ROTATE CCW TO REMOVE Figure 6 5 Air Fuel Valve Cover Location 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...

Page 80: ...EVICE TESTING Page 80 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 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 81: ...ite Ignition Burkert valve Part No 58131 06 NOTE The 24 Month Waterside Fireside Inspection Kit also includes the items contained in the Annual Maintenance Kit Therefore only Kit Part No 58025 06 or 58131 06 is required for the waterside fireside inspection Appendix K contains recommended spare parts lists for maintenance of the boiler WARNING TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THA...

Page 82: ... may be hot therefore care should be exercised to avoid burns It is easier to remove the igniter 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 2 0LN Burner Assembly Shown Removed from Boiler To inspect replace the igniter 1 Set the ON OFF switch on the control panel...

Page 83: ...burner plate using a 1 open end wrench 6 Check the igniter for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter 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 combust...

Page 84: ...he top of the unit see Figures 7 1 and 7 2 The flame detector may be hot Allow the unit to cool sufficiently before removing the flame detector To inspect or replace the flame detector 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remove the side and top panels from the unit 3 Disconnect the flame detector lead wire 4 Remove the two 2 screws s...

Page 85: ...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 24176 is located at the top of the unit s heat exchanger The burner assembly may be hot Therefore allow the unit to cool sufficiently before removing the burner assembly It should be noted that the complete burner assembly also includes the blower and...

Page 86: ... gas injector tube of the igniter to the elbow of the staged ignition assembly see Figure 7 2 Disconnect the staged ignition assembly from the igniter IMPORTANT Prior to removing the igniter note the position of the gas injector tube relative to the burner plate and blower This is necessary to ensure that the igniter injector is reinstalled in the proper orientation when it is reconnected to the s...

Page 87: ... IGNITION ASSEMBLY FLAME DETECTOR BURNER PLATE HEX NUTS WASHERS 6 BLOWER GASKET IGNITOR INJECTOR BURNER BLOWER BURNER GASKET BURNER GASKET Figure 7 5 Burner Assembly Exploded View NOTE The burner assembly is heavy weighing approximately 30 pounds 17 Remove the burner assembly from burner flange by pulling straight up 18 Remove and replace the two 2 burner gaskets NOTE During reassembly apply high ...

Page 88: ...operation To inspect and clean the trap proceed as follows 1 Disconnect the external condensate trap by loosening the union pipe connection between the trap and the exhaust manifold drain pipe 2 Remove the connections on the inlet and outlet sides of the condensate trap shown in Figure 7 6 3 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover 4 Remove the float...

Page 89: ...t down the boiler s operating controls 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 9 PLACING THE 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 ...

Page 90: ... Installation Operation Maintenance Manual CHAPTER 7 MAINTENANCE Page 90 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 91: ... 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 1 Observe the fault messages displayed in the Control Box display 2 Refer to the F...

Page 92: ...allation Operation Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE Page 92 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 93: ...f 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 blocked air in...

Page 94: ...LOW FAULT DURING IGNITION applies for this fault 1 Start the unit If the blower does not run check the blower solid state relay for input and output voltage If the relay is okay check the blower 2 Start the unit If the blower runs check the airflow switch for continuity Replace the switch if there is no continuity 3 Remove the air flow switch and inspect for signs of blockage clean or replace as n...

Page 95: ...leading up to the combustion blower for signs of blockage 3 Remove the airflow switch and inspect for signs of blockage clean or replace as necessary 4 Measure the airflow 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 5 Run unit to full fire If the unit rumbles or runs rough ...

Page 96: ...lame detector 3 No spark from Spark Plug 4 Defective Ignition Transformer 5 Defective Ignition Stepper IGST Board 6 Defective SSOV 7 Staged ignition ball valve closed 8 Staged ignition solenoid valve does not open 9 Clogged staged ignition piece 1 Inspect and install retighten Burner Ground Screw 2 Remove and inspect the flame detector for signs of wear Replace if necessary 3 Close the internal ga...

Page 97: ...ibration Adjust as necessary 4 Remove the burner and inspect for any carbon or debris Clean and reinstall 5 Remove blockage in condensate drain HEAT DEMAND FAILURE 1 The Heat Demand Relays on the Ignition Stepper board failed to activate when commanded 2 Relay is activated when not in Demand 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Defec...

Page 98: ...urrent readings then reset them to the default values 3 Using the resistance charts in the Appendix C Measure the resistance of Shell sensor and BTU sensor at a known water temperature 4 If unit is in Manual Mode switch to Auto Mode 5 Check setpoint of unit and setpoint of Temperature Switch Ensure that the temperature switch is set higher than the unit s setpoint 6 Check the BMS ACS for changes t...

Page 99: ...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 not replace IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 2 De...

Page 100: ... Incorrect supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the supply gas regulator with the unit firing Refer to paragraph 2 7 1 to ensure that the gas pressure is correct for the type of fuel and gas train being used 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 replace if ne...

Page 101: ...correctly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 1 If the air fuel valve does rotate check the 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 numb...

Page 102: ...place actuator SSOV RELAY FAILURE 1 SSOV relay failed on board 2 Floating Neutral 3 Hot and Neutral reversed at SSOV 1 Press CLEAR button and restart unit If fault persists replace Ignition Stepper IGST 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 mi...

Page 103: ... Board 1 Refer to GF 112 and perform Stepper Test para 6 3 5 to ensure stepper motor rotates properly between the 0 fully closed and 100 fully open positions Verify that the VALVE POSITION bargraph and the dial on the Air Fuel Valve track each other to indicate proper operation If operation is not correct perform the Stepper Feedback Calibration GF 112 paragraph 6 2 1 2 Check that the Air Fuel Val...

Page 104: ...move and inspect Gas Injector to ensure it is not clogged or damaged 3 Close the 2 and the 1 4 Ball Valve downstream of the SSOV Fig 8 1 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 fluct...

Page 105: ...itani Dr Blauvelt NY 10913 Page 105 of 168 GF 123 Ph 800 526 0288 06 18 2015 Figure 8 1 High Gas Pressure Switch Snubber Locations BURNER PLATE BURNER STAGED IGNITION SOLENOID GAS INJECTOR Figure 8 2 Staged Ignition Solenoid Location AIR FUEL VALVE SNUBBE MANUAL SHUT OFF VALVE FLEX GAS LINE to STAGED IGNITION SOLENOID VALVE GAS INLET ...

Page 106: ...anual CHAPTER 8 TROUBLESHOOTING GUIDE Page 106 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT DAMPING ORIFICE Figure 8 3 Damping Orifice Location ...

Page 107: ... PuTTY Application Download the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it 9 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote...

Page 108: ...ticular configuration 9 1 3 Running a Command on a Remote Machine Using PuTTY PuTTY may also be used to run some command residing on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open dep...

Page 109: ...tware program and ensure that the specified 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 Di...

Page 110: ...nication link press L followed by Rtn 9 4 DATA LOGGING During operation the C More Control Panel continuously monitors and logs data associated with operational events faults and sensor readings associated with the boiler 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...

Page 111: ...ed by 0 zero and then press Enter i e S0 Enter To view earlier records in reverse chronological order enter S and press Enter To go back 200 or 700 records enter S200 or S700 etc and press Enter 9 4 3 Sensor Log The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu The log interval can vary from once every minute to once every day ...

Page 112: ...EN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 ...

Page 113: ...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 and enabled Valve P...

Page 114: ...0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set to 2400 4800 9600 or 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...

Page 115: ...t 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 function to ...

Page 116: ...d Default is Disabled Setpt Limit Band When Setpt Limiting is enabled this menu item allows the Setpt Limit Band to be set from 0ºF to 10ºF Default is 5ºF 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 fe...

Page 117: ...utlet Temperature reaches Active Setpoint and remains there for a period of 15 seconds the unit will go into a DEADBAND MODE at which point no Valve Position corrections will be attempted while the Outlet Temperature remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the DE...

Page 118: ...is 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 2 00 Default is 1 00 for boilers 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 the following three m...

Page 119: ...he 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 Allows for setting...

Page 120: ...ion Operation Maintenance Manual APPENDIX A BOILER MENU ITEM DESCRIPTIONS Page 120 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 121: ...te 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 cycle du...

Page 122: ...e 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 Th...

Page 123: ...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 duri...

Page 124: ...on Operation Maintenance Manual APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 124 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 125: ...istance 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 15 2...

Page 126: ...ion Operation Maintenance Manual APPENDIX C SENSOR TEMPERATURE RESISTANCE Page 126 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 127: ...0 120 130 140 150 160 170 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 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...

Page 128: ...9 161 173 185 197 209 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 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 ...

Page 129: ...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 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...

Page 130: ... 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 12...

Page 131: ...uage English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130 F Unit Type BMK Boiler LN Unit Size 2000 MBH 2 0 MBTU 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 Di...

Page 132: ... Continued Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Position 0 10V CAUTION DO NOT Change Low Fire Timer 2 sec Setpt Limiting Disabled 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 Gai...

Page 133: ...0 Oritani Dr Blauvelt NY 10913 Page 133 of 168 GF 123 Ph 800 526 0288 06 18 2015 Table E 1 Boiler Default Settings Continued MENU OPTION FACTORY DEFAULT Combustion Cal CAL Voltage 18 1 00v CAL Voltage 30 2 30v CAL Voltage 45 2 95v CAL Voltage 60 3 60v CAL Voltage 80 5 30v CAL Voltage 100 9 10v SET Valve Position 0 Blower Output 00v ...

Page 134: ...ation Operation Maintenance Manual APPENDIX E BOILER DEFAULT SETTINGS Page 134 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 135: ...EPARATELY IN SHIPMENT JK 092608 INTERNATIONAL INC AERCO NORTHVALE NJ 07647 APPD REV DATE SCALE DWN BY CHKD DATE SIZE REV D CONTROL PANEL DISPLAY 3 4 ELECTRICAL CONDUIT CONNECTION 5 36 23 12 1 4 28 OPTIONAL CONNECTION FOR 8 DIAMETER SEALED COMBUSTION AIR DUCTWORK LIFTING LUGS 79 56 71 7 00 13 1 4 15 7 3 4 12 3 4 23 1 2 2 1 2 1 1 4 7 1 2 18 00 THIS AREA TO BE ACCESSIBLE FOR MAINTENANCE 4 150 FLG D H...

Page 136: ...tion Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS Page 136 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 Drawing Number SD A 767 rev B ...

Page 137: ...ation Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 137 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number SD A 730 rev C ...

Page 138: ...llation Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS Page 138 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 Drawing AP A 842 rev C ...

Page 139: ...ation Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 139 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number AP A 843 rev D ...

Page 140: ...tion Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS Page 140 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 Drawing Number PL A 159 rev G ...

Page 141: ...UAL FUEL STAGED IGNITION ASSY 50 1 161521 THERMOWELL DUAL AQUASTAT BULB 21022 AERLite IGNITOR ASSY 21003 AERLite DUAL FUEL IGNITOR ASSY 8 2 81101 GASKET BURNER 9 65 DIA LN CP 61002 1 LOW GAS PRESSURE SWITCH non Dual Fuel 9 1 46012 BURNER BMK 2 0 LOW NOX 51 1 61002 18 LOW GAS PRESSURE SWITCH Dual Fuel Nat Gas 61002 18 LOW GAS PRESSURE SWITCH Dual Fuel Propane HEAT EXCHANGER 61002 12 HIGH GAS PRESSU...

Page 142: ... PANEL 73 2 49064 TOP RAIL ENCLOSURE 74 1 201233 PANEL MOUNTING BMK 75 1 201113 FRONT PANEL 76 1 201120 FRONT DOOR ASSY 77 2 122620 HANDLE FLUSH PULL SNAP IN 78 1 37019 TOP PANEL 79 2 37002 PANEL SIDE 80 1 74002 LOGO BMK 2 0 LOW NOX OTHER PARTS 81 1 99017 GAS PRESSURE SNUBBER PRESSURE 1 4 NOTES Not shown on drawing 69087 5 30 50 PSI Relief valve setting 69087 6 60 75 100 125 PSI Relief valve setti...

Page 143: ... F PARTS AND DIMENSIONAL DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 143 of 168 GF 123 Ph 800 526 0288 06 18 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2 0 LN Part List 07 11 2013 28073 1 rev G PL A 158 Sheet 3 of 7 ...

Page 144: ...F PARTS AND DIMENSIONAL DRAWINGS Page 144 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 AERCO International Inc Blauvelt NY 10913 Benchmark 2 0 LN Part List 07 11 2013 28073 1 rev G PL A 158 Sheet 4 of 7 ...

Page 145: ... F PARTS AND DIMENSIONAL DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 145 of 168 GF 123 Ph 800 526 0288 06 18 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2 0 LN Part List 07 11 2013 28073 1 rev G PL A 158 Sheet 5 of 7 ...

Page 146: ...F PARTS AND DIMENSIONAL DRAWINGS Page 146 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 AERCO International Inc Blauvelt NY 10913 Benchmark 2 0 LN Part List 07 11 2013 28073 1 rev G PL A 158 Sheet 6 of 7 ...

Page 147: ... F PARTS AND DIMENSIONAL DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 147 of 168 GF 123 Ph 800 526 0288 06 18 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2 0 LN Part List 07 11 2013 28073 1 rev G PL A 158 Sheet 7 of 7 ...

Page 148: ...on Operation Maintenance Manual APPENDIX F PARTS AND DIMENSIONAL DRAWINGS Page 148 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 149: ...Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 149 of 168 GF 123 Ph 800 526 0288 06 18 2015 APPENDIX G PIPING DRAWINGS Drawing Number SD A 870 rev B ...

Page 150: ...nstallation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 150 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 Drawing Number SD A 868 rev B ...

Page 151: ... Installation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 151 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number SD A 869 rev B ...

Page 152: ...nstallation Operation Maintenance Manual APPENDIX G PIPING DRAWINGS Page 152 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 Drawing Number SD A 874 rev C ...

Page 153: ...Installation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 168 GF 123 Ph 800 526 0288 06 18 2015 APPENDIX H WIRING SCHEMATICS ...

Page 154: ...tallation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS Page 154 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This Page Is Intentionally Blank ...

Page 155: ...tenance Manual APPENDIX H WIRING SCHEMATICS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 155 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number 68023 rev G Sheet 1 of 2 WIRING SCHEMATIC BMK 2 0 LN CP 120VAC 60 Hz ...

Page 156: ...allation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS Page 156 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 157: ...tenance Manual APPENDIX H WIRING SCHEMATICS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number 68023 rev G Sheet 2 of 2 WIRING SCHEMATIC BMK 2 0 LN CP 120VAC 60 Hz ...

Page 158: ...allation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS Page 158 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 159: ...llation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 168 GF 123 Ph 800 526 0288 06 18 2015 Drawing Number 68032 rev C Sheet 1 of 2 ...

Page 160: ...allation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS Page 160 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 161: ...N OUT IN IN OUT FAULT RELAY NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK N O C 4 3 5 1 2 NOT USED N C C N O N C RELAY AUX 12 13 14 11 SENSOR EXCIT 12 VDC BMS PWM IN ANALOG IN OXYGEN SENSOR IN FLOW SENSOR IN CO SENSOR IN AUX SENSOR IN SENSOR COMMON IN 1 OUTDOOR AIR SENSOR IN 9 8 7 5 3 4 2 6 10 IN GND 4 1 2 1 2 2 1 3 3 ANALOG OUT 15 16 SHIELD B RS 485 IN A 1 2 4 3 7 8 6 5 9 10 12 11 8 7 6 5 4 3 ...

Page 162: ...allation Operation Maintenance Manual APPENDIX H WIRING SCHEMATICS Page 162 of 168 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 This page left intentionally blank ...

Page 163: ...cators Daily Operator Visual inspection and record readings in operator log Instrument and equipment settings Daily Operator Visual check against factory recommended specifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Tech Verify factory settings Annually Service Tech Check with combustion calibration test equipment See paragraph 7 4 and Chapter 4 Flue ...

Page 164: ...water temperature safety control test Annually Service Tech See paragraph 6 5 Operating controls Annually Operator See paragraph 3 2 Low air flow Monthly Operator See paragraph 6 8 High and low gas pressure interlocks Monthly Operator See paragraphs 6 2 and 6 3 Air Fuel Valve purge position switch Annually Service Tech See paragraph 6 10 Air Fuel Valve ignition position switch Annually Service Tec...

Page 165: ...Manual APPENDIX J BENCHMARK CONTROL PANEL FEATURES OMM 0046_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 168 GF 123 Ph 800 526 0288 06 018 2015 APPENDIX J BENCHMARK CONTROL PANEL FEATURES Figure J 1 Control Panel Exploded View ...

Page 166: ... NY 10913 OMM 0046_0J 06 18 2015 Phone 800 526 0288 GF 123 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 167: ...in 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 124866 Table K 2 Spare Parts Recommended for Maintenance Description Ignition Type Kit Part Number Annual Maintenance Kits Staged Ignition 58025 01 AERLite Ignition 58131 01 24 month Waterside Fireside...

Page 168: ...e Description Changed By 02 25 2013 Rev H Chris Blair 06 18 2015 Rev J PIR 793 Revised wiring diagram in Appendix H updated drawing PL A 159 in Appendix F addition of Time Delay Relay replaced Flame Rod with s n 66020 replaced drawing AP A 843 PIR 934 123 Added new section 2 12 4 Ducted Combustion Air added Direct Spark to Table 7 1 and section 7 2 2 DIR 196 Added AERLight ignition Burkert valve p...

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