Aerco Benchmark 3.0LN Series Installation, Operation & Maintenance Instructions Manual Download Page 39

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4-5

INITIAL START-UP

37. Press the

▼ arrow key until

CAL Voltage

40%

is displayed.

38. Press the

CHANGE

key.

CAL Voltage 40%

will begin to flash.

39. The oxygen level at the 40% valve position

should be as shown below. Also, ensure that
the carbon monoxide (CO) and nitrogen
oxide (NOx) readings do not exceed the
values shown.

Combustion Oxygen Level at

40% Valve Position

Oxygen %

± 0.2

Carbon

Monoxide

NOx

7.8 %

<50 ppm

<20 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  blower  motor  as  indicated  on
the  display.  Pressing  the

▲ arrow key

increases the oxygen level and pressing the

▼ arrow key decreases the oxygen level.

41. Once the oxygen level is within the specified

range at 40%, press the

ENTER

key to store

the selected blower output voltage for the
40% valve position.

42. Press the

▲ arrow key until

SET Valve

Position

appears on the C-MORE display.

43. Press the

CHANGE

key.

SET

Valve Position

will begin to flash.

44. Press the

▼ arrow key until the

SET Valve

Position

reads

30%

, then press the

ENTER

key.

45. Press the

▼ arrow key until

CAL Voltage

30%

is displayed.

46. Press the

CHANGE

key.

CAL Voltage 30%

will begin to flash.

47. The oxygen level at the 30% Valve Position

should be as shown below. Also, ensure that
the carbon monoxide (CO) and nitrogen
oxide (NOx) readings do not exceed the
values shown.

Combustion Oxygen Level at

30% Valve Position

Oxygen %

± 0.2

Carbon

Monoxide

NOx

8.0 %

<50 ppm

<20 ppm

48. 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

▼ arrow key decreases the oxygen level.

49. Once the oxygen level is within the specified

range at 30%, press the

ENTER

key to store

the selected blower output voltage for the
30% valve position.

50. Press the

▲ arrow key until

SET Valve

Position

appears on the C-MORE display.

51. Press the

CHANGE

key.

SET Valve Position

will begin to flash.

52. Press the

▼ arrow key until the

SET Valve

Position

reads

14%

, then press the

ENTER

key.

53. Press the

▼ arrow key until

CAL Voltage

14%

is displayed.

54. Press the

CHANGE

key.

CAL Voltage 14%

will begin to flash.

55. The oxygen level at the 14% Valve Position

should be as shown below. Also, ensure that
the carbon monoxide (CO) and nitrogen
oxide (NOx) readings do not exceed the
values shown.

Combustion Oxygen Level at

14% Valve Position

Oxygen %

± 0.2

Carbon

Monoxide

NOx

8.5 %

<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

▼ arrow key decreases the oxygen level.

57. Once the oxygen level is within the specified

range at 14%, press the

ENTER

key to store

the selected blower output voltage for 14%
Valve Position.

IMPORTANT

Repeat steps 18 through 57 until the
blower output voltage does not require
adjustment when sequencing from 70% to
14%.

58. This completes the natural gas combustion

calibration procedure.

Summary of Contents for Benchmark 3.0LN Series

Page 1: ...0E Applicable for Serial Numbers G 12 0454 and above Installation Operation Maintenance Instructions Benchmark 3 0 Series Gas Fired Low NOx Boiler System Condensing Modulating Forced Draft Hot Water Boiler 3 000 000 BTU H Input Latest Revision October 10 2017 ...

Page 2: ...manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual Nor for incidental or consequential damages occurring in connection with the furnish...

Page 3: ...AERCO BENCHMARK 3 0LN GAS FIRED LOW NOx BOILER Operating Maintenance Instructions FOREWORD A Chapter 1 SAFETY PRECAUTIONS 1 1 Para Subject Page 1 1 Warnings Cautions 1 1 1 2 Emergency Shutdown 1 2 Chapter 2 INSTALLATION 2 1 Para Subject Page 2 9 Modes of Operation and Field Control Wiring 2 7 2 10 I O Box Connections 2 9 2 11 Auxiliary Relay Contacts 2 11 2 12 Flue Gas Vent Installation 2 11 2 13 ...

Page 4: ...5 5 4 Remote Setpoint Mode 5 2 CCS 5 5 Direct Drive Modes 5 3 Chapter 6 SAFETY DEVICE TESTING PROCEDURES 6 1 Para Subject Page 6 1 Testing of Safety Devices 6 1 6 2 Low Gas Pressure Fault Test 6 1 6 3 High Gas Pressure Test 6 2 6 4 Low Water Level Fault Test 6 2 6 5 Water Temperature Fault Test 6 2 6 6 Interlock Tests 6 3 6 7 Flame Fault Test 6 3 Purge Ignition Test Chapter 7 MAINTENANCE REQUIREME...

Page 5: ...DICES App Subject Page App Subject Page A Boiler Menu Item Descriptions A 1 G Piping Drawings G 1 B Startup Status and Fault B 1 H Wiring Schematics H 1 Messages I Recommended Periodic Testing I 1 C Temperature Sensor Resistance C 1 Checklist Chart J Benchmark Control Panel Views J 1 D Indoor Outdoor Reset Ratio D 1 K Recommended Spare Parts K 1 Charts E Boiler Default Settings E 1 F Dimensional a...

Page 6: ...iv ...

Page 7: ...ler is a function of the unit s firing rate and return water temperature Output ranges from 198 000 BTU hr to 2 900 000 BTU hr depending on operating conditions When installed and operated in accordance with this Instruction Manual the Benchmark 3 0 Boiler complies with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 1 Whether used in singular or...

Page 8: ...B ...

Page 9: ...nstaller and kept in a safe place for future reference WARNINGS MUST BE OBSERVED TO PREVENT SERIOUS INJURY WARNING BEFORE ATTEMPTING TO PER FORM ANY MAINTENANCE ON THE UNIT SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT WARNING THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THERE FORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPAC...

Page 10: ...rgency shut off device MANUAL GAS SHUTOFF VALVE VALVE OPEN VALVE CLOSED Figure 1 1 Manual Gas Shutoff Valve IMPORTANT FOR MASSACHUSETTS INSTALLATIONS ONLY Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts Prior to unit operation the c...

Page 11: ...ns shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than o...

Page 12: ...he website phone number or manufacturer s address where the venting system installation instructions can be obtained and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled...

Page 13: ...t indicated by the Tip N Tell indicator The freight carrier should be notified immediately if any damage is detected The following accessories come standard with each unit and are either packed separately within the unit s packing container or are factory installed on the boiler Pressure Temperature Gauge ASME Pressure Relief Valve Condensate Drain Trap Adapter 2 Gas Supply Shutoff Valve When orde...

Page 14: ...nsure proper condensate drainage If anchoring the unit refer to the dimensional drawings in Appendix F for anchor locations A total of 3 lifting tabs are provided at the top of the primary heat exchanger as shown in Figure 2 2 However USE ONLY TABS 1 AND 2 SHOWN IN FIGURE 2 2 TO MOVE THE ENTIRE UNIT Tabs 1 and 3 are used only when removing or replacing the unit s primary heat exchanger Remove the ...

Page 15: ...eat Exchanger Prior to connecting the external gas supply or electrical power to the unit the strap and packing material must be removed from the top of the primary heat exchanger This material is located in the area of the ignitor injector and staged ignition solenoid on the burner assembly This can be easily accomplished by removing the top panel nearest to the front of the unit 2 5 SUPPLY AND R...

Page 16: ...1 I D polypropylene hose to the outlet side of the condensate trap and route it to a nearby floor drain VIEW A A VIEW B B If desired a Tee fitting may be used to connect the two drain hoses from the exhaust manifold and the outlet side of the of the condensate trap attached to Figure 2 5 Condensate Drain Connection Location 2 6 1 Exhaust Manifold Condensate Drain Refer to Figure 2 5 View A A and i...

Page 17: ...the gas pressure applied to the unit exceed 2 psi Leak test all external piping thoroughly using a soap and water solution or suitable equivalent The gas piping used must meet all applicable codes 2 7 1 Gas Supply Specification The gas supply input specifications to the unit for Natural Gas are as follows The maximum static pressure to the unit must 2 7 2 Manual Gas Shutoff Valve A manual shut off...

Page 18: ...l supply line in an easily accessible location to quickly and safely disconnect electrical service DO NOT attach the switch to sheet metal enclosures of the unit After placing the boiler in service the ignition safety shutoff device must be tested If an external electrical power source is used the installed boiler must be electrically bonded to ground in accordance with the requirements of the aut...

Page 19: ...provided in the following paragraphs Additional information concerning field wiring is provided in paragraphs 2 9 1 through 2 9 9 Refer to Chapter 5 for detailed information on the available modes of operation TERMINAL STRIPS LOWER RIGHT CORNER OF FRONT PANEL Figure 2 10 Input Output I O Box Location OUTDOOR SENSOR IN SENSOR COMMON AIR AUX SENSOR IN REMOTE INTL K IN EXHAUST SWITCH IN DELAYED INTL ...

Page 20: ...l types of signal formats from an Energy Management System EMS Building Automation System BAS or other source to control either the setpoint Remote Setpoint Mode or firing rate Direct Drive Mode of the Boiler These formats are 4 to 20 mA 1 to 5 VDC 0 to 20 mA 0 to 5 VDC PWM Pulse Width Modulated signal See para 2 10 4 Network RS485 Modbus See para 2 10 8 While it is possible to control a boiler or...

Page 21: ...y be changed to 0 to 20 mA 0 to 5 VDC using the Configuration Menu described in Chapter 3 If voltage rather than current is selected as the drive signal a DIP switch must be set on the PMC Board located inside the Control Box Contact the AERCO factory for information on setting DIP switches All of the supplied signals must be floating ungrounded signals Connections between the signal source and th...

Page 22: ... by the Boiler s auxiliary relay The delayed interlock must be closed for the boiler to fire If the delayed interlock is connected to a proving device that requires time to close make a time delay Aux Start On Dly that holds the start sequence of the boiler long enough for a proving switch to make can be programmed Should the proving switch not prove within the programmed time frame the boiler wil...

Page 23: ...gth For a natural draft installation the draft must not exceed 0 25 inch W C These factors must be planned into the vent installation If the maximum allowable equivalent lengths of piping are exceeded the unit will not operate properly or reliably For Massachusetts boiler installations the Heatfab Division of the Selkirk Corporation provides vent systems which conform to all applicable requirement...

Page 24: ...must be removed The inlet air ductwork must then be attached directly to the unit s air inlet In a sealed combustion air application the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run See the AERCO Benchmark Venting and Combustion Air Guide GF 2050 When using the boiler in a sealed combustion air configuration each unit mu...

Page 25: ... 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 PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY 3 2 CONTROL PANEL DESCR...

Page 26: ... 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 boiler alarm condition occurs An alarm message will appear in the VFD 6 CLEAR Key Tu...

Page 27: ...hing pressing the arrow key will increment the selected setting When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting Permits a setting to be changed edited When the CHANGE key is pressed the displayed menu item will begin to ...

Page 28: ...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 the Operating Menu 2 Press the MENU key The display will show the Setup Menu which is the next menu category shown in Figure 3 2 This menu contains the Password opti...

Page 29: ...enter the unit password 159 which is required to change the menu options To prevent unauthorized use the password will time out after 1 hour Therefore the correct password must be reentered when required In addition to permitting password entries the Setup Menu is also used to enter date and time units of temperature measurements and entries required for external communication and control of the u...

Page 30: ... entries This menu contains a number of other configuration settings which may or may not be displayed depending on the current operating mode setting NOTE The Configuration Menu settings shown in Table 3 4 are Factory Set in accordance with the requirements specified for each individual order Therefore under normal operating conditions no changes will be required Table 3 4 Configuration Menu Menu...

Page 31: ... Hi Limit 60 F Setpt Hi Limit Setpt Lo Limit 195 F 195 F Temp Hi Limit 40 F 210 F 195F Max Fire Rate 40 100 100 Pump Delay Timer 0 min 30 min 0 min Aux Start On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown 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 ...

Page 32: ...u Sure No Table 3 6 Combustion Cal Menu Menu Item Display Available Choices or Limits Default Minimum Maximum CAL Voltage 14 25 8 20 1 80v CAL Voltage 30 25 8 20 3 20v CAL Voltage 45 25 8 20 3 70v CAL Voltage 50 25 8 20 3 80 CAL Voltage 70 25 8 20 4 60 CAL Voltage 100 25 8 20 6 00 SET Valve Position 0 100 0 Blower Output Monitor Blower Output Voltage 00 3 9 START SEQUENCE When the Control Box ON O...

Page 33: ...the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 c The VALVE POSITION bargraph will show 100 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...

Page 34: ...ll be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 7 After 2 seconds of continuous flame Flame Proven will be displayed and the flame strength will be indicated After 5 seconds the current date and time will be displayed in place of the flame strength Normally these settings should not require adjustment Note that the energy input of t...

Page 35: ... to AERCO at AERCO International Inc 159 Paris Ave Northvale NJ 07647 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 PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY CAUTION All applicable installation procedures in Chapter 2 must be completed before attempting to start the unit ...

Page 36: ...s will keep readjustments to a minimum and provide optimum performance 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Open the natural gas supply valve s to the 1 8 Inch Gas Plug Location 4 2 3 Accessing the Vent Probe Port The unit contains NPT plugs on both the left and right side of the exhaust manifold at the rear of the unit as shown in Fi...

Page 37: ...e oxygen level is within the range specified in Table 4 1 15 Once the oxygen level is within the specified range at 100 decrease the valve position to 70 TO AIR FUEL VALVE GAS INLET PARTIAL TOP VIEW Figure 4 3 Regulator Adjustment Screw Location 11 Increase the valve open position to 100 and verify that the gas pressure downstream of the SSOV remains at 1 8 W C Readjust pressure if necessary 12 Wi...

Page 38: ...gen level is within the specified range at 70 press the ENTER key to store the selected blower output voltage for the 70 valve position NOTE The remaining steps basically repeat the procedures in steps 18 through 25 for air fuel valve positions of 50 40 30 and 14 open However since oxygen levels vary these steps are repeated in their entirety When performing these steps also ensure that the carbon...

Page 39: ...xygen 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 arrow key decreases the oxygen level 49 Once the oxygen level is within the specified range at 30 press the ENTER key to store the selected blower output voltage...

Page 40: ...f the unit The manual reset switch is not adjustable and is permanently fixed at 210 F This switch will shut Figure 4 5 Over Temperature Limit Switch Locations 4 5 1 Digital Alarm Switch Checks and Adjustments The digital alarm switch settings can be checked or adjusted using the controls and display on the front panel of the switch illustrated and described in Figure 4 6 and Table 4 2 temperature...

Page 41: ...rature 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 with the code set at 0 AERCO recommends that you do not change this code 7 Press...

Page 42: ...INITIAL START UP 4 8 ...

Page 43: ...hen at an outside temperature of 69 F the supply header temperature will increase by 1 6 to 71 6 F 5 2 3 Outdoor Air Temperature Sensor Installation The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected The sensor must be shielded from the sun s direct rays as well as direct impingement by the elements ...

Page 44: ...c 0 20 mA 0 5 Vdc The factory default setting for the Remote Setpoint mode is 4 20 mA 1 5 Vdc With this setting a 4 to 20 mA 1 to 5 Vdc signal sent by an EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F setpoint while a 20 mA 5V signal is equal to a 240 F setpoint When a 0 to 20 mA 0 to 5 Vdc signal is used 0 mA is equal to a 40 F setpoint In addition to the c...

Page 45: ... current and voltage signals described above the Direct Drive mode can also driven by a RS485 Modbus Network signal from an EMS or BAS When in a Direct Drive mode the unit is a slave to the EMS or BAS and does not have a role in temperature control Direct Drive can be used to drive single or multiple units NOTE If a voltage rather than current signal is used to control the remote setpoint a DIP sw...

Page 46: ...OMM terminals in the I O Box on the front of the boilers Wire the units using shielded twisted pair wire between 18 and 22 AWG Observe the proper polarity for the B M S PWM IN and or RS485 COMM wiring connections Shields should be terminated only at the BMS and the boiler end must be left floating Each unit s wiring must conform to the above 5 6 2 BMS Setup and Startup This mode of operation is fa...

Page 47: ... s wiring must conform to the above For a complete CCP system wiring diagram see the AERCO CCP 1 literature 5 7 2 Combination Control System Setup and Startup Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode remote signal type and setpoint The setpoint is adjustable from 40 F to 240 F Enter the following settings in the Configuration Menu MENU OP...

Page 48: ...pter 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 460 220 120 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 and ensure that the leak detec...

Page 49: ...ace 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 Open the water shut off valve in the return piping ...

Page 50: ...t the unit in the Manual Mode and set the valve position between 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 t...

Page 51: ... and allow it to prove flame 8 Once flame is proven close the manual gas valve located between the SSOV and the Air Fuel Valve 9 The unit should shut down and display FLAME LOSS DURING RUN 10 Open the valve previously closed in step 8 11 Press the CLEAR button The unit should restart and fire AIRFLOW FAULT DURING PURGE 4 Re enable the blower output drive voltage by performing the following steps a...

Page 52: ...the CLEAR button 8 Set the ON OFF switch to ON to start the unit 9 Remove the wire again when the unit reaches the purge cycle and PURGING is displayed 10 The unit should shut down and display SSOV FAULT DURING PURGE 11 Replace the wire on the SSOV and press the CLEAR button The unit should restart Figure 6 4 SSOV Actuator Cover Location 6 10 PURGE SWITCH OPEN DURING PURGE The Purge Switch and Ign...

Page 53: ...ve one of the two wires 169 or 170 from the Ignition Switch Figure 6 6 TO BLOWER STEPPER MOTOR DIAL AIR IN 5 Initiate a unit start sequence 6 The unit should begin its start sequence and then shut down and display IGN SWITCH IGNITION POSITION SWITCH Figure 6 6 PURGE POSITION SWITCH OPEN DURING IGNITION 7 Replace the wire on the Ignition Switch and press the CLEAR button The unit should restart Fig...

Page 54: ...ins a gas injector tube which connects to the staged ignition assembly The ignitor injector may be hot therefore care should be exercised to avoid burns It is easier to remove the ignitor injector from the unit after the unit has cooled to room temperature BURNER HOUSING STAGED IGNITION ASSY Appendix K contains recommended spare parts lists for maintenance of the boiler IGNITOR INJECTOR Figure 7 1...

Page 55: ...d to properly position the gas injector tube of the ignitor injector within the 120 angle shown in Figure 7 2 DEG GAS INJECTOR TUBE MUST BE WITHIN THIS RANGE Figure 7 2 Burner Assembly Top View 8 Reinstall the ignitor injector in the burner housing and torque to 80 to 90 in lbs However if the burner housing was replaced just prior to replacing the ignitor injector torque to 180 in lbs then loosen ...

Page 56: ...vice Testing Procedures 7 6 BURNER ASSEMBLY INSPECTION The burner assembly is located at the top front of the unit The burner assembly may be hot Allow the unit to cool sufficiently before removing the burner assembly The following replacement parts will be necessary for reassembly following inspection Part No Description 81030 Burner Gaskets Qty 2 81019 Burner Housing Gasket 81048 Flame Detector ...

Page 57: ... that the grounding screw is reinstalled Also ensure that conductive high temperature anti seize compound is applied to the threads of the ground screw and the ignitor injector Figure 7 4 Burner Assembly Exploded View 22 Install the ignitor injector in the burner housing flange and torque to 15 ft lbs Do not over tighten 23 Reinstall the Flame Detector using a new Flame Detector gasket part no 810...

Page 58: ...ue from the exhaust manifold 3 From the top of the exhaust manifold remove the float and orifice gasket from the condensate trap 4 Thoroughly clean the trap float and gasket Also inspect the drain hose for blockage 5 After the above items have been inspected and cleaned replace the gasket and float in the condensate trap 6 Replace the four bolts securing the flue to the exhaust manifold and connec...

Page 59: ...ater 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 Review installation requirements included in Chapter 2 Inspect all piping and connections to the unit Inspect exhaust vent ...

Page 60: ...ch 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 Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best...

Page 61: ...ckage 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 inlet switch for continuity with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater...

Page 62: ...the switch to ground If 24VAC is not present refer to qualified service personnel 6 See CORRECTIVE ACTION 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 inlet or inlet ductwork 3 Blocked airflow switch 4 Defective airflow switch 5 Combustion oscillations 6 PROBABLE CAUSES from 3 to 12 for AIRFLOW ...

Page 63: ...iring between source and boiler 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent Check control signal type set in Configuration Menu FLAME LOSS DURING IGN 1 Burner Ground Screw not installed or loose 2 Worn flame detector 3 No spark from Spark Plug 4 Defective Ignition Transformer 5 Defective Ignition ...

Page 64: ...sary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressures into and out of the valve are correct 3 Check combustion calibration 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 Stepp...

Page 65: ...point 6 Boiler Management System PID or other settings not correctly setup 7 No interlock to boiler or BMS to disable boiler s in event that system pumps have failed 8 System flow rate changes are occurring faster than boilers can respond 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against Menu Default settings in the Appendix If th...

Page 66: ...y when not in contact with the cam replace the switch 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST B...

Page 67: ...of the supply gas regulator with the unit firing Ensure it is at least 3 5 W C for FM gas train or 4 0 W C for IRI gas train Max allowable pressure is 2 psig see para 2 7 1 2 Measure gas pressure at the low gas pressure switch If it is greater than 2 6 W C measure continuity across the switch and replace if necessary LOW WATER LEVEL 1 Insufficient water level in system 2 Defective water level circ...

Page 68: ... side of the switch to ground If 24VAC is not present refer fault to qualified service personnel 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST Board OUTD...

Page 69: ...ed between the two Normally this measurement should be near zero or no more than a few millivolts 3 Check SSOV power wiring SSOV SWITCH OPEN 1 Actuator not allowing for full closure of gas valve 2 SSOV powered when it should not be 3 Defective Switch or Actuator 4 Incorrectly wired switch 1 Observe operation of the Safety Shut Off Valve SSOV through indicator on the Valve actuator and ensure that ...

Page 70: ...OBABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Staged Ignition Ball Valve closed 2 Clogged damaged Ignitor Injector Figure 8 2 3 Defective Staged Ignition Solenoid Figure 8 2 1 Open the 1 4 Ball Valve downstream of the SSOV Fig 8 1 2 Remove and inspect gas injector to ensure it is not clogged or damaged 3 Close the 2 and the 1 4 Ball Valve downstream of the SSOV Fig 8 1 Start the unit and listen...

Page 71: ...SSEMBLY FLAME DETECTOR Figure 8 2 IGNITOR INJECTOR Staged Ignition Solenoid Location SSOV ACTUATOR FRONT DAMPING ORIFICE Figure 8 1 High Pressure Gas Switch Snubber Locations TO AIR FUEL VALVE GAS INLET PARTIAL TOP VIEW Figure 8 3 Damping Orifice Location ...

Page 72: ...mb terminal display with a listing of the following available entry choices M Display next Menu D Display menu items N Display next menu items Cxx Change item xx F Fault log display S Sensor log display T Time line display L Log off NOTE The Level 1 password 159 must be entered to change options in the Setup Configuration and Tuning Menus The Level 2 password 6817 must be entered to view or change...

Page 73: ...sts of a string of ASCII records stored in non volatile memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate or flame strength must change by more than 5 or the run mode must chang...

Page 74: ...5 1 15 02 12 30pm Run Manual 40 100 0 1 15 02 11 55am Ignition 0 0 0 1 15 02 11 55am Power up 0 0 0 1 15 02 11 50am 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 OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OP...

Page 75: ...oor 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 Position In Desired input valve position This would normally be the same as the fire rate shown on ...

Page 76: ...Software Version Identifies the current software version of the control box Ver 0 0 to Ver 9 9 CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of KC Boiler KC Boiler LN BMK Boiler BMK Boiler LN BMK Boiler Dual KC Water Heater KC Water Heater LN Water Heater 2010 Default is BMK BOILER LN Unit Size Sets unit size from 0 5 to 6 0 MBT...

Page 77: ...his setting will turn off the unit The temperature must then drop 5 below this setting to allow the unit to run Default Hi Limit is 195 F Max Valve Position Sets the maximum allowable valve position for the unit 40 to 100 Default is 100 Pump Delay Timer Specifies the amount of time 0 to 30 min to keep the pump running after the unit turns off Default is zero Aux Start On Dly Specifies the amount o...

Page 78: ...tion In reaches the Start Level value There will not be a one minute delay when firing at the 29 Fire Rate level Setting range is 0 to 25 Default is 10 Deadband High Deadband Low Deadband High and Deadband Low settings create an Outlet Temperature Zone In which no Valve Position corrections will be attempted The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoi...

Page 79: ...ual to or greater than the proportional band setting the fire rate will be 100 Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 0 10 Derivative Time This value 0 0 to 20 0 min responds to the rate of change of the setpoint error This is the time that t...

Page 80: ...A 6 ...

Page 81: ...econds 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 duration of the purge cycle counts up in seconds STANDBY Displayed when ON OFF switch...

Page 82: ...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 The High Water Temperature Limit Switch is open IGN BOARD COMM FAULT A communication fault has occurred be...

Page 83: ...RING 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 DURING PURGE The SSOV switch opened during purge SSOV FAULT DURING IGN The SSOV s...

Page 84: ...B 4 ...

Page 85: ...0 240 250 779 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 2 30 2 32 2 34 2 36 2 39 2 41 2 43 2 45 2 47 2 50 2 52 2 54 2 56 2 58 Voltage at AUX Common terminals in the I O Box ...

Page 86: ...C 2 APPENDIX C ...

Page 87: ... 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 Temperatrure 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 80 82 84 45F 69 72 75 78 81 84 87 90 93 96 40F 72 76 80 84 88 92 96 100 104 108 35F 7...

Page 88: ...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 78 80 82 84 86 88 90 92 94 55F 79 82 85 88 91 94 97 100 103 106 50F 82 86 90 94 98 102 106 110 114 118 45F 85...

Page 89: ...5 150 165 180 195 210 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 87 88 89 90 91 92 70F 86 88 90 92 94 96 98 100 102 104 65F 89 92 95 98 101 104 107 110 113 116 60F 92 96 10...

Page 90: ... 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 123 134 145 156 167 178 189 200 30F 126 138 150 162 174 186 198 210 25F 129 142 155 168 181 194 207 20F 132 146...

Page 91: ...de 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 195 F Temp Hi Limit 195 F Max Fire Rate 100 Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Positio...

Page 92: ...S Continued MENU OPTION FACTORY DEFAULT Configuration Menu Continued 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 E 2 ...

Page 93: ...APPENDIX F APPENDIX F F 1 ...

Page 94: ...APPENDIX F F 2 ...

Page 95: ...APPENDIX F F 3 ...

Page 96: ...APPENDIX F F 4 ...

Page 97: ...APPENDIX F F 5 ...

Page 98: ...APPENDIX F F 6 ...

Page 99: ...APPENDIX F F 7 66034 ...

Page 100: ...APPENDIX F F 8 ...

Page 101: ...APPENDIX F F 9 ...

Page 102: ...APPENDIX F F 10 ...

Page 103: ...APPENDIX F F 11 ...

Page 104: ...APPENDIX F F 12 ...

Page 105: ...APPENDIX F F 13 ...

Page 106: ...APPENDIX F F 14 ...

Page 107: ...APPENDIX G APPENDIX G G 1 ...

Page 108: ...APPENDIX G G 2 ...

Page 109: ...APPENDIX G G 3 ...

Page 110: ...APPENDIX G G 4 ...

Page 111: ...APPENDIX G G 5 ...

Page 112: ...APPENDIX G G 6 ...

Page 113: ...APPENDIX H APPENDIX H H 1 ...

Page 114: ...APPENDIX H H2 ...

Page 115: ...APPENDIX H H 3 ...

Page 116: ...APPENDIX H H 4 ...

Page 117: ...APPENDIX H H 5 ...

Page 118: ...APPENDIX H H 6 ...

Page 119: ...APPENDIX H H 7 ...

Page 120: ...APPENDIX H H 8 ...

Page 121: ...ions Igniter Weekly Operator See paragraph 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial paragraph 3 9 SSOV Leakage test Annually Service 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 paragraph 6 7 Flame signal strength Weekly Oper...

Page 122: ...APPENDIX I I 2 ...

Page 123: ...EN LED P N 124948 ROCKER SWITCH P N 124947 V F D DISPLAY MODULE P N 124527 FISH PAPER INSULATOR P N 124960 ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 PUSH BUTTON SWITCHES P N 124954 FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 BENCHMARK CONTROL PANEL EXPLODED VIEW ...

Page 124: ...PIN TO INPUT OUTPUT I O BOX SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX SENSOR HARNESS CONNECTOR 7 PIN BENCHMARK CONTROL PANEL REAR VIEW J 2 ...

Page 125: ...2 69038 Temperature Switch Manual Reset SEE NOTE 3 123552 Table K 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 04 Table K 3 Optional Spare Parts DESCRIPTION PART NUMBER C More Control Box 181197 Burner 46013 Temperature Switch Auto Reset SEE NOTE 3 123966 NOTES 1 For boilers with FM gas train and ...

Page 126: ...NOTES ...

Page 127: ...Log Date Description Changed By 04 08 2013 Rev D updated drawings in Appendix F replaced Flame Rod with s n 66020 Chris Blair 10 10 2017 Rev E DIR 355 Updated burner reassembly instructions in section 7 6 replaced Flame Detector 66020 with 66034 PIR 764 Updated schematic drawings Chris Blair ...

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