Aerco Benchmark BMK 1000 User Manual Download Page 192

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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual

Page

192

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0082_0J

05/21/2014

Ph.: 800-526-0288

GF-130

Inc., 2014

Change Log:

Date

Description

Changed By

03/19/2014

Rev I:

PIR 780

: replaced mechanical latch with magnetic

PIR 981

: Expanded Table A in Appendix F Part List

PIR 934-33

: Modified step 13 in Combustion

Calibration regarding defective O

Sensor.

PIR 934-37

: Modified Blocked Inlet Switch Test

instructions, section 6.8.2.

PIR 960

: Addition of two sub-sections in 2.10.12;

addition of section 2.15 Sequencing Isolation Valve
Installation; 3.9 _BST Menu; addition of Chapter 10
– Boiler Sequencing Technology; replaced all wiring
schematics in Appendix I, addition of 24V
Sequencing Valve & Flame Rod Amplifier.

PIR 974

: Replaced Gas train harness 161450 with

63147 in Appendix G.

PIR 1000

: P/N 61026 now labeled “Lean Oxygen

Sensor,” 64081 now named “ECU”

PIR 1005:

Changed 12 Month Maintenance Kit part

number to 58025-01

Chris Blair

05/21/2014

Rev J:

PIR 749

: Added Propane to section 2.8 Gas supply

Piping; new Propane combustion calibration section
4.4; modified sections 6.2 & 6.3; added Propane
gas train 22140-3 drawings to Appendix G.

PIR 934-65

: Added explanatory paragraph & note to

section 2.15 – Sequencing Isolation Valve
Installation

Chris Blair

Summary of Contents for Benchmark BMK 1000

Page 1: ...ni Dr Blauvelt NY 10913 Page 1 of 192 GF 130 Ph 800 526 0288 05 21 2014 BENCHMARK Series Gas Fired Boilers USER MANUAL Installation Operation and Maintenance Natural Gas Propane Modulating Condensing Hot Water Boiler Models BMK 750 BMK 1000 Applicable to Serial Numbers G 14 0752 and above Latest Update 05 21 2014 ...

Page 2: ...information 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 ...

Page 3: ...e 23 2 8 3 External Gas Supply Regulator 23 2 8 3 1 Massachusetts Installations Only 23 2 8 3 2 All Installations Except Massachusetts 23 2 9 AC ELECTRICAL POWER WIRING 24 2 9 1 Electrical Power Requirements 25 2 10 FIELD CONTROL WIRING 26 2 10 1 OUTDOOR AIR IN Terminals 28 2 10 2 COMBUSTION AIR Terminal 29 2 10 3 O2 SENSOR Terminals 29 2 10 4 SPARK SIGNAL Terminals 29 2 10 5 ANALOG IN Terminals 2...

Page 4: ...ART UP REQUIREMENTS 55 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION 55 4 2 1 Required Tools Instrumentation 56 4 2 2 Installing Gas Supply Manometer 56 4 2 3 Accessing the Analyzer Probe Port 57 4 3 NATURAL GAS COMBUSTION CALIBRATION 58 4 4 PROPANE COMBUSTION CALIBRATION 61 4 5 REASSEMBLY AFTER COMBUSTION CALIBRATION 64 4 6 OVER TEMPERATURE LIMIT SWITCHES 65 4 6 1 Digital Alarm Switch ...

Page 5: ...tch Test 84 6 9 SSOV PROOF OF CLOSURE SWITCH 86 6 10 PURGE SWITCH OPEN DURING PURGE 87 6 11 IGNITION SWITCH OPEN DURING IGNITION 87 6 12 SAFETY PRESSURE RELIEF VALVE TEST 88 CHAPTER 7 MAINTENANCE 89 7 1 MAINTENANCE SCHEDULE 89 7 2 IGNITER INJECTOR REPLACEMENT 90 7 3 FLAME DETECTOR REPLACEMENT 92 7 4 O2 SENSOR REPLACEMENT 93 7 5 COMBUSTION CALIBRATION 93 7 6 SAFETY DEVICE TESTING 93 7 7 BURNER ASSE...

Page 6: ...Header Sensor AND MODBUS Outdoor Sensor 129 10 3 5 Option 5 Remote Setpoint with DIRECT WIRED Header Sensor AND 4 20ma Setpoint Drive 131 10 3 6 Option 6 Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive 133 10 3 7 Option 7 Remote Setpoint with MODBUS Header Sensor AND 4 20ma Setpoint Drive 134 10 3 8 Option 8 Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Dr...

Page 7: ... output of each boiler model 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 750 and BMK 1000 MBH Boilers comply with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the BMK 750 and ...

Page 8: ... 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 Communication BTU British Thermal Unit A unit of energy ap...

Page 9: ...inimum 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 RS 232 networks PWM Pulse ...

Page 10: ...s Abbreviations and Acronyms Continued Phrase Abbreviation or Acronym Meaning 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 VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Watt W C Water Column µA Micro amp 1 millionth of an ampere ...

Page 11: ... and applicable Provincial regulations for the class which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made See pages 13 and 14 for important information regarding installation of units within the Commonwealth of Massachusetts IMPORTANT This Instruction Manual is an integral part of the product and must be maintained in leg...

Page 12: ...FELY DISCONNECT ELECTRICAL SERVICE DO NOT AFFIX SWITCH TO UNIT SHEET METAL ENCLOSURES Many soaps used for gas 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 EM...

Page 13: ...s and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In additio...

Page 14: ...de 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 or the venting system components and 2 A complete parts list for the venting system de...

Page 15: ...ing shipment If the Tip 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 UNPACKING Carefully unpack the unit taking care not to damage the unit enclosure w...

Page 16: ...ne at a minimum pressure of 11 W C 2 4 1 Installation Clearances Benchmark Models 750 and 1000 are packaged in enclosures having identical exterior dimensions The unit must be installed with the prescribed clearances for service as shown in Figure 2 1a The minimum clearance dimensions required by AERCO are listed below However if Local Building Codes require additional clearances these codes shall...

Page 17: ...The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate drainage see NOTE below If anchoring the unit refer to the dimensional drawings in Figure 2 1b for anchor locations NOTE When using the AERCO Condensate Neutralizer Tank for proper condensate drainage the Neutralizer Tank must be stored in a pit OR the boiler and AERCO Condensate Trap must be elevated hig...

Page 18: ...ws hex nuts and flat washers 2 Remove the top shroud from the boiler by grasping the handle on the top of the unit and lifting straight up Locate the lifting tab at the top rear of the heat exchanger 3 Refer to Figure 2 2 View B and attach the lifting bar to the heat exchanger lifting tab using the hardware removed in step 1 The upper end of the lifting bar containing the oval cutout should be pos...

Page 19: ... shown in Figure 2 3 Refer to Appendix F Drawing AP A 891 for additional dimensional data Figure2 3 Supply and Return Locations 2 6 PRESSURE RELIEF VALVE INSTALLATION An ASME rated Pressure Relief Valve is supplied with each Benchmark Boiler The pressure rating for the relief valve must be specified on the sales order Available pressure ratings range from 30 psi to 160 psi The relief valve is inst...

Page 20: ... NPT ports Figure2 5 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2 6 However the actual installation details for the trap will vary depending on the available clearances 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...

Page 21: ...with a hose clamp 4 Route the hose on the trap outlet to a nearby floor drain If a floor drain is not available a condensate pump can be used to remove the condensate to an appropriate drain The maximum condensate flow rate is 10 GPH The condensate drain trap associated fittings and drain line must be removable for routine maintenance Use PVC stainless steel aluminum or polypropylene for condensat...

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

Page 23: ...f 4 0 W C to the unit PROPANE The external natural gas regulator must be capable of regulating 49 000 1 020 000 BTU HR while maintaining a minimum gas pressure of 11 0 W C to the unit A lock up style regulator MUST be used when gas supply pressure will exceed 14 W C 2 8 3 1 Massachusetts Installations Only For Massachusetts installations a mandatory external gas supply regulator must be positioned...

Page 24: ... front panel to access the Power Box which is mounted in the upper right corner of the unit as shown in Figure 2 8 Open the hinged cover of the Power Box to access the AC terminal block connections and other internal components shown in Error Reference source not found 2 9 Figure2 8 Power Box With Closed Cover POWER BOX WITH HINGED FRONT COVER FRONT UPPER RIGHT CORNER OF UNIT 1 MANUAL SHUTOFF VALV...

Page 25: ...not found 2 9 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 2 9 1 Electrical Power Requirements The Benchmark Boiler accepts 120 VAC single phase 60 Hz 20A The Power B...

Page 26: ... 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 wiring diagrams see the AERCO Benchmark Electrical Power Guide GF 2060 2 10 FIELD CONTROL ...

Page 27: ...x Location The I O board terminal strip connections are shown in Figure 2 12 All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided on the sides of the I O board NOTE Use Figure 2 12 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 I O BOARD ECU FOR O2 S...

Page 28: ...ith another mode if it is desired to use the outdoor sensor enable disable feature This feature allows the boiler to be enabled or disabled based on the outdoor air temperature The factory default for the outdoor 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...

Page 29: ... and are used when an external signal is used to change the setpoint Remote Setpoint Mode of the boiler Either a 4 to 20 mA 1 to 5 VDC or a 0 to 20 mA 0 to 5 VDC signal may be used to vary the set point or air fuel valve position The factory default setting is for 4 to 20 mA 1 to 5 VDC however this may be changed to 0 to 20 mA 0 to 5 VDC using the Configuration Menu described in Chapter 3 If volta...

Page 30: ...be connected to the boiler The RS 232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing fault and sensor log displays 2 10 11 VFD Blower 0 10 AGND 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 ...

Page 31: ...d To use this option you must disconnect the harness from the Delayed Interlock terminals and connect the proving device in its place Should the proving switch not prove within the programmed time frame the unit will shut down The AUX START ON DLY can be programmed from 0 to 120 seconds This option is located in the Configuration Menu Chapter 3 2 10 13 FAULT RELAY NC COM NO Terminals The fault rel...

Page 32: ...ed or installed Air supply is a direct requirement of ANSI 223 1 NFPA 54 CSA B149 1 and local codes These codes should be consulted before a permanent design is determined The combustion air must be free of chlorine halogenated hydrocarbons or other chemicals that can become hazardous when used in gas fired equipment Common sources of these compounds are swimming pools degreasing compounds plastic...

Page 33: ...nfiguration each unit must have a minimum 6 inch diameter connection at the unit 2 14 BENCHMARK PUMP RELAY OPTION An optional Benchmark pump relay allows the user to turn a pump on off and open close a motorized valve as the boiler cycles on and off on demand The Pump Delay Timer feature allows the user to keep the pump running and keep the motorized valve open for up to 30 minutes after the boile...

Page 34: ...hipped with a connection for an optional motorized external sequencing isolation valve p n 92084 TAB included in the shipping 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 enti...

Page 35: ...wired to accept the sequencing isolation valve Installation consists of installing the sequencing isolation valve in the hot water outlet pipe and then connecting it into the shell harness as described below NOTE When the Sequencing Isolation Valve is used the AUX START ON DLY in the Configuration menu must be set to at least 120 seconds The Sequencing Isolation Valve control is only available whe...

Page 36: ... One end of this cable is connected to the DELAYED INTERLOCK IN terminals in the I O board see Figure 2 14 while the other end contains a Molex connector with a jumper wire inserted in it this jumper wire allows units that do not have a sequencing isolation valve to operate normally Find the free end of this cable inside the unit s enclosure Figure 2 14 Sequencing Isolation Valve Installed 3 Remov...

Page 37: ...S SYSTEM INCLUDE 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 star...

Page 38: ... 1 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...

Page 39: ...isplaying 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 c...

Page 40: ... the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key is presse...

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

Page 42: ...M 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 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: ...Temp 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...

Page 44: ...re 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 entere...

Page 45: ...ater LN Innovation WH BMK Blr LN Unit Size Only the unit sizes available for the Unit Type will be displayed 750 MBH 1000 MBH 1500 MBH 2000 MBH 2500 MBH 3000 MBH 6000 MBH 750 MBH or 1000 MBH Fuel Type Natural Gas Propane Natural Gas Boiler Mode Constant Setpoint Remote Setpoint Direct Drive Combination Outdoor Reset Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combinatio...

Page 46: ...t 5 Sec 999 Sec 30 Sec HI DB Setpt EN 0 100 30 Demand Offsert 0 25 0 Deadband High 0 25 0 Deadband Low 0 25 0 Spark Monitor Enabled or Disabled Disabled Spark Current Display DO NOT CHANGE the Analog Output Menu Item from its Default setting Valve Position 0 10V 3 7 TUNING MENU The Tuning Menu items shown in Table 3 5 are Factory set for each individual unit Do not change these menu entries unless...

Page 47: ...lt Minimum Maximum CAL Voltage 16 1 70 2 20 1 80 CAL Voltage 30 1 90 3 50 3 20 CAL Voltage 45 2 60 4 40 3 70 CAL Voltage 60 2 70 4 50 3 80 CAL Voltage 80 3 60 4 40 4 60 CAL Voltage 100 4 80 6 20 6 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...

Page 48: ...mp NA Header Temp F BST Fire Rate 0 100 Fire rate BST Ave Fire 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 ...

Page 49: ...ST Max Boilers 1 8 8 BST On Delay 30 sec 300 sec 60 sec BST On Timeout 15 sec 300 sec 60 Sec Valve Override Off Closed 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...

Page 50: ...hes include Safety Shut Off Valve SSOV Proof of Closure POC switch Low Water Level switch High Water Temperature switch High Gas Pressure switch Low Gas Pressure switch Blower Proof switch Blocked Inlet switch If all of the above switches are closed the READY light above the ON OFF switch will light and the unit will be in the Standby mode When there is a demand for heat the following events will ...

Page 51: ...urge cycle will be initiated and the following events will occur a The Blower relay energizes and turns on the blower b The Air Fuel Valve rotates to the full open purge position and closes purge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 c The VALVE POSITION bargraph will show 100 Figure 3 4 Air Fuel Valve In Purge Position SSOV GA...

Page 52: ...el Valve rotates to the low fire ignition position and closes the ignition switch The dial on the Air Fuel Valve Figure 3 6 will read between 25 and 35 to indicate that the valve is in the low fire position b The igniter relay is activated and provides ignition spark Current to the spark igniter is monitored for proper level If no spark is present the Controller will stop the ignition process at 3...

Page 53: ...will be closed Standby will be displayed 3 11 START STOP LEVELS The start and stop levels are the Air Fuel Valve positions open that start and stop the unit based on load These levels are Factory preset as follows Start Level 22 Stop Level 18 Normally these settings should not require adjustment Note that the energy input of the boiler is not linearly related to the Air Fuel Valve position Refer t...

Page 54: ... Energy Input For 750 MBH 1000 MBH Units Running On PROPANE Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 750 MBH 1000 MBH 750 MBH 1000 MBH 0 0 0 0 0 10 0 0 0 0 18 Stop Level 50 000 50 000 6 7 5 0 20 71 000 71 000 9 5 7 1 30 128 000 181 000 17 18 40 373 000 400 000 50 40 50 508 000 562 000 68 56 60 565 000 703 000 75 70 70 621 000 791 000 83 79 80 660 000 86...

Page 55: ...fficiency 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...

Page 56: ...d plastic tubing 1 4 inch NPT to barbed fittings for use with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to monitor the gas pressure on the downstream side of the SSOV during the Combustion Calibration procedures described in section 4 3 The gas supply manometer is i...

Page 57: ...e on the downstream side of the SSOV as shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 4 2 3 Accessing the Analyzer Probe Port The unit contains a 1 4 NPT port on the side of the exhaust manifold as shown in Figure 4 2 Prepare the port for the combustion analyzer ...

Page 58: ... Data sheets are shipped with each unit These sheets must be filled out and returned to AERCO for proper Warranty Validation It is important to perform the following procedure as outlined This will keep readjustments to a minimum and provide optimum performance NATURAL GAS Combustion Calibration 1 Open the water supply and return valves to the unit and ensure that the system pumps are running 2 Op...

Page 59: ...defective and need to be replaced 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 If you are not in a NOx limited area and or do not have a NOx measurement in your analyzer set the oxygen O2 at 5 5 0 5 Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NO...

Page 60: ...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 61: ...dix G 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 NATURAL GAS combustion calibration procedures 4 4 PROPANE COMBUSTION CALIBRATION Complete the instructions below if the unit will run on PROPANE gas rather than Natural Gas ...

Page 62: ...s pressure adjustment is required remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 above Make gas pressure adjustments using a flat tip screwdriver to obtain the gas pressure listed above 11 Using the arrow key increase the valve open position to 100 Verify that the gas pressure on the downstream side of the SSOV settles within the range listed i...

Page 63: ...hese steps assume that the inlet air temperature is within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O2 level up to 1 higher than the listed calibration range Record the increased O2 value on the Combustion Calibration sheet 18 Press the MENU key on the front panel of the C More and access the Setup menu Enter password 6817 and then press the ENTER key ...

Page 64: ...le Record the increased O2 value on the Combustion Calibration sheet Propane Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 60 5 6 30 ppm 100 ppm 45 5 6 30 ppm 100 ppm 30 5 8 6 8 30 ppm 100 ppm 18 5 6 30 ppm 100 ppm 29 If the oxygen level at the 18 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw...

Page 65: ... front panel from the unit The manual reset switch is not adjustable and is permanently fixed at 210 F This switch will shut down and lock out the boiler if the water temperature exceeds 210 F Following an over temperature condition it must be manually reset by pressing the manual reset button shown in Figurer 4 4 before the boiler can be restarted The rotary dial temperature limit switch is manua...

Page 66: ...larm 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 5 F Alarm RST SET Limit Control Figure 4 5 Digital Alarm Switch Front Panel PARTIAL FRONT VIEW WITH PANEL REMOVED Digital Over Temperature Limit Controller Reset button for Manual Temperature Limit Swit...

Page 67: ... not show the required over temperature alarm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210ºF is displayed press the SET button to store the setting in memory 6 To calibrate the offset P1 press and hold the SET button for 8 seconds on the Digital Alarm Switch Access code value 0 should appear in the ...

Page 68: ...ler Installation Operation Maintenance Manual CHAPTER 4 INITIAL START UP Page 68 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 69: ...eset Ratio Reset ratio is an adjustable number from 0 1 to 9 9 Once adjusted the supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ratio of 1 6 is used for each degree that outside air temperature decreases the supply header temperature will increase by 1 6 degrees 5 2 2 Building Reference Temperature This is a...

Page 70: ... display will begin to flash 8 Use the and arrow keys to select the desired Building Reference Temperature 9 Press ENTER to save any changes 10 Next scroll through the Configuration Menu until 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 S...

Page 71: ...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 current and voltage signals described above the Remote Setpoint mode can also driven by a RS 485 Modbus Network signal from an EMS or BAS The Remote Setpoint modes of operation can be used to drive single as well as multiple units N...

Page 72: ...controlled no startup instructions are necessary In this mode the REMOTE LED will light when the external signal is present To operate the unit in the Manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Remote Setpoint mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 5 DIRECT DRIV...

Page 73: ... used must be a two wire shielded pair from 18 to 22 AWG Polarity must be observed The source end of the shield must be connected at the source When driving multiple units each unit s wiring must conform to the above 5 5 2 Direct Drive Startup Since this mode of operation is factory preset and the valve position is being externally controlled no startup instructions are necessary In this mode the ...

Page 74: ...n There are no setup instructions for each individual unit To operate the unit in manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to ACS mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 7 COMBINATION CONTROL SYSTEM CCS NOTE Only ACS can be utilized for the Combination Control System ...

Page 75: ...tween the BLDG PRIORITY and the DHW PRIORITY boilers In Option 2 when the space heating load is such that when all the space heating boilers are at the 100 valve position the ACS will then ask the ACS Relay Box for the domestic boilers to become space heating boilers Provided the domestic hot water load is satisfied the combo hot water boilers will then become space heating boilers If the domestic...

Page 76: ...unctions for combination mode these functions are preset to their factory default values These default settings work well in most applications It is suggested that AERCO be contacted prior to changing 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...

Page 77: ...er the start sequence The following tests check to ensure that the system is operating as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Ch...

Page 78: ...5 While the unit is firing slowly close the external manual gas shut off valve 6 The unit should shut down and display a GAS PRESSURE fault message and the FAULT indicator should also start flashing at the following approximate pressures BMK 750 1000 NATURAL GAS gas trains 2 6 W C BMK 750 PROPANE gas train 4 4 W C BMK 1000 PROPANE gas train 7 5 W C 7 Fully open the external manual gas shut off val...

Page 79: ...essure using the adjustment screw on the SSOV see Figure 4 3 in Chapter 4 7 The unit should shut down and display a GAS PRESSURE fault message and the FAULT indicator should also start flashing at the following approximate pressures BMK 750 1000 NATURAL GAS gas trains 4 7 W C BMK 750 PROPANE gas train 4 7 W C BMK 1000 PROPANE gas train 10 5 W C 8 Reduce the gas pressure back to the value recorded ...

Page 80: ... LOW WATER LEVEL fault message is displayed and the FAULT indicator flashes 5 Place the unit in the Manual Mode and raise the valve position above 30 6 Set the ON OFF switch to the ON position The READY light should remain off and the unit should not start If the unit does start shut the unit off immediately and refer fault to qualified service personnel 7 Close the drain and pressure relief valve...

Page 81: ...ITCH OPEN fault message should be displayed It should not be possible to restart the unit 4 Reset the adjustable over temperature switch to its original setting 5 The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature 6 Once the adjustable over temperature switch setting is approximately at or just below the actual outlet water tempe...

Page 82: ...et 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 the interlock connection is reconnec...

Page 83: ...ly 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 Figure 6 3 and the Air Fuel Valve 9 The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps a The unit will execute a shutdown purge cycle for a period of 15 seconds and display WAIT FAULT PU...

Page 84: ... 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 displayed then press the CHANGE key c Press the arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key d Press the CLEAR button to clear the airflow fault 6 Once the unit has proved flam...

Page 85: ... Ramp the boiler up to 100 fire rate and then turn on the main ON OFF switch on the front of the Control Panel b Push the BACK button three 3 times to return to the upper level menu c When the Controller gets into the ignition phase the Control Panel will show IGNITION TRIAL At that point attach the alligator clip see Figure 6 3a to any bare metal surface or ground The C More display should now sh...

Page 86: ...cate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 5 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 6 The unit should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press the CLEAR button 8 Set the ON OFF switch to the ON position to start the unit 9 Remove ...

Page 87: ...t down and display PRG SWITCH OPEN DURING PURGE 6 Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart Figure 6 6 Air Fuel Valve Cover Location 6 11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch and the Purge Switch is located on the Air Fuel Valve To check the switch proceed as follows Ignition Switch Open During Ignition 1 Set the unit s ON OFF swi...

Page 88: ...10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 Ignition Switch Open During Ignition Continued Figure 6 7 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI Ignition Position Switch Purge Position Switch AIR IN TO BLOWER ...

Page 89: ...al Maintenance Kit 58025 01 Therefore only Kit Part No 58025 08 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUAL S...

Page 90: ...er injector flame detector and other related components Figure 7 1 Benchmark Burner Assembly Removed from Boiler The igniter injector may be hot therefore care should be exercised to avoid burns It is easier to remove the igniter injector from the unit after the unit has cooled to room temperature To inspect replace the Igniter Igniter Injector Replacement 1 Set the ON OFF switch on the control pa...

Page 91: ...4 for combustion calibration procedures Figure 7 2 Igniter Injector Flame Detector Mounting Details 7 Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench 8 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present c...

Page 92: ...Allow the unit to cool sufficiently before removing the flame detector Inspect or replace the flame detector as follows Flame Detector Replacement 1 Set the control panel ON OFF switch to the OFF position Disconnect AC power from the unit 2 Remove the top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels 3...

Page 93: ...ery cloth 6 Reinstall the O2 sensor and crush washer on the burner plate 7 Reconnect the sensor lead wire 8 Reinstall the shroud on the unit 7 5 COMBUSTION CALIBRATION Combustion settings must be checked at the intervals shown in Table 7 1 as part of the maintenance requirements Refer to Chapter 4 section 4 3 for combustion calibration instructions 7 6 SAFETY DEVICE TESTING Systematic and thorough...

Page 94: ...e burner plate 6 Disconnect the cable from the igniter injector 7 Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly see Figure 7 2 Disconnect the staged ignition assembly from the igniter injector 8 Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench...

Page 95: ...Figure 7 4 Burner Assembly Mounting Details Overhead View Figure 7 5 Burner Assembly Exploded View AIR FUEL VALVE BLOCKED INLET SWITCH BURNER GASKET FLAME DETECTOR O2 SENSOR STAGED IGNITION SOLENOID BURNER BLOWER BLOWER PROOF SWITCH BURNER PLATE BURNER PLATE 3 16 16 HEX NUTS 8 IGNITOR INJECTOR STAGED IGNITION ASSEMBLY BLOCKED INLET SWITCH BLOWER PROOF SWITCH AIR FILTER BLOWER FRONT 1 2 BOLTS NUTS ...

Page 96: ...e fully torqued to 22 ft lbs 19 Ensure that the igniter injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange 7 8 CONDENSATE DRAIN TRAP MAINTENANCE Benchmark boilers contain a condensate trap as shown in Chapter 2 Figure 2 6 The trap is located external to the unit and attached to the drain pipe from the exhaust manifold This trap should be...

Page 97: ...ly different types of condensate traps that may be used in your configuration an older style with a separate inlet adapter and a newer style with a built in adapter see Figure 7 6 Maintenance is the same except that the newer style does not need an orifice gasket Step 7 Figure 7 6 External Condensate Trap THUMB SCREWS COVER GASKET FLOAT GUIDE FLOAT CONDENSATE TRAP P N 24060 OUTLET Condensate Trap ...

Page 98: ...lifting straight up This will disengage the shroud from the four 4 pins in the side panels 3 Refer to Figure 7 7 and locate the air filter attached to the air fuel valve inlet 4 Using a flat tip screwdriver or 5 16 nut driver loosen the clamp securing the filter to the inlet flange of the air fuel valve Remove the filter and clamp 5 The filter may be cleaned in hot soapy water to remove oil and di...

Page 99: ...he boiler s operating controls 2 Disconnect AC power from the unit 3 Close the water supply and return valves to isolate boiler 4 Close external gas supply valve 5 Open relief valve to vent water pressure 7 11 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown one year or more the following procedures must be followed Placing Boiler Back In Service After a Pro...

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Page 101: ...evice This 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 Troubleshooting Instructions 1 Observe the fault messages displayed in the Control Box ...

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Page 103: ...ch and inspect for signs of blockage clean or 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 blower running If the resistance reading is erratic or is greater than zero ohms replace the switch 6 Turn off unit and check the continuity of the Blocked Inlet switch If the ...

Page 104: ...er including any ductwork leading up to the combustion blower for signs of blockage 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current...

Page 105: ... 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 being sent Check control signal type set in Configuration Menu FLAME LOS...

Page 106: ...egulator 3 Poor combustion calibration 4 Debris on burner 5 Blocked condensate drain 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a gauge or manometer into and out of the Air Fuel Valve to ensure that the gas pressure into and out of the valve is correct 3 Check combustion calibration using procedures in Chapt...

Page 107: ...de 5 Unit setpoint is greater than Over Temperature Switch setpoint 6 System flow rate changes are occurring faster than units can respond 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against Menu Default settings in Appendix E If the settings have been changed record the current readings then reset them to the default values 3 Using...

Page 108: ...h 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 Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position...

Page 109: ...ncorrect supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is between 4 0 W C and 14 W C For IRI gas trains ensure it is between 4 2 W C and 14 W C see section 2 8 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...

Page 110: ...ST Board PRG 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 f...

Page 111: ...pe of signal being sent Check control signal type set in Configuration Menu RESIDUAL FLAME 1 Defective Flame Detector 2 SSOV not fully closed 1 Replace Flame Detector 2 Check open close indicator window of Safety Shut Off Valve SSOV and ensure that the SSOV is fully closed If not fully closed replace the valve and or actuator Close the 1 Gas Shut Off Valve downstream of SSOV Figure 6 1 Install a m...

Page 112: ... personnel 3 Remove the electrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve closed either adjust or replace the switch or actuator 4 Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE 1 Air Fuel Valve out of calibration 2 Air Fuel Valve unplugged 3 Loose wiring connection to the stepper motor 4 Defe...

Page 113: ...nition Assembly solenoid from the Gas injector Tube of the Igniter Injector Figure 8 2 and inspect Gas Injector to ensure it is not clogged or damaged 3 Close the Manual Shutoff Valve Figure 8 1 below Attempt to start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignitio...

Page 114: ...800 526 0288 GF 130 Figure 8 1 Gas Train Component Locations Figure 8 2 Staged Ignition Connection to Gas Injector Tube SSOV GAS INLET TO AIR FUEL LEAK DETECTION BALL VALVE HIGH PRESSURE GAS SWITCH MANUAL SHUT OFF VALVE COMPRESSION FITTING ELBOW GAS INJECTOR TUBE O2 SENSOR WASHERS STAGED IGNITION SOLENOID INDEXING WASHERS Quantity 0 3 as required FLAME DETECTOR GASKET BURNER PLATE INJECTOR IGNITOR...

Page 115: ...OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 115 of 192 GF 130 Ph 800 526 0288 05 21 2014 Figure 8 3 SSOV Actuator With Gas Pressure Adjustment Damping Orifice SSOV ACTUATOR COVER COVER SCREW BRASS HEX HEAD CAP Remove to access Gas Pressure Adjustment screw DAMPING ORIFICE ...

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Page 117: ...om www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it 9 1 2 Logging on to a Remote Machine Using PuTTY To use PuTTY to logon to a remote machine bring up the PuTTY application by double clicking its icon ...

Page 118: ...ed 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 Running a Command on a Remote Machine Using PuTTY 1 Bring up the PuTTY application and select the server you wish to connect to 2 At the bottom of the Basic ...

Page 119: ...sure that the specified baud rate and data formats have been entered 2 Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS 232 password jaguar in lower case letters and press Enter 4 Welcome to Aerco will appear in the laptop or dumb terminal display with a listing of the following available entry choices M Display next Menu D Display menu items N ...

Page 120: ...edisplay the menu and view the option which was just changed in step 5 enter D and press Rtn 10 To display the Fault F Log Sensor S Log or Time T Line Log press F S or T followed by Rtn Refer to section 9 4 for descriptions and samples of these data logs 11 To log off and terminate the RS 232 communication link press L followed by Rtn 9 4 DATA LOGGING During operation the C More Control Panel cont...

Page 121: ...um of 30 minutes before the record is logged This means that no more than 30 minutes of data can be lost if the unit loses power Table 9 2 shows a sample Operation Time Log for a boiler The Operation Time Log can only be accessed through the RS 232 interface using a laptop or other terminal device Ten operation time records are displayed for each T command entry The operation time log can be clear...

Page 122: ... a boiler running in Constant Setpoint mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15...

Page 123: ...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 all Slave units st...

Page 124: ...on 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 Wired Header Complete ...

Page 125: ...er Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration Menu and set the BST Menu item to Enabled 2 Go to the BST Menu and set the BST Mode i...

Page 126: ...eld 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 the Configuration M...

Page 127: ... 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 terminals in the I O Box ...

Page 128: ...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 item and select Outd...

Page 129: ...or 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 Shielded pair 18 22 AWG...

Page 130: ...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 and select Enabled 1...

Page 131: ...arness Via the terminal block labeled Header Temp sensor in the I O Box NOTES The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant 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 sh...

Page 132: ...nabled 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 Remote Setpoint 6 Go to the Head Temp Source item and select FFWD Temp 7 Go to the BST Remote Signal and select either 4 20ma or 0 20ma When ALL C More...

Page 133: ...eader Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Step 3 Configure ALL C More Units On ALL Boil...

Page 134: ... 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 downstream of the LAS...

Page 135: ...e 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 240 9 Go to the Hea...

Page 136: ...erature Transmitter to the RS485 terminal on the I O Box of any of the Boiler units 2 Using Shielded 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 S...

Page 137: ...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 Network 7 Go to the Head Temp Source item and select Network 8 Go to the Header Temp Addr item and enter the Modbus Address 240 9 Go to the Header T...

Page 138: ...k 750 1000 Boiler CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Page 138 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 139: ...alue from 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 ...

Page 140: ...Comm Address For RS 485 communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The COMM LED will li...

Page 141: ...ng reference 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 Se...

Page 142: ...ing is 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 ...

Page 143: ...ill be attempted while the Outlet Temperature remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the 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...

Page 144: ... 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 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 ne...

Page 145: ...nd 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 cyc...

Page 146: ...me signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F GAS PRESSURE FAULT The High Gas Pressure Switch OR Low Gas Pressure Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP ...

Page 147: ...RING IGNITION The Purge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN The SSOV switch opened...

Page 148: ...allation Operation Maintenance Manual APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 148 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 149: ...esistance 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...

Page 150: ...llation Operation Maintenance Manual APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 150 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 151: ...110 120 130 140 150 160 170 5F 83 94 105 116 127 138 149 160 171 182 10F 86 98 110 122 134 146 158 170 182 194 15F 89 102 115 128 141 154 167 180 193 206 20F 92 106 120 134 148 162 176 190 204 218 Table D 2 Header Temperature for a Building Reference Temperature of 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 5...

Page 152: ...9 161 173 185 197 209 0 104 117 130 143 156 169 182 195 208 5 107 121 135 149 163 177 191 205 219 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Table D 4 Header Temperature for a Building Reference Temperature of 70F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70F 70 70 70 70 70 70 70 70 70 70 65F 73 74 75 76 77 78 79 80 81 82 60F 76 ...

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

Page 154: ... 80F 96 98 100 102 104 106 108 110 112 114 75F 99 102 105 108 111 114 117 120 123 126 70F 102 106 110 114 118 122 126 130 134 138 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126 132 138 144 150 156 162 55F 111 118 125 132 139 146 153 160 167 174 50F 114 122 130 138 146 154 162 170 178 186 45F 117 126 135 144 153 162 171 180 189 198 40F 120 130 140 150 160 170 180 190 200 210 35F 12...

Page 155: ...nternal Setpt 130 F Unit Type BMK Boiler LN Unit Size 750 MBH or 1000 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 L...

Page 156: ...Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 BOILER DEFAULT SETTINGS Continued MENU OPTION FACTORY DEFAULT Configuration Menu Cont Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min ...

Page 157: ...Operation Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 192 GF 130 Ph 800 526 0288 05 21 2014 APPENDIX F DIMENSIONAL DRAWINGS Drawing Number AP A 891 rev F ...

Page 158: ...er Installation Operation Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS Page 158 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 Drawing Number SD A 871 rev B ...

Page 159: ...er Installation Operation Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 192 GF 130 Ph 800 526 0288 05 21 2014 Drawing Number SD A 872 rev B ...

Page 160: ... Installation Operation Maintenance Manual APPENDIX F DIMENSIONAL DRAWINGS Page 160 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 161: ...A F Valve FRU kit 46 1 60019 DISCONNECT FUSIBLE 1 24367 2 BMK 750 A F Valve FRU kit 47 2 124512 FUSE 4 AMP 13 1 24277 STAGED IGNITION ASSY 48 1 123449 SENSOR TEMPERATURE 14 1 81143 GASKET BURNER 49 1 93359 THERMOWELL 15 1 59171 REFLECTOR SIGHT GLASS 50 1 33137 ELECTRICAL PANEL 16 1 59104 OBSERVATION PORT 51 1 181197 CONTROL BOX C MORE 17 1 28317 BMK 750 HEAT EXCHANGER 52 1 69151 PCB ASSY 1 28249 B...

Page 162: ...3 CONDENSATE FLOAT 78 1 50010 LATCH DRAW 93 1 24060 COND TRAP ASSEMBLY 79 1 50011 KEEPER DRAW LATCH 94 1 59178 VENT AIR 1 8 NPT 80 1 74023 LOGO LABEL BMK 1000 95 1 124008 NIPPLE 1 8 NPT X 3 00 LG 74026 LOGO LABEL BMK 750 100 1 92084 6 MOTORIZED SEQUENCING ISOLATION VALVE OPTIONAL 81 4 123621 BOLT HEX HD 1 4 20 X 50 LG 101 1 63150 HARNESS FLAME ROD 82 1 39125 ADAPTER AIR INLET 6 PVC NOTES NOT SHOWN...

Page 163: ...International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 192 GF 130 Ph 800 526 0288 05 21 2014 ITEM 4 FM GAS TRAIN 22140 1 ITEM 4 DBB GAS TRAIN 22140 2 TOP VIEW FRONT VIEW AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 07 2014 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 3 of 6 ...

Page 164: ...PARTS LIST DRAWINGS Page 164 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 07 2014 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 4 of 6 ...

Page 165: ...PARTS LIST DRAWINGS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 192 GF 130 Ph 800 526 0288 05 21 2014 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 07 2014 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 5 of 6 ...

Page 166: ...PARTS LIST DRAWINGS Page 166 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 07 2014 28321 1 rev D 28253 1 rev F reference PL A 173 Sheet 6 of 6 ...

Page 167: ... BOX 22 1 93364 TEE 1 X 1 X 1 2 NPT 7 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 23 1 123311 BUSHING REDUCING 1 2 NPT X 1 4 NPT 8 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 24 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 9 1 99015 DAMPING ORIFICE SSOV 25 1 94028 13 25 NIPPLE 1 NPT TBE X 13 25 LG 10 1 63147 HARNESS WIRING GAS TRAIN 26 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 11 2 124084 ELBOW 1 4 NPT 150...

Page 168: ...ESSURE 1 4 8 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 27 1 93187 TEE REDUCING 1 X 3 4 X 1 9 1 99015 DAMPING ORIFICE SSOV 28 3 9 222 ELBOW 90 MOD DEG 1 NPT M I 10 1 63147 HARNESS GAS TRAIN WIRING 4 SEC IGN 29 1 93364 TEE 1 X 1 X 1 2 NPT 11 3 124084 ELBOW 1 4 NPT 150 M I 30 4 94028 2 00 NIPPLE 1 NPT TBE X 2 00 LG 12 1 12607 2 CLOSE NIPPLE 1 4 NPT SCH 40 C S 31 1 94028 3 50 NIPPLE 1 NPT TBE X 3 50 LG 13 ...

Page 169: ...ACK MI 25 2 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 8 1 93423 ELBOW 45 FEMALE NPT BLK M I 26 1 61002 8 BMK750 LOW GAS PRESSURE SWITCH 4 4 W C 9 2 124084 ELBOW 1 4 NPT 150 M I 61002 8 BMK1000 LOW GAS PRESSURE SWITCH 7 5 W C 10 1 93418 TEE NPT BLACK MI 27 1 61002 12 BMK750 HIGH GAS PRESSURE SWITCH 4 7 W C 11 2 124083 TEE 1 4 NPT 150 61002 17 BMK1000 HIGH GAS PRESSURE SWITCH 10 5 W C 12 1 93420 UNION...

Page 170: ...VATION PORT 18 1 59171 REFLECTOR SIGHT GLASS 6 1 24277 STAGED IGNITION ASSY 19 1 61026 LEAN OXYGEN SENSOR 7 1 66020 FLAME DETECTOR 20 1 61024 AIR INLET TEMPERATURE SENSOR 8 1 88004 O RING 2 244 BUNA N 21 1 56064 NUT M8 X 1 25 HEX JAM 9 1 81048 GASKET FLAME DETECTOR LOW NOX 22 5 56060 NUT M8 X 1 25 FLANGED SERRATED 10 4 54028 SCREW HEX HD SERRATED 5 16 18 23 2 54095 SCREW SOC HD 10 32 X 3 8 LG 11 1...

Page 171: ...tion Operation Maintenance Manual APPENDIX H PIPING DRAWINGS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 192 GF 130 Ph 800 526 0288 05 21 2014 APPENDIX H PIPING DRAWINGS Drawing Number SD A 870 rev B ...

Page 172: ...iler Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS Page 172 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 Drawing Number SD A 868 rev B ...

Page 173: ...iler Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 192 GF 130 Ph 800 526 0288 05 21 2014 Drawing Number SD A 869 rev B ...

Page 174: ...iler Installation Operation Maintenance Manual APPENDIX H PIPING DRAWINGS Page 174 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 Drawing Number SD A 874 rev C ...

Page 175: ...on Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 192 GF 130 Ph 800 526 0288 05 21 2014 APPENDIX I C MORE WIRING DIAGRAMS Drawing Number 68038 rev E Sheet 1 of 2 ...

Page 176: ...Installation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 176 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 177: ...tallation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 192 GF 130 Ph 800 526 0288 05 21 2014 Drawing Number 68038 rev E Sheet 2 of 2 ...

Page 178: ...Installation Operation Maintenance Manual APPENDIX I C MORE WIRING DIAGRAMS Page 178 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 179: ...isual 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 4 and Chapter 4 Flue vent stack or intake air duct Monthly Operator Visually inspection condition and check for obstructions Spark Ignite...

Page 180: ...nterlocks Monthly 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...

Page 181: ... BENCHMARK 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 BENCHM...

Page 182: ...NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 P1 P2 P3 P4 P5 P6 SHELL HARNESS CONNECTOR 19 PIN GAS TRAIN HARNESS CONNECTOR 9 PIN A F VALVE HARNESS CONNECTOR 16 PIN SENSOR HARNESS CONNECTOR 7 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX Figure K 2 Benchmark Control Panel Rear View ...

Page 183: ...gas train models Downstream SSOV of IRI gas train models 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset 123552 Staged Ignition Assembly 24277 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 08 Table L 3 O...

Page 184: ...r Installation Operation Maintenance Manual APPENDIX K RECOMMENDED SPARES Page 184 of 192 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0082_0J 05 21 2014 Ph 800 526 0288 GF 130 This Page Is Intentionally Blank ...

Page 185: ... combustion calibrate the boiler to the 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 s...

Page 186: ...s soon 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 O...

Page 187: ...e CHANGE 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 rea...

Page 188: ...ge 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 G 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 calibrati...

Page 189: ...s stated in the said warranty An Officer of AERCO must do any modifications to this warranty in writing AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES AERCO disclaims all responsibility for any special incidental or consequential damages Any claim relating to the product must be filed with AERCO not later than 14 days after t...

Page 190: ...ched to the shipping carton which identifies the item s return address register number and factory authorized RGA number Warranty coverage for all components and equipment mentioned in said warranty are not valid unless the water heater is started up by a factory certified SST Service Start Up and Troubleshooting Technician and an AERCO start up sheet is completed This warranty coverage is only ap...

Page 191: ...Benchmark 750 1000 Boiler Installation Operation Maintenance Manual OMM 0082_0J AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 192 GF 130 Ph 800 526 0288 05 21 2014 NOTES ...

Page 192: ...n 2 10 12 addition of section 2 15 Sequencing Isolation Valve Installation 3 9 _BST Menu addition of Chapter 10 Boiler Sequencing Technology replaced all wiring schematics in Appendix I addition of 24V Sequencing Valve Flame Rod Amplifier PIR 974 Replaced Gas train harness 161450 with 63147 in Appendix G PIR 1000 P N 61026 now labeled Lean Oxygen Sensor 64081 now named ECU PIR 1005 Changed 12 Mont...

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