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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual

CHAPTER 6 – SAFETY DEVICE TESTING

OMM-0086_0D

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

Page

210

GF-133

Ph.: 800-526-0288

03/20/14

Flame Fault Tests

1. Set the

ON/OFF

switch to the

OFF

position.

2. Place the unit in the Manual Mode and set the valve position between 25% and 30%.

3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV)

and the Air/Fuel Valve (see Figure 6-3).

Set the

ON/OFF

switch to the

position to start the unit.

The unit should purge and light the Pilot flame and then shut down after reaching the main

Burner Ignition cycle and display

FLAME LOSS DURING IGN.

Open the valve previously closed in step 3 and press the

CLEAR

button.

7. Restart the unit 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 (Figure 6-3).

9. The unit should shut down and Lockout. A flashing

FLAME LOSS DURING RUN

should

appear in the display.

10. Open the valve previously closed in step 8.

11. Press the

CLEAR

button. The unit should restart and fire.

Figure 6-3: Bare Boiler – Partial View

6.8 AIR FLOW FAULT TESTS

These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in
Figure 6-4.

AIR FILTERS

MANUAL GAS
SHUT-OFF VALVE

GAS TRAIN

AIR/FUEL VALVE

BLOWER

Y-DUCT

Summary of Contents for BENCHMARK 6000

Page 1: ...onal Inc 100 Oritani Dr Blauvelt NY 10913 Page 1 of 210 GF 133 Ph 800 526 0288 03 20 14 BENCHMARK 6000 Gas Fired Boiler USER MANUAL Installation Operation and Maintenance Natural Gas Modulating Condensing Hot Water Boiler Applicable to Serial Numbers N 14 0172 and Above Latest Update 03 20 14 ...

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: ...Gas Shutoff Valve 24 2 8 3 External Gas Supply Regulator 24 2 8 3 1 Massachusetts Installations Only 24 2 8 3 2 All Installations Except Massachusetts 24 2 9 AC ELECTRICAL POWER WIRING 25 2 9 1 Electrical Power Requirements 27 2 10 FIELD CONTROL WIRING 27 2 10 1 OUTDOOR AIR IN Terminal 29 2 10 2 COMBUSTION AIR Terminal 30 2 10 3 O2 SENSOR Terminals 30 2 10 4 SPARK SIGNAL Terminals 30 2 10 5 ANALOG...

Page 4: ... 2 INDOOR OUTDOOR RESET MODE 69 5 2 1 Reset Ratio 69 5 2 2 Building Reference Temperature 69 5 2 3 Outdoor Air Temperature Sensor Installation 69 5 2 4 Indoor Outdoor Reset Mode Startup 69 5 3 CONSTANT SETPOINT MODE 70 5 3 1 Setting the Setpoint 70 5 4 REMOTE SETPOINT MODES 71 5 4 1 Remote Setpoint Field Wiring 71 5 4 2 Remote Setpoint Startup 72 5 5 DIRECT DRIVE MODES 72 5 5 1 Direct Drive Field ...

Page 5: ... Application 129 9 1 2 Logging on to a Remote Machine Using PuTTY 129 9 1 3 Running a Command on a Remote Machine Using PuTTY 130 9 2 RS 232 COMMUNICATION SETUP 131 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION 131 9 4 DATA LOGGING 132 9 4 1 Fault Log 133 9 4 2 Operation Time Log 133 9 4 3 Sensor Log 134 CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 135 10 1 INTRODUCTION 135 10 2 AERCO BST Quick St...

Page 6: ...0 14 Ph 800 526 0288 GF 133 APPENDIX G PARTS LIST DRAWINGS 173 APPENDIX H PIPING DRAWINGS 185 APPENDIX I C MORE WIRING DIAGRAMS 189 APPENDIX J RECOMMENDED PERIODIC TESTING 197 APPENDIX K C MORE CONTROL PANEL VIEWS 199 APPENDIX L RECOMMENDED SPARES 201 APPENDIX M LONG TERM BLOWER STORAGE 203 APPENDIX N ULTRA LOW NOx CALIBRATION 205 LIMITED WARRANTY 209 ...

Page 7: ...the boiler is a function of the unit s firing rate valve position and return water temperature When installed and operated in accordance with this Instruction Manual the BMK 6000 MBH Boiler complies with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the BMK 6000 offer the maximum venting flexib...

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

Page 9: ...e MAX Max Maximum MIN Min Minimum Modbus A serial half duplex data transmission protocol developed by AEG Modicon NC N C Normally Closed NO N O Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen O D Outside Diameter PMC Board A Primary Micro Controller PMC board is contained in the C More Control Box used on all Benchmark units PPM Parts Per Million PTP Point to Point usually over...

Page 10: ...Phrase Abbreviation or Acronym Meaning SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each end of a daisy chain or multi drop network in order to prevent reflections that may cause invalid data in the communication VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column µA ...

Page 11: ...aving jurisdiction should be consulted before installations are made See pages 14 and 15 for important information regarding installation of units within the Commonwealth of Massachusetts IMPORTANT This Instruction Manual is an integral part of the product and must be maintained in legible condition It must be given to the user by the installer and kept in a safe place for future reference DO NOT ...

Page 12: ...as pipe leak testing are corrosive to metals The piping must be rinsed thoroughly with clean water after leak checks have been completed 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 val...

Page 13: ...s including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment th...

Page 14: ...ENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design...

Page 15: ...N Tell indicator is tripped 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 MOVING UNPACKING THE UNIT While packaged in the shipping container the unit can be moved using a forklift ...

Page 16: ...hes W C with the unit in operation approximately 20 W C static 2 4 1 Installation Clearances The Benchmark Model 6000 Boiler dimensions and minimum acceptable clearances are shown in Figure 2 2 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 clearanc...

Page 17: ... service maintenance of the AERCO Condensate Trap Refer to section 2 7 for Condensate Trap installation details When using the AERCO Condensate Neutralizer Tank for condensate drainage the tank must be installed in a pit OR the boiler and AERCO Condensate Trap must be elevated higher than 4 above the floor See Condensate Neutralizer Tank Instructions TID 0074 for details Figure 2 2 Benchmark Boile...

Page 18: ...using the AERCO Condensate Neutralizer Tank for proper condensate drainage the Neutralizer Tank must be stored in a pit OR the boiler and AERCO Condensate Trap must be elevated higher than 4 above the floor Ensure that the condensate assembly is not positioned above the housekeeping pad during installation so as not to interference with condensate piping See Condensate Tank Instructions TID 0074 f...

Page 19: ...uirements 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 Boiler utilizes 6 flang...

Page 20: ...or the pressure rating specified on the Sales Order The appropriate size reducing bushing and nipple are also included in the kit The pressure relief valves nipples and bushings are connected to 45º street elbows already installed on the heat exchanger of the boiler The relief valves are installed on the top of the boiler as shown in Figure 2 5A A suitable pipe joint compound should be used on all...

Page 21: ...elief Valve Installation Locations 2 6 2 Pressure Temperature Gauge Installation A manual Pressure Temperature Gauge is included in the loose parts kit for installation for installation in the boiler outlet piping It must be installed so that the sensing bulb is inserted into the hot water outlet flow from the boiler Refer to Figure 2 5B for sample installations Figure 2 5B Pressure Temperature Ga...

Page 22: ...es housekeeping pad height dimensions and other prevailing conditions at the site The following general guidelines must be observed to ensure proper condensate drainage The condensate trap inlet Figure 2 7 must be level with or lower than the exhaust manifold drain port The base of the condensate trap must be supported to ensure that it is level horizontal The trap must be removable for routine ma...

Page 23: ...te Trap Installation 2 8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide GF 2030 must be consulted prior to designing or installing any gas supply piping NEVER USE MATCHES CANDLES FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS Many soaps used for gas pipe leak testing are corrosive to metals Therefore piping must be rinsed thoroughly with clean water after ...

Page 24: ...xceed 56 inches W C 2 psi The gas supply piping and pressure to the unit must be sufficient to provide 6000 cfh while maintaining a gas pressure of 14 inches W C for FM gas trains while in operation 2 8 2 Manual Gas Shutoff Valve A manual shut off valve must be installed in the gas supply line upstream of the boiler as shown in Figure 2 8 Maximum allowable gas pressure to the boiler is 56 W C 2 ps...

Page 25: ...GF 2060 must be consulted prior to connecting any AC power wiring to the unit External AC power connections are made to the unit inside the Power Box on the front of the unit Remove the unit s front panel to access the Power Box which is mounted in the upper right corner of the unit as shown in Figure 2 9 Loosen the four Power Box cover screws and remove the cover to access the AC terminal block c...

Page 26: ...h the exception of the transformer shown in Figure 2 10 all of the components in the Power Box are mounted on a DIN rail NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers inhibit service maintenance or prevent access between the unit and walls or another unit Power Box located in the unit s upper right corner WIRE CONDUITS ...

Page 27: ...t be tested If an external electrical power source is used the installed boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction In the absence of such requirements the installation shall conform to National Electrical Code NEC ANSI NFPA 70 and or the Canadian Electrical Code CEC Part I CSA C22 1 Electrical Code For electrical power wir...

Page 28: ... 2 12a Input Output I O Box Location Figure 2 12b Input Output I O Box Interior NOTE Use Figure 2 13 to determine the functions of the I O PCB connections Do not use the silkscreened labels on the PCB itself as these may not match the function names There is a diagram of the connection functions on the cover of the I O Box as well I O PCB BOARD TERMINAL STRIPS I O Box located in the unit s upper l...

Page 29: ...he outdoor air temperature The factory default for the outdoor sensor is DISABLED To enable the sensor and or select an enable disable outdoor temperature see the Configuration menu in Chapter 3 The outdoor sensor may be wired up to 200 feet from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O Box see Figure 2 13 Wire the sensor using a twisted shielded ...

Page 30: ...n 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 Refer to Appendix D of the C More Control Panel OMM GF 112 for information on setting DIP switches All supplied signals must be floating ungrounded signals Connections between the source and the boiler s I O Box must be made using twisted shielded pair...

Page 31: ...d sensor log displays 2 10 11 VFD BLOWER Terminals These terminals 0 10 AGND send an analog signal to control the blower speed When any of the 4 20mA options is selected for the Analog Outputs Section 2 10 8 the output from the VFD Blower terminals is disabled 2 10 12 Interlock Terminals The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment s...

Page 32: ...nergized until the fault is cleared and the CLEAR button is depressed The fault relay connections are shown in Figure 2 13 2 10 14 AUX RELAY Terminals Each unit is equipped with a single pole double throw SPDT auxiliary relay that is energized when there is a demand for heat and de energized after the demand for heat is satisfied The relay is provided for the control of auxiliary equipment such as...

Page 33: ...f these compounds are swimming pools degreasing compounds plastic processing and refrigerants Whenever the environment contains these types of chemicals combustion air MUST be supplied from a clean area outdoors for the protection and longevity of the equipment and warranty validation The more common methods of combustion air supply are outlined in the following sections For combustion air supply ...

Page 34: ...container This valve is an integral component of the AERCO s on board Boiler Sequencing Technology BST solution BST allows sites with multiple boilers to have one boiler acting as a master to manage the other boilers at the site in such a way that the efficiency of the entire boiler array is maximized The implementation of BST and the installation and use of this valve is optional The boiler IS pr...

Page 35: ...2 INSTALLATION OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 35 of 210 GF 133 Ph 800 526 0288 03 20 14 Figure 2 14 Sequencing Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing valve s connector ...

Page 36: ...iler Installation Operation Maintenance Manual CHAPTER 2 INSTALLATION Page 36 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 37: ...INCLUDE 460 OR 208 120 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS DO NOT ATTEMPT TO DRY FIRE THE UNIT STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY All of the installation procedures in Chapter 2 must be completed before attempting to st...

Page 38: ...Control Panel Front View NOTE If there is a requirement to use the RS232 port Item 4 on the C More controller front panel contact AERCO to purchase the RS232 Adaptor Cable P N 124675 which is designed for this purpose This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports 3 1 8 9 10 11...

Page 39: ...aying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection BST Messages 4 RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the unit s Control Panel AERCO offers for purchase the RS232 Adaptor Cable P N 124675 which is designed to work with this port This cable features a DB9 conne...

Page 40: ...e 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 edited When the CHANGE key is pressed t...

Page 41: ...option is accomplished using the Menu Keys shown in Figure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures Menu Processing Procedure 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 ...

Page 42: ... 0086_0D 03 20 14 Ph 800 526 0288 GF 133 Only if BST is enabled see Chapter 10 Figure 3 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer to Appendix A for detailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages ...

Page 43: ...p 70 F 245 F Outdoor Temp 70 F 130 F Valve Position In 0 100 Valve Position Out 0 100 Exhaust Temp F F Flame Strength 0 100 Oxygen Level 0 21 Run Cycles 0 999 999 999 Run Hours 0 999 999 999 Fault Log 0 19 0 NOTE The Outdoor Temp and Valve Position Out display items shown with an asterisk in Table 3 2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Me...

Page 44: ...Serial 0 9999 0000 C More Alpha A Z A IP Address Software Ver 0 00 Ver 9 99 3 6 CONFIGURATION MENU The Configuration Menu shown in Table 3 4 permits adjustment of the Internal Setpoint Setpt temperature regardless of whether the valid password has been entered Setpt is required for operation in the Constant Setpoint mode The remaining options in this menu require the valid password to be entered p...

Page 45: ...750 MBH 1000 MBH 1500 MBH 2000 MBH 2500 MBH 3000 MBH 6000 MBH 6000 MBH Fuel Type Natural Gas or Propane Natural Gas Boiler Mode Constant Setpoint Remote Setpoint Direct Drive Combination Outdoor Reset Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V 0 20 mA 0 5V PWM Input Legacy BMS Network 4 20 mA 1 5V Outdoor Sensor Enabled or Disabled Disabled Bld...

Page 46: ...N 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 Spark Monitor Enabled or Disabled Disabled Spark Current Display NOTE Spark Monitor and Spark Current are not used on the Benchmark 6000 DO NOT change the Analog Output Menu Item from its Default setting Valve Position 0 10V 3 7 TUNING MENU The Tuning Menu items in Table 3 5 are Factory set for each individual unit Do not ch...

Page 47: ...inimum Maximum CAL Voltage 14 1 70 2 70 2 20 CAL Voltage 30 1 90 2 50 2 00 CAL Voltage 40 1 90 3 40 2 25 CAL Voltage 50 2 20 3 50 2 70 CAL Voltage 70 3 20 4 40 3 95 CAL Voltage 100 7 20 10 00 8 00 SET Valve Position 0 100 Variable Blower Output Monitor Blower Output Voltage Set Stdby Volt 0 4 00 V 0 2 00 V Oxygen Level 0 25 Variable 3 9 BST BOILER SEQUENCING TECHNOLOGY MENU The BST Menu must be En...

Page 48: ...e Rate 0 100 Avg Fire Rate BST Outdoor Temp NA Outdoor Temp F Units Available 0 8 Units Present Units Ignited 0 8 Units firing BST Valve State 0 CLOSED 1 OPEN 0 1 Comm Errors 8 0 9 0 1 BST Units 8 0 see table 0 see table 0 BST SETUP MENU Disabled Enabled Disabled BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header Tem...

Page 49: ...d Open Off Valve Off Delay 0 15 min 1 min BST Sequencing Run Hours Unit Size Select Lead Run Hours Select Lead Unit 0 127 0 Select Lag Unit 0 127 0 Lead Lag Hours 25 hours 225 hours 72 hours BST TEMP CTRL MENU Disabled Enabled Disabled BST Temp Hi Limit 40 F 210 F 210 F BST Setpt Lo Limit 40 F BST Setpt HI Limit 60 F BST Setpt HI Limit BST Setpt Lo Limit 220 F 195 F BST Prop Band 1 F 120 F 100 F B...

Page 50: ...s Pressure switch Low Gas Pressure switch Blower Proof switch Blocked Inlet switch NOTE The downstream Low Gas Pressure switch is not checked prior to starting the pre purge If all of the above switches are closed the READY light above the ON OFF switch will light and the unit will be in the Standby mode When there is a demand for heat the following events will occur NOTE If any of the Pre Purge s...

Page 51: ... the following events will occur a The Blower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve will read 100 Figure 3 4 to indicate that it is full open 100 c The VALVE POSITION bargraph will show 100 Figure 3 4 Air Fuel Valve In Purge Position STEPPER MOTOR TO BLOWER 100 AIR IN DOWN...

Page 52: ...completion of the purge cycle the Control Box initiates an ignition cycle and the following events occur a The Air Fuel Valve rotates to the low fire Ignition Position position and closes the ignition switch The Dial on the Air Fuel Valve will read between 45 and 50 Figure 3 6 to indicate that the valve is in the low fire position b Power is supplied to the Spark Igniter c Power is supplied to the...

Page 53: ...m SSOV actuator 7 A maximum of 7 seconds are allowed for the entire ignition sequence from applying power to the ignition transformer through actual Burner flame establishment The igniter relay will be turned off one second after flame is detected 8 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 ...

Page 54: ...s 30 T 60s T 7 sec C MORE CONTROL BOX Scanner Power Ignition Power SSOV Power PILOT VALVE Pilot Valve Closed Pilot Valve Open IGNITION TRANSFORMER Transformer Off Transformer On UV SCANNER Powered Ignored In Use RELAY 1 R1 Coil C NC C NO RELAY 2 R2 Coil Power from R1 Coil Power from SKP 15 AUX C NC C NO UPSTREAM SSOV SKP15 Power through R1 Power through R2 and AUX POC C NC POC C NO AUX C NC AUX C ...

Page 55: ...osition Refer to Table 3 8 and the chart in Figure 3 8 for the relationship between the energy input and Air Fuel Valve position for a BMK 6000 MBH boiler running on natural gas The boiler has a downstream low pressure gas switch that will shut down the boiler when the gas pressure drops below 7 W C See Table 3 9 Table 3 8 Relationship Between Air Fuel Valve Position and Energy Input For 6000 MBH ...

Page 56: ...20 14 Ph 800 526 0288 GF 133 Table 3 9 Gas Pressure De Rating Chart Gas Pressure SSOV inches W C Energy Input BTU hr Oxygen O2 DeRating Full Fire Inlet Outlet 56 8 6 000 000 5 40 0 14 8 6 000 000 5 40 0 13 8 5 860 000 5 45 2 12 7 95 5 860 000 5 41 2 11 5 7 5 5 740 000 5 77 4 11 7 1 5 610 000 6 17 6 Figure 3 8 Relationship Between Air Fuel Valve Position and Energy Input ...

Page 57: ...Installation Operation Maintenance Manual CHAPTER 3 OPERATION OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 57 of 210 GF 133 Ph 800 526 0288 03 20 14 Figure 3 9 Burner Ignition Sequence Flowchart ...

Page 58: ... Boiler Installation Operation Maintenance Manual CHAPTER 3 OPERATION Page 58 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page intentionally blank ...

Page 59: ...cy with low flue gas emissions Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this Chapter it will be necessary to perform the Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Benchmark must b...

Page 60: ...ings for use with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to monitor the gas pressure on the downstream side of the SSOV during the Combustion Calibration procedures described in section 4 4 The gas supply manometer is installed at the downstream location shown in...

Page 61: ...s shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 4 2 3 Accessing the Analyzer Probe Port For easy access the unit contains a total of two 2 1 4 NPT ports One port is located on the left side of the exhaust manifold and the other is on the right side see Figure 4 2...

Page 62: ...ensor has a red LED which changes from flashing to steady ON when the sensor encounters the flicker of a flame that meets or exceeds the internal sensing threshold The sensor is inserted into a tube with a quartz window and observes the Pilot through a hole in the refractory The hole in the refractory should be checked annually to ensure that the optical path to the Pilot Burner is clear NOTE The ...

Page 63: ...ual mode by pressing the AUTO MAN key A flashing manual valve position message will be displayed with the present position in Also the MANUAL LED will light 6 Adjust the air fuel valve position to 0 by pressing the arrow key 7 Ensure that the leak detection ball valve downstream of the SSOV is open and the manometer is attached and functioning properly 8 Set the ON OFF switch to the ON position 9 ...

Page 64: ...in your analyzer set the oxygen O2 at 5 1 0 5 Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 100 5 4 6 3 20 ppm 100 ppm 15 If the oxygen level is not within the required tolerance the gas pressure on the downstream side of the SSOV must be adjusted using the gas pressure adjustment screw on the SSOV Figure 4 3 Slowly rotate the gas pressure adjustmen...

Page 65: ... arrow key until CAL Voltage 70 is displayed 24 Press the CHANGE key and observe that CAL Voltage 70 is flashing 25 The oxygen level at the 70 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the following values Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 70 6 0 6 5 20 p...

Page 66: ...hown 20 ppm increase the O2 level up to 1 higher than the listed calibration range shown in the table Record the increased O2 value on the Combustion Calibration sheet Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 50 6 7 20 ppm 100 ppm 40 6 7 20 ppm 100 ppm 30 6 7 20 ppm 100 ppm 18 5 7 20 ppm 100 ppm 29 If the oxygen level at the 18 valve position i...

Page 67: ...stments are properly set the unit can be reassembled for service operation Reassembly 1 Set the ON OFF switch in the OFF position 2 Disconnect AC power from the unit 3 Shut off the gas supply to the unit 4 Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound 5 Remove the combustion analyzer probe from the 1 4 vent hole in the exhaust manifold Re...

Page 68: ...iler Installation Operation Maintenance Manual CHAPTER 4 INITIAL START UP Page 68 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page intentionally blank ...

Page 69: ... 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 references to begin increas...

Page 70: ...the display shows Reset Ratio 11 Press the CHANGE key The display will begin to flash 12 Use the and arrow keys to select the Reset Ratio determined in step 5 13 Press ENTER to save the change 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 exchanger...

Page 71: ...DIP switch settings 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 section 3 3 for detailed instructions on changing menu options If the Network setting is selected for RS 485 ...

Page 72: ...r 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 When a 0 20 mA 0 5 Vdc sign...

Page 73: ...he REMOTE LED will light when the signal is present To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Direct Drive mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 6 AERCO CONTROL SYSTEM ACS NOTE ACS is for installations with 9 or more boilers It utilizes ...

Page 74: ... 5 7 COMBINATION CONTROL SYSTEM CCS NOTE Only ACS can be utilized for the Combination Control System A Combination Control System CCS is one that uses multiple boilers to cover both space heating and domestic hot water needs The theory behind this type of system is that the maximum space heating load and the maximum domestic hot water load do not occur simultaneously Therefore boilers used for dom...

Page 75: ...stic hot water load is not satisfied the combo boiler s remain on the domestic hot water load If the combo boilers switch over to space heating but there is a call for domestic hot water the ACS Relay Box switches the combo units back to the domestic load The ACS in combination with the ACS Relay Box will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boi...

Page 76: ...anging settings other than the unit s setpoint For a complete listing of temperature related function defaults see Appendix E To set the unit to the manual mode press the AUTO MAN switch The MANUAL LED will light To set the unit back to the auto mode press the AUTO MAN switch The MANUAL LED will go off and the REMOTE LED will light When the boiler is switched to ACS control the ACS controls the va...

Page 77: ...s such as ASME CSD 1 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Chapter 3 Also it will be necessary to remove the front door and side panels from the unit to perform the following tests ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 208 230 OR 460 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIR...

Page 78: ...alve upstream of the unit 4 Place the unit in Manual Mode and adjust the Air Fuel Valve position open to 50 5 While the unit is firing slowly close the external gas supply shut off valve 6 The unit should shut down and display a GAS PRESSURE fault message at approximately 8 5 W C The FAULT indicator should also start flashing 7 Fully open the external gas supply ball valve and press the CLEAR butt...

Page 79: ...Pressure Test High Gas Pressure Fault Test 1 Remove the 1 4 plug from the ball valve shown in Figure 6 1B 2 Install a NPT to barbed fitting and a 0 16 W C manometer where the 1 4 plug was removed Open the ball valve at the High Gas Pressure switch 3 Open the external gas supply ball valve upstream of the unit 4 Start the unit in the Manual mode at a valve position open between 25 and 30 5 With the...

Page 80: ...fault proceed as follows Low Water Level Fault Test 1 Set the ON OFF switch to the OFF position 2 Close the water shut off valves in the supply and return piping to the unit 3 Slowly open the drain valve on the rear of the unit If necessary the unit s relief valve may be opened to aid in draining 4 Continue draining the unit until a LOW WATER LEVEL fault message is displayed and the FAULT indicato...

Page 81: ...table over temperature switch setting to match the displayed OUTLET TEMPERATURE 3 Once the adjustable over temperature switch setting is approximately at or just below the actual outlet water temperature the unit should shut down The FAULT indicator should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should be displayed It should not be possible to restart the unit 4 Reset the ad...

Page 82: ...INTL K IN terminals remove one side of the jumper If the interlock is being controlled by an external device either open the interlock via the external device or disconnect one of the wires leading to the external device 4 The unit should shut down and display INTERLOCK OPEN 5 Once the interlock connection is reconnected the INTERLOCK OPEN message should automatically clear and the unit should res...

Page 83: ... flame and then shut down after reaching the main Burner Ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve previously closed in step 3 and press the CLEAR button 7 Restart the unit and allow it to prove flame 8 Once flame is proven close the manual gas valve located between the SSOV and the Air Fuel Valve Figure 6 3 9 The unit should shut down and Lockout A flashing FLAME LOSS DURI...

Page 84: ...owing AIRFLOW FAULT DURING PURGE in the display 4 The unit should perform one IGNITION RETRY cycle and then shut down since the blower is disabled The unit will then display AIRFLOW FAULT DURING PURGE 5 Re enable the blower output drive voltage by performing the following steps a Press the MENU key until CONFIGURATION MENU is displayed b Press the arrow key until the ANALOG OUTPUT function is disp...

Page 85: ...LADES DO ALLOW ANYTHING TO BE PULLED INTO THE BLOWER DO NOT WEAR ANYTHING THAT COULD GET CAUGHT AND PULL YOU INTO THE BLOWER 3 Turn off the gas supply ball valve to the boiler and then complete the following steps a Use jumper wires to jump out the Low Gas Pressure Switch and the Blower Proof Switch b Remove the black connector boot from the Flame Detector c Connect the Flame Signal Generator to t...

Page 86: ... a thick metal plate 7 The unit should shut down and display AIRFLOW FAULT DURING RUN This step confirms proper operation of the Blocked Inlet Switch 8 Remove the cover from the air inlet opening and reinstall the Combustion Air Duct or Y Duct and air filters 9 Remove the jumper wires installed in step 2 and replace the black connector boot on the Flame Detector 10 Press the CLEAR button The unit ...

Page 87: ... to Figure 6 1 and locate the downstream SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 6 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 6 The unit should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press the CLEAR button 8 Set the ON OFF switch to the ON posi...

Page 88: ... unit s ON OFF switch to the OFF position Place the unit in manual mode and set the valve position between 25 and 30 2 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 6 7 3 Remove one of the two wires 171 or 172 from the Purge Switch Figure 6 8 4 Initiate a unit start sequence 5 The unit should begin its start sequence then shut down and display PRG S...

Page 89: ...During Ignition 1 Set the unit s ON OFF switch to the OFF position 2 Place the unit in Manual Mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 6 7 by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove one of the two wires 169 or 170 from the Ignition Switch Figure 6 8 5 Initiate a unit start sequence 6 The unit should begin its st...

Page 90: ...ETY DEVICE TESTING Page 90 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 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 91: ...nual Maintenance Kit 58025 11 Therefore only Kit Part No 58025 12 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spares TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUA...

Page 92: ...orm the following procedure Pilot Burner Maintenance Procedure 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 For easy access open the front panel and right side door If you are working on the left unit of a two unit zero side clearance installation you may want to remove the top panel and service the unit from above 3 Disconnect the ignition c...

Page 93: ...lbs 11 Reassemble the remaining components in the reverse order that they were removed 12 Reconnect the ignition cable 13 Close the right side door and front panel Replace the top panel if the unit was serviced from above 7 3 MAIN FLAME DETECTOR The Main Flame Detector part no 65136 is located on the Blower Flange near the top of the unit see Figures 7 1 The Main Flame Detector may be hot Allow th...

Page 94: ...only once every 5 years The O2 Sensor is removed and inspected by performing the following procedural steps O2 Sensor Maintenance Procedures 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remove the rear right side panel from the unit by removing the screws at the top and rear Figure 7 2 3 Disconnect the O2 sensor lead wire by pushing in on the...

Page 95: ... 4 for combustion calibration instructions Pilot Regulator tests and adjustments are performed using the procedures in sections 7 5 1 and 7 5 2 which follow 7 5 1 Pilot Regulator Pressure Testing The BMK6000 unit has a Pilot Regulator system in the gas train that should be pressure tested annually as described in the following procedure However if the pressure is above 5 0 W C or below 4 0 W C the...

Page 96: ...t beneath cap clockwise CW to its highest possible pressure setting 6 Next rotate the adjustment screw 2 turns counterclockwise CCW 7 OPEN the main gas supply upstream of the unit 8 Turn ON electrical power to the system 9 Start the boiler in MANUAL Mode Observe the manometer pressure when the Pilot solenoid clicks open after purge It should now provide a reading of 4 9 0 2 W C 10 Pull out the opt...

Page 97: ...or Figure 7 3 and insert a NPT to barbed adapter fitting 4 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 5 Remove the cap from the Pilot pressure regulator and rotate the regulator adjustment beneath cap clockwise CW to its highest possible pressure setting 6 OPEN the main gas supply upstream of the unit 7 Turn ON electrical power to the syste...

Page 98: ...th a strong orange flame after the Pilot ignition solenoid valve opens NOTE Clear any Flame Loss During Ignition messages during the tests by pressing the CLEAR key on control panel 13 Close the external gas supply valve Disconnect the manometer tubing and barbed fitting from the 1 4 NPT port hole 14 Replace the 1 4 plug where the barbed fitting was removed 15 OPEN the gas supply upstream of the u...

Page 99: ...emove the front panel top panel and front side panels from the unit by grasping and lifting straight up and outward This will expose the blower assembly for removal 3 Disconnect the lead wire from the Main Flame Detector installed on the Blower Flange Figure 7 1 4 Remove the Main Flame Detector from the Blower Flange 5 Remove the Pilot sensors and observation ports from the Burner Plate Figure 7 4...

Page 100: ...d tearing the mesh burner fabric or cock the Burner to one side or the other 18 Remove and replace the two 2 Burner Gaskets see Figure 7 5 19 To reassemble begin with the Burner assembly and reinstall all the components in the reverse order that they were removed The Burner may have a nut installed at the base position to keep the Burner level while installing the Blower Figure 7 5 20 Ensure that ...

Page 101: ...pection and Maintenance Procedures Continued Figure 7 4b Burner Assembly Mounting Details Figure 7 5 Burner Assembly Exploded View GAS TRAIN AIR FUEL VALVE TURN BUCKLE SIGHT GLASS BLOCKED INLET SWITCH BLOWER 1 2 NUTS BOLTS 4 A F VALVE TO GAS TRAIN BLOWER PROOF SWITCH AIR FUEL VALVE O RING BLOWER FLANGE BLOWER BURNER FRONT PLATE 3 8 HEX NUTS WASHERS 8 EA BURNER GASKET P N 81159 BURNER FLANGE BURNER...

Page 102: ...e refractory material The procedures for removal of the rear refractory and front refractory materials are provided in sections 7 8 1 and 7 8 2 respectively 7 8 1 Rear Refractory Removal Replacement In order to access and replace the rear refractory the following steps must be performed Rear Refractory Replacement Procedure 1 Turn off gas and electrical power to the unit In addition turn off any o...

Page 103: ... metal tabs located on the outer edge of the fiber blanket then alternately pull on the other two opposing tabs Continue this process until the fiber refractory package can be removed from the combustion chamber 12 Place the fiber insulation package metal face down in a safe location to avoid damage 13 The combustion chamber can now be viewed and inspected with a full view of the Burner assembly a...

Page 104: ...ctory Replacement Procedure Continued Figure 7 6 Rear View Showing Rear Panel Nut Latch Locations Figure 7 7 Partial Rear View Showing Rear Burner Plate THERMAL SWITCH REAR BURNER PLATE O2 SENSOR GAS SUCTION LINE FROM EXHAUST MANIFOLD RIGHT REAR COVER SPRING LATCH LEFT REAR COVER Access the rear panel nuts dotted yellow arrows on the rail base inside the unit through the open side panel on each si...

Page 105: ...Continued Figure 7 8 Partial View with Rear Plate and Refractory Removed THE HEAT EXCHANGER INSULATION UTILIZES CERAMIC FIBER MATERIAL WEAR A FITTED NIOSH APPROVED PARTICULATE RESPIRATOR 3M N95 OR EQUIV WHEN SERVICING THE HEAT EXCHANGER AND BURNER ASSEMBLIES AT HIGH TEMPERATURES CERAMIC FIBERS CAN BE CONVERTED TO CRYSTALINE SILICA FIBERS WHICH HAVE BEEN IDENTIFIED AS CARCINOGENIC WHEN INHALED WARN...

Page 106: ...The front refractory and Burner Shield should slide out of the combustion chamber with the plate 6 Spray the refractory with a water mist to reduce airborne dust 7 Remove the three 3 10 32 screws securing the Burner Shield to the Burner Plate Figure 7 9 8 Place the Burner Shield on a flat surface with the three tabs facing upward 9 Straighten the 90º bend in each tab so they are even with the side...

Page 107: ...ion Maintenance Manual CHAPTER 7 MAINTENANCE OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 107 of 210 GF 133 Ph 800 526 0288 03 20 14 Front Refractory Replacement Procedure Continued Figure 7 9 Front Plate Assembly ...

Page 108: ...ening the thumb screw on the trap inlet shown in Figure 7 10 2 Remove the connection on the outlet side of the condensate trap 3 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover 4 Remove the float and float guide from the condensate trap 5 Remove the O ring from the trap AERCO recommends that this O ring be replaced annually 6 Thoroughly clean the trap and f...

Page 109: ... Remove the front panel from the unit by grasping the handles and pulling outward 3 Refer to Figure 7 11 and locate the air filters attached to the Y shaped duct connected to the air fuel valve inlet 4 Using a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the Y duct at the air fuel valve inlet Remove the filter and clamp 5 The filters may be cleaned in hot soapy w...

Page 110: ...e boiler 4 Close external gas supply valve 5 Open relief valve to vent water pressure 7 12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing the Boiler Back in Service 1 Review installation requirements included in Chapter 2 2 Inspect all piping and connections to the unit 3 Inspect exhaust ve...

Page 111: ... RS 232 communication feature permits service personnel to view menu items and data logs which can be useful in isolating faults Refer to Chapter 9 of this manual for detailed RS 232 communication set up and procedures When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Isolation and Correction 1 Observe the fault messages displayed in the Control Box display ...

Page 112: ...nstallation Operation Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE Page 112 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 113: ...r replace as necessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 Check the continuity of the Blower Proof switch with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 6 Turn off unit and check the continuity of the Blocked Inlet switch If there is ...

Page 114: ... is OK check the blower 2 Start the unit If the blower runs turn off unit and check the Blocked Inlet switch for continuity Replace the switch if continuity does not exist 3 Remove the air filter and Blocked Inlet switch and inspect for signs of blockage Clean or replace as necessary 4 Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs o...

Page 115: ... 3 Control Box signal type selection switches not set for correct signal type voltage or current 1 Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Check signal at source to ensure it is isolated 3 Check DIP switch on PMC board to ensure it is set correctly for the type of signal ...

Page 116: ...inspect staged ignition piece for blockage FLAME LOSS DURING RUN 1 Worn Flame Detector or cracked ceramic 2 Defective Regulator 3 Poor combustion calibration 4 Debris on Burner 5 Blocked condensate drain 6 Main Flame Detector is touching burner mesh 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manom...

Page 117: ...ch 2 Incorrect PID settings 3 Faulty shell temperature sensor 4 Unit in Manual mode 5 Unit setpoint is greater than Over Temperature Switch setpoint 6 System flow rate changes are occurring faster than units can respond 7 Refractory failure 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against Menu Default settings in Appendix E If th...

Page 118: ...he ignition switch for continuity between the N O and COM terminals If the switch shows continuity when not in contact with the cam replace the switch 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 Bo...

Page 119: ...wiring 1 Check hot and neutral in AC Power Box to ensure they are not reversed 2 Check transformer wiring in AC Power Box against the power box transformer wiring diagram to ensure it is wired correctly GAS PRESSURE FAULT Due to Low Gas Pressure 1 Incorrect supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas...

Page 120: ...tively replace O2 sensor O2 OUT OF RANGE 1 Combustion Calibration incorrect 2 Blocked inlet air duct 1 Check Combustion Analyzer and recalibrate boiler 2 Unblock inlet measure open area for combustion air to room OUTDOOR TEMP SENSOR FAULT 1 Loose or broken wiring 2 Defective Sensor 3 Incorrect Sensor 1 Inspect Outdoor Temperature sensor for loose or broken wiring 2 Check resistance of sensor to de...

Page 121: ...G SWTCH OPEN DURING PURGE 1 Defective purge switch 2 No voltage present at switch 3 Switch wired incorrectly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 1 If the air fuel valve does rotate check purge switch for continuity when closing Replace switch if continuity does not exist 2 Measure for 24 VAC from each side of the switch to ground If 24VAC is not present refer fault to qua...

Page 122: ...ype set in Configuration Menu RESIDUAL FLAME 1 Defective Flame Detector 2 SSOV not fully closed 1 Replace Flame Detector 2 Check open close indicator window of Safety Shut Off Valve SSOV and ensure that the SSOV is fully closed If not fully closed replace the valve and or actuator Close the 2 Gas Shut Off Valve downstream of SSOV Figure 8 1 Install a manometer or gauge at the leak detection port b...

Page 123: ...ity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator 4 Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE 1 Air Fuel Valve out of calibration 2 Air Fuel Valve unplugged 3 Loose wiring connection to the stepper motor 4 Defective Air Fuel Valve stepper motor 5 Defective Power Supply Board or fuse 6 Def...

Page 124: ...se the 2 Manual Shutoff Valve and the 1 4 Pilot Gas Valve that connects to the flex hose of the Pilot Ignition Assy Figure 8 1 Attempt to start the unit and listen for a clicking sound that the Pilot Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Pilot Ignition Solenoid 3 Refer to Chapter 7 section 7 5 2 and check the calibration of t...

Page 125: ...t Burner Flame Detector Locations SIGHT GLASS MAIN FLAME DETECTOR TO PILOT GAS LINE BLOWER BLOWER FLANGE BURNER PLATE PILOT BURNER PILOT FLAME DETECTORS 2 EA TO AIR FUEL VALVE GAS INLET DOWNSTREAM LOW GAS PRESSURE SWITCH 6 9 W C HIGH GAS PRESSURE SWITCH 10 5 W C MANUAL SHUT OFF VALVE UPSTREAM LOW GAS PRESSURE SWITCH 8 5 W C LEAK DETECTION BALL VALVE WITH 1 4 NPT PLUG PILOT REGULATOR TEE WITH 1 4 P...

Page 126: ...HOOTING GUIDE Page 126 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 Figure 8 3 SSOV Actuator With Gas Pressure Adjustment SKP25 BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw DAMPING ORIFICE COVER SCREW ...

Page 127: ...n Operation Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 127 of 210 GF 133 Ph 800 526 0288 03 20 14 Figure 8 4 Pilot Assembly Troubleshooting Sheet 1 of 2 ...

Page 128: ...n Operation Maintenance Manual CHAPTER 8 TROUBLESHOOTING GUIDE Page 128 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 Figure 8 4 Pilot Assembly Troubleshooting Sheet 2 of 2 ...

Page 129: ...ation 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 machine brin...

Page 130: ...achine Using PuTTY PuTTY may also be used to run some command residing on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open depending on how you configure the session Here are the steps ...

Page 131: ...l are o 2400 o 4800 o 9600 Default o 19 2K Data Format The program must be set for o 8 data bits o 1 stop bit o no parity o either Xon Xoff or No flow control 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS 232 communication is accomplished as follows Menu Processing Utilizing Rs 232 Communication 7 Start the emulator...

Page 132: ...agnostic Menu 14 To change a value or setting for a displayed menu option proceed as follows a Enter C followed by the number to the right of the displayed option to be changed and then press Rtn b Enter the desired value or setting for the option and press Rtn Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning Menus T...

Page 133: ...d in non volatile memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate or flame strength must change by more than 5 or the run mode must change At steady state the run length is al...

Page 134: ...erval in the Diagnostics Menu The log interval can vary from once every minute to once every day Table 9 3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm...

Page 135: ...reach or exceed a defined Valve Position Fire Rate Operating all boilers below the defined Fire Rate Next on VP for Next Turn on Valve Position insures that they are firing at their most efficient Fire Rate One C More unit is defined as the MASTER unit and all other C More units on the BST Modbus Network are defined as SLAVE units The Master unit will monitor the system Header Temperature monitor ...

Page 136: ...tpoint choose option 1 or 2 Option 1 Direct Wired Header Complete section 10 3 1 OR Option 2 Modbus Header Complete section 10 3 2 Outdoor Reset choose option 3 or 4 Option 3 Direct Wired Header AND Direct Wired Outdoor Air Complete section 10 3 3 OR Option 4 Modbus Header AND Modbus Outdoor Air Complete section 10 3 4 Remote Setpoint choose option 5 through 8 Option 5 4 20ma Drive AND Direct Wire...

Page 137: ... supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Go to the BST Menu and ...

Page 138: ...ground for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 2 Configure ALL C More Units On ALL Boilers 1 Go to t...

Page 139: ...ant s supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Direct Wired Outdoor Sensor 1 On the MASTER Unit Connect the Outdoor Temperature Sensor AERCO PN 123525 to the OUT and COM termina...

Page 140: ...d 2 Go to the BST Menu and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Outdoor Reset 6 Go to the Head Temp Source item and select FFWD Temp 7 Go to the BST Outdoor Sens item and select Enabled 8 Go to the Outdoor Temp Source it...

Page 141: ...ox The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 2 Modbus Outdoor Sensor Wiring 1 If you have not already done so when installing the Modbus Header Sensor use Shiel...

Page 142: ... only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Outdoor Reset 6 Go to the Head Temp Source item and select Network 7 Go to the Header Temp Addr item and enter the Modbus Address 240 8 Go to the Header Temp Point item and enter the Modbus Point 14 9 Go to the BST Outdoor Sens item an...

Page 143: ...be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Direct Wired 0 20ma or 4 20ma Wiring 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master Unit s I O Box NOTE Shielded pair 18 22 AWG cable is recommended for this connection Polarity must b...

Page 144: ...t s supply water header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Step 3 Configure ALL C More...

Page 145: ...hielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor AERCO PN 24410 to pins 2 and 3 of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES Polarity must be observed for the RS485 connections The ground for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet dow...

Page 146: ...e item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Remote Setpoint 6 Go to the BST Remote Signal and select either 4 20ma or 0 20ma 7 Go to the Head Temp Source item and select Network 8 Go to the Header Temp Addr item and enter the Modbus Address 2...

Page 147: ...ctions The ground for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure...

Page 148: ...allation Operation Maintenance Manual CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Page 148 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 149: ...rom the charts in Appendix D Inlet Water Temp Displays the inlet water temperature in ºF or ºC Default is ºF Air Temp Air Temp is the air temperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed Outdoor Temp Outdoor temperature is displayed in ºF default or ºC only if outdoor sensor is installed and enabled Valve Position In Desire...

Page 150: ...ddress For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The COMM LED will light du...

Page 151: ...ference temperature to be set when operating a boiler in the Outdoor Reset Mode Default is 70 F Reset Ratio If Boiler Mode Outdoor Reset Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode Reset Ratio is adjustable from 0 1 to 9 9 Default is 1 2 Outdoor Sensor Allows outdoor sensor function to be enabled or disabled Default is disabled System Start Tmp If Outdoor Sensor ...

Page 152: ...Enabled Setpt Limit Band The Setpoint Limit Band can be set from 0 to 10 The default setting is 5 Network Timeout Specifies the timeout value seconds before a Modbus fault is declared Available settings range from 5 to 999 seconds Default is 30 seconds Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temperature value the Outlet ...

Page 153: ...e attempted while the Outlet Temperature remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 to 25 Default is 2 for both Deadband High and Deadband Low IGST...

Page 154: ...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 1 0 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output WARMUP The feature embodied in the next thr...

Page 155: ...cribed in Chapter 4 of this Manual CAL Voltage 14 CAL Voltage 30 CAL Voltage 40 CAL Voltage 50 CAL Voltage 70 CAL Voltage 100 Displays the default DC drive voltage provided to the blower at each of the Air Fuel Valve positions show in the left hand column This drive voltage adjusts the rotational speed of the blower to maximize combustion efficiency Set Valve Position Permits selection of the Air ...

Page 156: ...tallation Operation Maintenance Manual APPENDIX A BOILER MENU DESCRIPTIONS Page 156 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 157: ...date that the unit was disabled FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during the purge cycle ...

Page 158: ...HAUST TEMP SENSOR SHORT Exhaust temperature sensor is shorted FFWD TEMP SENSOR FAULT The temperature measured by the Feed Forward FFWD Sensor is out of range FLAME LOSS DURING IGN The Flame signal was not seen during ignition or lost within 5 seconds after ignition FLAME LOSS DURING RUN The Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to ...

Page 159: ...rcentage measured by the O2 sensor is below O2 SENSOR MALFUNCTION A fault exists in the O2 sensor OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range OUTLET TEMP SENSOR FAULT The temperature measured by the Outlet Sensor is out of range OUTLET TEMPERATURE display SHt Indicates sensor is shorted OUTLET TEMPERATURE display Opn indicates sensor is open circuit...

Page 160: ... IGN The SSOV switch closed or failed to open during ignition SSOV FAULT DURING RUN The SSOV switch closed for more than 15 seconds during run SSOV RELAY FAILURE A failure has been detected in one of the relays that control the SSOV STEPPER MOTOR FAILURE The Stepper Motor failed to move the Air Fuel Valve to the desired position WARNING EXHAUST TEMP HIGH The exhaust temperature measured by the exh...

Page 161: ...stance 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 162: ...lation Operation Maintenance Manual APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 162 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 163: ... 120 130 140 150 160 170 5F 83 94 105 116 127 138 149 160 171 182 10F 86 98 110 122 134 146 158 170 182 194 15F 89 102 115 128 141 154 167 180 193 206 20F 92 106 120 134 148 162 176 190 204 218 Table D 2 Header Temperature for a Building Reference Temperature of 60ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 60F 60 60 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72 50F...

Page 164: ...61 173 185 197 209 0 104 117 130 143 156 169 182 195 208 5 107 121 135 149 163 177 191 205 219 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Table D 4 Header Temperature for a Building Reference Temperature of 70ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70F 70 70 70 70 70 70 70 70 70 70 65F 73 74 75 76 77 78 79 80 81 82 60F 76 78...

Page 165: ...9 171 183 195 207 219 10F 114 127 140 153 166 179 192 205 218 5F 117 131 145 159 173 187 201 215 0F 120 135 150 165 180 195 210 5F 123 139 155 171 187 203 219 10F 126 143 160 177 194 211 15F 129 147 165 183 201 219 Table D 6 Header Temperature for a Building Reference Temperature of 80ºF RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 80F 80 80 80 80 80 80 80 80 80 80 75F 83 84 85 86 ...

Page 166: ...0F 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 123 ...

Page 167: ...u Internal Setpt 130 F Unit Type BMK Boiler LN Unit Size 6000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bldg Ref Temp If Boiler Mode Outdoor Reset 70 F Reset Ratio If Boiler Mode Outdoor Reset 1 2 Outdoor Sensor Disabled System Start Tmp If Outdoor Sensor Enabled 60 F Setpt Lo Limit 60 F Setpt Hi Limit 195...

Page 168: ...uvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 BOILER DEFAULT SETTINGS Continued MENU OPTION FACTORY DEFAULT Configuration Menu Continued Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min ...

Page 169: ... Operation Maintenance Manual APPENDIX F CLEARANCE DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 210 GF 133 Ph 800 526 0288 03 20 14 APPENDIX F CLEARANCE DRAWINGS Drawing Number AP A 901 rev H ...

Page 170: ...er Installation Operation Maintenance Manual APPENDIX F CLEARANCE DRAWINGS Page 170 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 Drawing Number SD A 919 rev E ...

Page 171: ...er Installation Operation Maintenance Manual APPENDIX F CLEARANCE DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 210 GF 133 Ph 800 526 0288 03 20 14 Drawing Number SD A 928 rev A ...

Page 172: ...Installation Operation Maintenance Manual APPENDIX F CLEARANCE DRAWINGS Page 172 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 173: ...BOX C MORE BLOWER ASSEMBLY 62 1 65085 TRANSFORMER IGNITION 19 1 58065 BLOWER REPLACEMENT KIT 63 2 65135 OMRON RELAY BASE 27 1 59198 TURNBUCKEL 64 2 65134 OMRON RELAY 120V 65 4 39168 CLIP SHIELD 66 1 61032 SURFACE TEMP SENSOR 67 1 123449 SENSOR TEMP 1 1 2 68 1 61026 SENSOR O2 69 1 61030 1 1 2 TEMP SENSOR BALCO WIRE AND RTD 70 1 93359 THERMOWELL 71 1 64081 ECU BURNER AIR FUEL VALVE HEAT EXCHANGER 72...

Page 174: ...CK HARNESS 109 8 59133 LATCH COMPRESSION 86 1 63090 HARNESS ASSY TEMP LIM CONT PWR 110 1 25078 ASSEMBLY FRONT PANEL 87 1 124310 TRANSFORMER STEPDOWN 500V 120V 111 2 35024 TOP RAIL 88 1 69161 2 DIN RAIL 112 1 72068 AERCO LOGO 89 1 124324 GROUND BAR 113 1 74024 LOGO BMK 6000 90 1 63125 1 GAS TRAIN HARNESS 114 2 33148 BRACE DIAGONAL 91 1 38035 PANEL COVER I O BOX 92 1 38036 POWER PANEL COVER HOSE INS...

Page 175: ...T LIST DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 210 GF 133 Ph 800 526 0288 03 20 14 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 3 of 8 FRONT CROSS SECTION REAR ...

Page 176: ...Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 24328 BURNER ASSEMBLY 460V w BLOWER 65127 24328 2 BURNER ASSEMBLY 208V w BLOWER 65127 1 30 NOTE A complete Blower and Air fuel Valve part list is shown on pages below AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 4 of 8 ...

Page 177: ...PENDIX G PART LIST DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 210 GF 133 Ph 800 526 0288 03 20 14 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 5 of 8 ...

Page 178: ...PART LIST DRAWINGS Page 178 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 6 of 8 REAR OVERHEAD VIEW ...

Page 179: ... 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 210 GF 133 Ph 800 526 0288 03 20 14 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 7 of 8 POWER I O BOX P N 2435 3 COVERS REMOVED RELAY BOARD P N 24358 ...

Page 180: ...00 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 Part List 02 01 2014 Whole Boiler p n 28510 PL A 178 Sheet 8 of 8 BENCHMARK 6000 GAS TRAIN P N 22172 1 7 6 A complete gas train part list is shown on the pages below DOUBLE BLOCK BLEED VENT LINE P N 22219 ...

Page 181: ...668 NUT JAM 3 8 16 4 1 65127 BLOWER 460V 14 3 124008 NIPPLE 1 8 NPT X 3 00 LG 1 65127 1 BLOWER 208V 15 2 123535 TEE 1 8 NPT 5 2 59192 OBSERVATION PORT 16 1 60011 4 SWITCH ASSY BLOWER PROOF 6 1 59140 SIGHT GLASS 1 17 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 7 1 24352 A F VALVE ASSY 18 1 93035 ELBOW STREET 1 4 NPT 8 8 52035 STUD 3 8 16 X 1 50 LG 19 1 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 9 12 56004 NUT F...

Page 182: ... APPENDIX G PART LIST DRAWINGS Page 182 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 AERCO International Inc Blauvelt NY 10913 Benchmark 6000 FM Gas Train 07 09 2013 22172 1 rev C AP A 912 Sheet 1 of 2 ...

Page 183: ... 123536 BUSHING REDUCING 1 4 X 1 8 NPT 20 1 61002 17 HIGH GAS PRESSURE SWITCH 10 5 W C 21 1 63125 HARNESS GAS TRAIN 7 SEC IGNITION 22 1 61002 18 LOW GAS PRESSURE SWITCH 8 5 W C 23 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 24 1 99015 DAMPING ORIFICE SSOV 25 1 122403 SWITCH LOW 6 90 W C 26 1 124862 RESISTOR ASSY 27 4 12951 2 BUSHING CONTROL BOX 28 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 29 3 92077 1 4 NPT ...

Page 184: ... Installation Operation Maintenance Manual APPENDIX G PART LIST DRAWINGS Page 184 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 185: ...ion Operation Maintenance Manual APPENDIX H PIPING DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 210 GF 133 Ph 800 526 0288 03 20 14 APPENDIX H PIPING DRAWINGS Drawing Number SD A 921 rev E ...

Page 186: ...ler Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS Page 186 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 Drawing Number SD A 922 rev E ...

Page 187: ...ler Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 187 of 210 GF 133 Ph 800 526 0288 03 20 14 Drawing Number SD A 924 rev C ...

Page 188: ...er Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS Page 188 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 189: ...WIRING DIAGRAMS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 189 of 210 GF 133 Ph 800 526 0288 03 20 14 APPENDIX I C MORE WIRING DIAGRAMS Drawing Number 68043 rev B Sheet 1 of 2 The AERCO BST sensor internally switches to neutral when the flame is proven ...

Page 190: ...stallation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 190 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 191: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 210 GF 133 Ph 800 526 0288 03 20 14 Drawing Number 68043 rev B Sheet 2 of 2 ...

Page 192: ...stallation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 192 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 193: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 210 GF 133 Ph 800 526 0288 03 20 14 Drawing Number 68048 rev B Sheet 1 of 2 ...

Page 194: ...stallation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 194 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 195: ...allation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0086_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 195 of 210 GF 133 Ph 800 526 0288 03 20 14 Drawing Number 68048 rev B Sheet 2 of 2 ...

Page 196: ...stallation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 196 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This page left intentionally blank ...

Page 197: ...og Instrument and equipment settings Daily Operator Visual check against factory recommended specifications Weekly Operator Verify factory settings Firing Rate Control Semi Annually Service Technician Verify factory settings Annually Service Technician Check with combustion calibration test equipment See section 7 5 and Chapter 4 Flue vent stack or intake air duct Monthly Operator Visually inspect...

Page 198: ...y Operator See sections 6 2 and 6 3 Air Fuel Valve purge position switch Annually Service Technician See section 6 10 Air Fuel Valve ignition position switch Annually Service Technician See section 6 11 Safety valves As required Operator Check per A S M E Boiler and Pressure Vessel Code Section IV Inspect Burner components Semi Annually Service Technician See section 7 7 Condensate Trap Semi Annua...

Page 199: ...NCHMARK P N 124718 FRONT FACE PLATE BENCHMARK P N 124949 FISH PAPER INSULATOR P N 124960 ENCLOSURE P N 124951 V F D DISPLAY MODULE P N 124527 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW WATER CUTOFF BOARD P N 124363 CONNECTOR BOARD P N 124366 IGNITION STEPPER BOARD P N 124361 POWER SUPPLY BOARD P N 124362 GREEN LED P N 124948 ROCKER SWITCH P N 124947 PUSH BUTTON SWITCHES P N 124954 BENCHMARK...

Page 200: ...Y 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 P1 P2 P3 P4 P5 P6 SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN SENSOR HARNESS CONNECTOR 7 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX Figure K 2 Benchmark Control Panel Rear View ...

Page 201: ...ommended Emergency Spare Parts DESCRIPTION PART NUMBER 208 VAC or 460 VAC Blower 24351 or 24350 SSOV Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of IRI gas train models 69005 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset 123552 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTI...

Page 202: ...Installation Operation Maintenance Manual APPENDIX L C RECOMMENDED SPARES Page 202 of 210 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0086_0D 03 20 14 Ph 800 526 0288 GF 133 This Page Is Intentionally Blank ...

Page 203: ...m construction vehicles erection equipment etc Accessible for periodical inspection and maintenance 2 The blower should be supported under each corner of its base to allow it to breath Supports 2 x 4 s timbers or railroad ties should be placed diagonally under each corner 3 If the equipment is to be stored for more than three 3 months the entire blower assembly must be loosely covered with plastic...

Page 204: ... drop in insulation resistance b DO NOT lubricate the motor bearings during storage Motor bearings are packed with grease at the factory c If the storage location is damp or humid the motor windings must be protected from moisture This can be done by applying power to the motor s space heaters IF AVAILABLE while the motor is in storage If the motor does not have space heaters storing it in a damp ...

Page 205: ...e ultra low NOx requirement of less than 9 ppm IT IS IMPORTANT TO PERFORM THE FOLLOWING PROCEDURE AS OUTLINED BELOW THIS WILL KEEP READJUSTMENTS TO A MINIMUM AND PROVIDE OPTIMUM PERFORMANCE Ultra Low NOx Natural Gas Combustion Calibration 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 unit 3 Set the co...

Page 206: ...n as possible If the readings differ by more than 1 5 use the on board O2 sensor to calibrate the unit Have your combustion analyzer serviced 14 Compare the measured oxygen level to the oxygen range shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readings do not exceed the values shown Ultra Low NOx Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide ...

Page 207: ...HANGE key SET Valve Position will begin to flash 22 Press the arrow key until SET Valve Position reads 80 Press the ENTER key 23 Next press the down arrow key until CAL Voltage 80 is displayed 24 Press the CHANGE key and observe that CAL Voltage 80 is flashing 25 The oxygen level at the 80 valve position should be as shown below Also ensure that the nitrogen oxide NOx and carbon monoxide CO readin...

Page 208: ...is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve see Appendix F Rotate the screw 1 2 turn clockwise CW to add fuel and reduce the O2 to the specified level Recalibration MUST be performed again from 60 down to 18 after making a change to the idle screw TAC valve 30 This completes the ultra low NOx Natural Gas combustion calibration ...

Page 209: ...ch claim Any claims relating to this product shall be limited to the sale price of the product at the time of sale The sale of the product is specifically conditioned upon acceptance of these terms CONDITIONS OF WARRANTY Should an AERCO gas fired natural gas propane and natural gas propane dual fuel only boiler fail for any of the above reasons within the specified time period from the date of ori...

Page 210: ...d graphics Curtis Harvey 03 20 2014 Rev D PIR 934 11 Changed 30 to 50 in step 9 of section 4 4 Combustion calibration PIR 967 Added DBB Vent Line 22219 to part list PIR 942 Replaced 460 V Power Box label in section 2 9 PIR 934 24 Increased max height of housekeeping pad to 8 inch Chapter 2 PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Valve Installation additi...

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