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Aerco Benchmark BMK 1500DF, User Manual

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Benchmark 2500 - 3000 Boilers  

CHAPTER 3 – OPERATION 

 

OMM-0094_0F 

 

 

AERCO International, Inc. 

•

 100 Oritani Dr. 

•

  Blauvelt, NY 10913  

 Page 

45

 of 

207

 

GF-137 

 

 Ph.: 800-526-0288  

 

09/30/2015 

3.8  COMBUSTION CAL MENU 

The 

Combustion Cal

 (Calibration) menu is protected by the level 2 password (6817) which must 

be entered to view or change the menu items shown in Table 3-6. These menu items are used 
to vary the speed of the unit’s blower motor based on air temperature and air density at 
prescribed Air/Fuel Valve positions (% open). This is accomplished by providing a DC drive 
voltage to the motor which adjusts the rotational speed of the blower to maximize combustion 
efficiency and ensure the unit conforms to the Nitrogen Oxide (NOx) and Carbon Monoxide 
(CO) emissions specified in Chapter 4. The valve positions (%) are listed in Table 3-6. 

 

Table 3-6:  Combustion Cal Menu 

 

Menu Item Display 

 

BMK 2500 

BMK 3000 

1 

CAL Voltage 16% 

CAL Voltage 14% 

2 

CAL Voltage 30% 

CAL Voltage 30% 

3 

CAL Voltage 40% 

CAL Voltage 40% 

4 

CAL Voltage 50% 

CAL Voltage 50% 

5 

CAL Voltage 70% 

CAL Voltage 70% 

6 

CAL Voltage 100% 

CAL Voltage 100% 

7 

SET Valve Position 

SET Valve Position 

8 

Blower Output 

Blower Output 

9 

Set Stdby Volt 

Set Stdby Volt 

10 

Oxygen Level 

Oxygen Level 

 
 

3.9  BST (Boiler Sequencing Technology) Menu  

The 

BST

 menu must be enabled in order to be displayed and accessed. The 

BST Menu

 item, 

located at the end of the 

Configuration

 menu (item 32 in Table 3-4), must be se to 

Enabled

. 

The 

BST

 menu contains all of the items required to configure, operate and monitor the 

functionality of the BST System. There are over 50 items in this menu, and selecting any 
particular item from the list, for inspection or modification, could be time consuming. As a result, 
the 

BST

 menu has been segmented into FIVE logical groups based on functionality.  

The five Item groups are:   

1.  BST Monitor Items 

2.   *

BST SETUP MENU*

 

3.  

*OPERATE MENU *

 

4.  

*TEMP CTRL MENU*

 

5.  

*BST COMM MENU*

 

These displayed item groups are displayed in UPPER CASE letters, and are bounded by an 
asterisk * in order to readily identify them within the item list. 

The Items contained in group 1 (BST Monitor Items) are ALWAYS displayed within the menu, 
as these items are critical for proper system operation. Therefore, the BST Monitor Items 
Header itself is NOT displayed. 

Summary of Contents for Benchmark BMK 1500DF

Page 1: ... Oritani Dr Blauvelt NY 10913 Page 1 of 207 GF 137 Ph 800 526 0288 09 30 2015 USER MANUAL Installation Operation and Maintenance BENCHMARK 2500 3000 Gas Fired Boilers Natural Gas Modulating Condensing Hot Water Boiler Models BMK 2500 BMK 3000 Applicable to Serial Numbers G 15 2700 and Above Latest Update 09 30 2015 ...

Page 2: ... The 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 occur...

Page 3: ... 2 8 3 External Gas Supply Regulator 22 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 Terminal 27 2 10 2 AIR TEMP SENSOR Terminals 27 2 10 3 O2 SENSOR Terminals 28 2 10 4 SPARK SIGNAL Terminals 28 2 10 5 ANALOG IN Terminals 28 2 10 6 VALVE FEEDBACK Terminals 28 2 10 7 SHIELD Terminals 29 2 10 8 ANALOG OUT Terminals 29 2 ...

Page 4: ... Adjustments 63 CHAPTER 5 MODE OF OPERATION 65 5 1 INTRODUCTION 65 5 2 INDOOR OUTDOOR RESET MODE 65 5 2 1 Reset Ratio 65 5 2 2 Building Reference Temperature 65 5 2 3 Outdoor Air Temperature Sensor Installation 65 5 2 4 Indoor Outdoor Startup 66 5 3 CONSTANT SETPOINT MODE 66 5 3 1 Setting the Setpoint 67 5 4 REMOTE SETPOINT MODES 67 5 4 1 Remote Setpoint Field Wiring 68 5 4 2 Remote Setpoint Start...

Page 5: ...AULT MESSAGES 117 CHAPTER 9 BOILER SEQUENCING TECHNOLOGY 121 9 1 INTRODUCTION 121 9 1 1 Installation Notes 122 9 2 AERCO BST QUICK START CHART 123 9 3 BST IMPLEMENTATION INSTRUCTION 124 9 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor 124 9 3 2 Option 2 Constant Setpoint with MODBUS Wired Header Sensor 125 9 3 3 Option 3 Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRE...

Page 6: ... NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 APPENDIX F DIMENSIONAL DRAWING 157 APPENDIX G CLEARANCE DRAWINGS 158 APPENDIX H PARTS LIST DRAWINGS 159 APPENDIX I C MORE WIRING DIAGRAMS 171 APPENDIX J PIPING DRAWINGS 191 APPENDIX K C MORE CONTROL PANEL VIEWS 199 APPENDIX L RECOMMENDED SPARES 201 APPENDIX M KOREAN GAS TRAINS 203 ...

Page 7: ...00 54 5 kW 2 790 000 818 kW The output of the boiler is a function of the unit s firing rate valve position and return water temperature When installed and operated in accordance with this Instruction Manual these boilers comply with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the BMK 2500 an...

Page 8: ...ent Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing Technology BTU British Thermal Unit A unit of energy approximately equal to the heat required to raise 1 pound 0 45 kg of water 1 F 0 55 C BTU HR BTUs per Hour 1 BTU hr 0 29 W CCP Combination Control Panel CCS Combination Control System C More Controller or Control Box A control system developed by AERCO and currently used in all ...

Page 9: ...rogen Oxide MA mA Milliampere 1 thousand th of an ampere MAX Max Maximum MBH 1000 BTUs per Hour 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 OMM O M Operation and Maintenance Manual OnAER AERCO s on line remote monitoring system P...

Page 10: ...based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Temperature SHLD Shld Shield SPDT Single Pole Double Throw a type of switch 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 Tip N Tell A device that indicates if a ...

Page 11: ...n 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 legible condition It must be given to the user by the installer and kept in a safe place for future reference WARNING Do not use match...

Page 12: ...ied service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the manual gas shutoff valve Figure 1 1 located external to the unit NOTE The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel Figure 1 1 Manual Gas Shutoff Valve 1 ...

Page 13: ...alled on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a cr...

Page 14: ...nting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisf...

Page 15: ... 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 when cutting away packaging mat...

Page 16: ...0 are packaged in an enclosure 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 supersede AERCO s requirements Minimum acceptable clearances required are as follows Sides...

Page 17: ... Precautions 2 4 2 Setting the Unit The unit must be installed on a concrete housekeeping pad a minimum of 4 inches 10 2 cm and a maximum of 8 inches 20 3 cm thick to ensure proper condensate drainage If anchoring the unit refer to Figure 2 1b for anchor locations NOTES 1 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2 ALL DIMENSIONS SHOWN ARE IN INCHES MILLIMETERS Figure 2 1b Benchmark...

Page 18: ...ce for piping connections and future service maintenance requirements must also be taken into consideration All piping must include ample provisions for expansion 2 5 SUPPLY AND RETURN PIPING All Benchmark 2500 and 3000 units have one 4 10 2 cm 150 flanges for the water INLET supply and one 4 10 2 cm 150 flanges for the hot water OUTLET return piping connections Some units have an optional second ...

Page 19: ...or additional information 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 207 to 1103 kPa The relief valve is installed on the hot water outlet of the boiler as shown in Figure 2 4 A suitable pipe joi...

Page 20: ...ner The condensate trap inlet features two integral O rings and a thumbscrew to allow direct connection of the drain port into the trap inlet See the Condensate trap Installation instructions and Figure 2 6 on the next page Figure 2 5 Condensate Drain Connection Location A sample condensate trap installation is shown in Figure 2 6 The following general guidelines must be observed to ensure proper ...

Page 21: ...d secure with a hose clamp 4 Route the hose on the trap outlet to a nearby floor drain If a floor drain is not available a condensate pump can be used to remove the condensate to drain The maximum condensate flow rate is 30 gallons 113 6 L per hour The condensate drain trap associated fittings and drain line must be removable for routine maintenance WARNING Use PVC stainless steel aluminum or poly...

Page 22: ...or ceiling or walls only and must not be supported by the unit A suitable piping compound approved for use with natural gas should be used Any excess must be wiped off to prevent clogging of components To avoid unit damage when pressure testing gas piping isolate the unit from the gas supply piping The gas pressure applied to the unit must NOT exceed 14 W C 3487 Pa at any time Leak test all extern...

Page 23: ... outdoors Consult the local gas utility for detailed requirements concerning venting of the supply gas regulator 2 8 3 2 All Installations Except Massachusetts For multi unit installations other than Massachusetts that exceed 7 W C 1744 Pa gas pressure a separate external gas supply regulator as shown in Figure 2 7 is highly recommended No regulator is required for gas pressures below 7 W C 1744 P...

Page 24: ...t panel to access the Power Box which is mounted in the upper right corner of the unit as shown in Figure 2 8 Loosen the two upper screws of the Power Box cover and remove cover to access the internal connections shown in Figure 2 9 Figure 2 8 Power Box Location with Cover Closed WARNING THE POWER BREAKER SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS Figure 2 9 Power Box Inter...

Page 25: ...er of the Power Box as shown in Figure 2 10 Figure 2 10 Power Box Cover Labels 208VAC Left and 460VAC Right Each unit must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A three pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service DO NO...

Page 26: ...upper left portion on the front of the unit as shown in Figure 2 11 The I O board terminal strip connections are shown in Figure 2 12 All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided on the sides of the I O board Refer to the wiring diagram provided below the I O Box Figure 2 12 when making all wiring connections Figure 2 11 In...

Page 27: ... wired up to 200 feet 61 m from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O PCB Figure 2 12 Wire the sensor using a twisted shielded pair wire from 18 to 22 AWG There is no polarity to observe when terminating these wires The shield is to be connected only to the terminals labeled SHIELD in the I O Box PCB The sensor end of the shield must be left fr...

Page 28: ...VDC using the Configuration menu described in Chapter 3 If voltage rather than current is selected as the drive signal a DIP switch must be set on the PMC Board located inside the C More Control Box Contact the AERCO factory for information on setting DIP switches All supplied signals must be floating ungrounded signals Connections between the source and the boiler s I O PCB Figure 2 12 must be ma...

Page 29: ... terminals labeled Analog Output 2 10 9 RS485 Comm Terminals The RS 485 communication terminals GND are used when the boiler plant is being controlled by an Energy Management System EMS or AERCO ACS formerly BMS BMS II using Modbus RS 485 communication 2 10 10 RS232 Comm Terminals As of Firmware version 4 0 and above these terminals are used only by factory trained personnel to monitor OnAER commu...

Page 30: ...ow SPDT relay having a normally open and normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC The relay energizes when any fault condition occurs and remains energized until the fault is cleared and the CLEAR button is depressed The fault relay connections are shown in Figure 2 12 2 10 14 Aux Relay Terminals Each unit is equipped with a single pole double...

Page 31: ...ous when used in gas fired equipment Common sources of 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 For combustion air supply from ducting consult the AERCO GF 2...

Page 32: ... opens for a programmed interval default 1 minute before closing When the system load is satisfied the BST system will open the isolation valves for all of the boilers The implementation of BST and the installation and use of this valve is optional The boiler is pre wired to accept the sequencing isolation valve Installation consists of installing the sequencing isolation valve in the hot water ou...

Page 33: ... Oritani Dr Blauvelt NY 10913 Page 33 of 207 GF 137 Ph 800 526 0288 09 30 2015 Install the Sequencing Isolation Valve Continued Figure 2 14 Sequencing Isolation Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve s connector ...

Page 34: ...Benchmark 2500 3000 Boilers CHAPTER 2 INSTALLATION Page 34 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 35: ... 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 CAUTION All of the installation procedures in Chapter 2 must be completed before attempting to star...

Page 36: ...0 3000 Boilers CHAPTER 3 OPERATION Page 36 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 Figure 3 1 Control Panel Front View 3 1 4 5 7 8 9 10 11 12 6 2 ...

Page 37: ...ader temperature 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection BST Messages 4 RS232 Port This port is used only factory trained personnel to monitor OnAER communications in combination with the RS232 Adaptor Cable...

Page 38: ... flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key is pressed the displayed m...

Page 39: ...lished using the menu keys shown in Figure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures Menu Processing Procedure 1 The Control Panel will normally be in the Operating menu and the VFD will display the current unit status Pressing the or arrow key will display the other available data items in th...

Page 40: ...5 Ph 800 526 0288 GF 137 Only if BST is enabled see Chapter 9 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 41: ...Outdoor Temp 70 F 56 7 C 130 F 54 4 C 5 Valve Position In 0 100 6 Valve Position Out 0 100 7 Exhaust Temp F F 8 Flame Strength 0 100 9 Oxygen Level 0 21 10 Ignition Time 0 00 10 00 11 SSOV Time to OPN 0 00 10 00 12 Spark Current 0 2 5 A 13 Run Cycles 0 999 999 999 14 Run Hours 0 999 999 999 15 Fault Log 0 19 NOTE The Outdoor Temp and Valve Position Out display items shown with an asterisk in Table...

Page 42: ... Unit Serial 0 9999 0 13 Software Ver 0 00 Ver 9 99 Current software version 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 ...

Page 43: ...rive Combination Outdoor Reset Constant Setpoint 6 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 7 Bldg Ref Temp If Mode Outdoor Reset 40 F 4 4 C 230 F 110 C 70 F 21 1 C 8 Reset Ratio If Mode Outdoor Reset 0 1 9 9 1 2 9 Outdoor Sensor Enabled or Disabled Disabled 10 System Start Tmp If Outdoor Sensor Enabled 30...

Page 44: ...n 0 sec 9 999 sec 60 sec 31 Slow Sht Threshold 40 100 60 32 BST Menu Enabled or Disabled Disabled NOTE The Bldg Ref Temp and Reset Ratio menu Items are only displayed when the Outdoor Sensor menu item is set to Enabled CAUTION 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 individua...

Page 45: ...70 CAL Voltage 70 6 CAL Voltage 100 CAL Voltage 100 7 SET Valve Position SET Valve Position 8 Blower Output Blower Output 9 Set Stdby Volt Set Stdby Volt 10 Oxygen Level Oxygen Level 3 9 BST Boiler Sequencing Technology Menu The BST menu must be enabled in order to be displayed and accessed The BST Menu item located at the end of the Configuration menu item 32 in Table 3 4 must be se to Enabled Th...

Page 46: ...SETUP MENU Disabled Enabled Disabled 13 BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt 14 Head Temp Source Network FFWD Temp FFWD Temp 15 Header Temp Addr 0 255 240 16 Header Temp Point 0 255 14 17 BST Outdoor Sens Disabled Enabled Disabled 18 Outdr Tmp Source Outdoor Temp Network Outdoor Temp 19 Outdoor Tmp Addr 0 255 240 20 Outdoor Tmp Pnt 0 255 215 21 BST Remot...

Page 47: ...RL MENU Disabled Enabled Disabled 44 BST Temp Hi Limit 40 F 4 4 C 210 F 98 9 C 210 F 98 9 C 45 BST Setpt Lo Limit 40 F 4 4 C BST Setpt HI Limit 60 F 15 5 C 46 BST Setpt HI Limit BST Setpt Lo Limit 220 F 104 4 C 195 F 90 6 C 47 BST Prop Band 1 F 17 2 C 120 F 48 9 C 100 F 37 8 C 48 BST Intgral Gain 0 00 2 00 0 50 49 BST Deriv Time 0 00 Min 2 00 Min 0 10 Min 50 BST Deadband Hi 0 25 1 51 BST Deadband ...

Page 48: ...e switches are closed the READY light above the ON OFF switch will light and the unit will be in the Standby mode When there is a demand for heat the following events will occur NOTE If any of the Pre Purge safety device switches are open the appropriate fault message will be displayed Also the appropriate messages will be displayed throughout the start sequence if the required conditions are not ...

Page 49: ...e 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 4 Next the Blower Proof switch on the Air Fuel Valve Figure 3 5 closes The display will show PURGING and indicate the elapsed time of the purge ...

Page 50: ...ec to define the duration of the Spark Element Cleaning Cycle This cycle turns on the spark transformer to produce a spark with no gas flowing to clean the spark element of moisture or carbon buildup For the duration of this cycle the C More will display the CLEANING IGNITER message c Following the Spark Element Cleaning Cycle power is applied to the Gas Safety Shut off Valve SSOV and the C More d...

Page 51: ...N will be displayed and the flame strength will be indicated After 5 seconds the current date and time will be displayed in place of the flame strength 8 With the unit firing properly it will be controlled by the temperature controller circuitry The boiler s VALVE POSITION will be continuously displayed on the front panel bargraph Once the demand for heat has been satisfied the Control Box will tu...

Page 52: ...er running on natural gas Table 3 8a BMK 2500 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 16 Stop Level 167 000 48 9 kW 6 7 30 430 000 126 0 kW 17 40 770 000 225 7 kW 31 50 1 440 000 422 0 kW 43 60 1 820 000 533 4 kW 58 70 1 815 000 531 9 kW 73 80 2 030 000 594 9 kW 81 90 ...

Page 53: ...ficiency 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 54: ... for use with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas Supply Manometer The gas supply manometer or gauge is used to monitor the gas pressure on the downstream side of the SSOV during the Combustion Calibration procedures described in section 4 3 The gas supply manometer is installed at the upstream and or downstream locat...

Page 55: ...gas train components 3 To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration section 4 3 remove the 1 4 NPT plug from the leak detection ball valve on the downstream side of the SSOV as shown in Figure 4 1a or 4 1b depending on the model being calibrated 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the ...

Page 56: ...View 4 3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark boiler is combustion calibrated at the factory prior to shipping This gas pressure must be within the following ranges for each model of boiler at full fire Table 4 1 Nominal Gas Pressure BMK Boiler Model Nominal Gas Pressure BMK 2500 2 0 W C 0 2 W C 498 Pa 50 Pa BMK 3000 2 1 W C 0 2 W C 523 Pa 50 Pa Recalibration as part of initial start u...

Page 57: ... remove the brass hex nut on the SSOV actuator to access the gas pressure adjustment screw Figure 4 3 Make gas pressure adjustments using a flat tip screwdriver to obtain a gas pressure within the range of 2 0 W C 0 2 W C 498 Pa 50 Pa 11 Using the arrow key increase the valve open position to 100 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2 0 0 1 W ...

Page 58: ...2 level up to 1 higher than the listed calibration range Record the increased O2 value on the Combustion Calibration sheet 18 Press the MENU key on the front panel of the C More and access the Setup menu Enter password 6817 and then press the ENTER key 19 Press the MENU key on the front panel of the C More until Combustion Cal menu appears on the display 20 Press the arrow key until SET Valve Posi...

Page 59: ...4 4 Combustion Calibration Readings Valve Position Oxygen O2 Nitrogen Oxide NOx Carbon Monoxide CO 50 6 0 0 5 20 ppm 100 ppm 40 6 3 0 5 20 ppm 100 ppm 30 6 3 0 5 20 ppm 100 ppm 16 6 0 0 5 20 ppm 100 ppm 29 If the oxygen level at the 16 valve position is too high and the Blower voltage is at the minimum value you can adjust the idle screw TAC valve which is recessed in the top of the Air Fuel Valve...

Page 60: ... 572 50 Pa 11 Using the arrow key increase the valve open position to 100 Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2 1 0 2 W C 523 50 Pa Readjust the gas pressure if necessary 12 With the valve position at 100 insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer reading to stabilize 13 ...

Page 61: ...nu appears on the display 20 Press the arrow key until SET Valve Position appears on the display 21 Press the CHANGE key SET Valve Position will begin to flash 22 Press the arrow key until the SET Valve Position reads 70 Press the ENTER key 23 Next press the down 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 t...

Page 62: ...screw TAC valve which is recessed in the top of the Air Fuel Valve see Figure 4 5 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 50 down to 14 after making a change to the idle screw TAC valve 30 This completes the BMK 3000 Natural Gas combustion calibration procedure 4 4 REASSEMBLY Once the combustion calibrat...

Page 63: ...manually adjustable from 32ºF 212ºF 0ºC 100ºC This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this switch to the desired setting The digital Over Temperature Alarm switch shown in Figures 4 5 and 4 6 is preset at the factory to 210ºF 98 9 C and should not be changed If an over temperature condition is detected t...

Page 64: ...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 Over Temperature Alarm switch Access code value 0 should appear in the display The switch ...

Page 65: ...umber 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 temperature from 40 F to 230 F 4 4 C to ...

Page 66: ...to section 3 3 for detailed instructions on menu changing 7 Press the CHANGE key The 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 t...

Page 67: ...setting for the Remote Setpoint mode is 4 20 mA 1 5 VDC With this setting a 4 to 20 mA 1 to 5 VDC signal sent by an EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F 4 4 C setpoint while a 20 mA 5V signal is equal to a 240 F 115 6 C setpoint When a 0 to 20 mA 0 to 5 VDC signal is used 0 mA is equal to a 40 F 4 4 C setpoint In addition to the current and voltage...

Page 68: ...When driving multiple units each unit s wiring must conform to the above 5 4 2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally 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 o...

Page 69: ...he only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the connections are made at the RS 485 COMM terminals in the I O Box The signal must be floating ungrounded at the I O Box...

Page 70: ... To enable the ACS Mode the following menu settings must be made in the Configuration menu Table 5 4 ACS Mode Settings Menu Option Setting Boiler Mode Direct Drive Remote Signal Network RS485 Refer to section 3 3 for instructions on changing menu options 5 6 1 ACS External Field Wiring Wiring connections for RS 485 Modbus control are made between the 485 A and 485 B terminals on the ACS boilers 9 ...

Page 71: ...ght combination boilers that are Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers OPTION 2 When this option is selected the ACS Relay Panel must be used in conjunction with the ACS For this option the ACS controls a boiler plant containing up to ...

Page 72: ... Table 5 5 Combination Mode Settings Menu Option Setting Boiler Mode Combination Remote Signal Network Internal Setpt 40 F to 190 F 4 4 C to 87 8 C Refer to section 3 3 for instructions on changing menu options While it is possible to change other temperature related functions for combination mode these functions are preset to their factory default values These default settings work well in most a...

Page 73: ...ollowing tests check to ensure that the system is operating as designed Operating controls and safety devices should be tested on a regular basis or following service or replacement All testing must conform to local codes such as ASME CSD 1 NOTE MANUAL and AUTO modes of operation are required to perform the following tests For a complete explanation of these modes see Chapter 3 NOTE It will be nec...

Page 74: ...h is closed Figure 6 1a BMK 2500 Low Gas Pressure Test Figure 6 1b BMK 3000 Low Gas Pressure Test NATURAL GAS INLET SSOV TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE 1 4 NPT PLUG And Ball Valve install manometer here for LOW GAS PRESSURE FAULT TEST NATURAL GAS INLET SSOV TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH LOW GAS PRESSURE SWITCH MANUAL SHUT OFF V...

Page 75: ...t off valve 6 The unit should shut down and display a GAS PRESSURE fault message at approximately 3 6 W C 897 Pa for BMK 2500 and 2 6 W C 648 Pa for BMK 3000 7 Fully open the external manual gas shut off valve and press the CLEAR button on the Control Box 8 The fault message should clear and the FAULT indicator should go off The unit should restart 9 Upon test completion close the ball valve and r...

Page 76: ...e adjustment screw on the SSOV see Figure 4 3 7 The unit should shut down and display a HIGH GAS PRESSURE fault message when the gas pressure exceeds 2 6 W C 648 Pa for BMK 2500 and 3 5 W C 872 Pa for BMK 3000 The FAULT indicator should also start flashing 8 Reduce the gas pressure back to the value recorded in step 5 This pressure should be BMK 2500 2 0 W C 0 2 W C 498 Pa 50 Pa BMK 3000 2 3 W C 0...

Page 77: ...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 used in draining the u...

Page 78: ...g and a HIGH WATER TEMP SWITCH OPEN fault message should be displayed It should not be possible to restart the unit 4 Reset the adjustable Over Temperature switch to its original setting 5 The unit should start once the adjustable Temperature Limit switch setting is above the actual outlet water temperature 6 Once the adjustable Over Temperature switch setting is approximately at or just below the...

Page 79: ...ion 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 reconnected the INTERLOCK ...

Page 80: ...ff valve located between the Safety Shut Off Valve SSOV and the Air Fuel Valve see Figure 6 4 4 Set the ON OFF switch to the ON position to start the unit 5 The unit should purge and light the Pilot Flame then it should shut down after reaching the main burner ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve previously closed in step 3 and press the CLEAR button 7 Restart the unit...

Page 81: ...hown NOTE The BMK 2500 bare boiler image in Figure 6 4 may be used to refer to the BMK 3000 model as well Both units are virtually identical except for the position of the High Gas Pressure switch on the gas train and the burner size BLOWER HEAT EXCHANGER BLOWER PROOF SWITCH AIR FUEL VALVE BLOCKED INLET SWITCH AIR FILTER SSOV IGNITER INJECTOR ASSEMBLY BLOWER PLENUM GAS INLET MANUAL SHUT OFF VALVE ...

Page 82: ... output drive voltage by performing the following steps a Press the MENU key until CONFIGUR ATION MENU is displayed b Press the arrow key until the ANALOG OUTPUT function is displayed then press the CHANGE key c Press the arrow key until VALVE POSITION 0 10V is displayed then press the ENTER key d Press the CLEAR button to clear the airflow fault 6 Once the unit has proved flame turn off the blowe...

Page 83: ...p 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 5 to any bare metal surface or ground The C More display should now show FLAME PROVEN and...

Page 84: ... Figure 6 1a or 6 1b and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 7 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 ...

Page 85: ...ng Purge 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 by rotating the cover counterclockwise to unlock it see Figure 6 8 4 Remove one of the two wires 171 or 172 from the Purge switch see Figure 6 9 below 5 Initiate a unit start sequence 6 The unit should begin its start sequence th...

Page 86: ...ANUAL mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 6 8 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 see Figure 6 9 below 5 Initiate a unit start sequence 6 The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION 7 ...

Page 87: ...6 0288 09 30 2015 Figure 6 9 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI 172 171 170 169 Ignition Position Switch Purge Position Switch AIR IN TO BLOWER VALVE POSITION DIAL AIR FUEL VALVE SWITCH WIRING BREAKOUT ...

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Page 89: ...1 Therefore only Kit P N 58025 10 is required when performing the waterside fireside inspections Refer to Appendix M for recommended spare WARNING To avoid personal injury prior to servicing ensure that the following guidelines are strictly observed Disconnect the AC power supply by turning off the service switch and ac supply circuit breaker Shut off the gas supply at the manual shut off valve pr...

Page 90: ...s Figure 7 1 Benchmark 2500 3000 Burner Assembly Removed from Boiler The igniter injector may be hot therefore care should be exercised to avoid burns It is easier to remove the igniter injector from the unit after the unit has cooled to room temperature To inspect replace the Igniter Igniter Injector Maintenance Procedures 1 Set the ON OFF switch on the control panel to the OFF position Disconnec...

Page 91: ...d up is an indication that the combustion settings of the unit should be checked Refer to Chapter 4 for combustion calibration procedures Figure 7 2 Igniter Injector Flame Detector Mounting Details 7 Next loosen and remove the igniter injector from the burner plate using a 1 open end wrench 8 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial ...

Page 92: ... 20 3 Nm DO NOT over tighten 11 Connect the staged ignition assembly to the gas injector tube of the igniter injector by securing the compression nut to the elbow of the staged ignition assembly 12 Reconnect the igniter injector cable 13 Reinstall the shroud on the unit 7 3 FLAME DETECTOR The flame detector kit P N 24356 1 is located on the burner plate at the top of the unit see Figures 7 1 and 7...

Page 93: ... 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 top shroud from the unit by grasping the top handle and lifting straight up This will disengage the shroud from the four 4 pins in the side panels 3 Disconnect the O2 sensor lead wire by pushing in on the release tab and pulling apart the connector 4 Next l...

Page 94: ... two 2 screws securing the flame detector to the plate The flame detector is secured to the burner plate with one 1 10 32 screw and one 1 8 32 screw 5 Remove the flame detector and gasket from the 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 stag...

Page 95: ...r assembly reinstall all the components in the reverse order that they were removed When reinstalling the blower plenum removed in step 11 tighten the 3 8 16 nuts using a typical torque pattern for example loosely tighten one nut then loosely tighten a second nut on the opposite side a third at 90 degrees to the first two and a fourth opposite the third and then repeat this pattern with the remain...

Page 96: ...unting Details BMK 2500 Shown Figure 7 5 Bare Burner and Replacement Gaskets Location 3 8 16 HEX NUTS 8 each 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each A F VALVE PLENUM AIR FILTER AIR FUEL VALVE GAS TRAIN BLOWER PLENUM GAS INLET PIPE BLOCKED INLET SWITCH BLOWER PROOF SWITCH BLOWER MANUAL SHUT OFF VALVE 81173 UPPER RELEASE GASKET 81180 MIDDLE BURNER GASKET 81185 LOWER RELEASE GASKET BARE BU...

Page 97: ...nect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 7 6 2 Loosen the four 4 thumbscrews securing the trap s cover and then remove the cover and the O ring from under the cover 3 Remove the float and then thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thorou...

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

Page 99: ...an illustration of the LWCO probe assembly and its typical installation Figure 7 8 LWCO Probe Location for BMK2500 3000 BMK2500 Shown 7 9 1 Low Water Cutoff LWCO Capacitor Electrical Short Test This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger Perform the capacitor electrical short test as described below LWCO Capacitor Electrical Short Test 1 T...

Page 100: ...hell Harness Cable from P5 Conn on C More Rear Panel 3 Using an ohmmeter connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure 7 10 4 Connect the second ohmmeter probe to Pin 6 of Shell Harness Connector removed from the C More controller as shown on right in Figure 7 10 Figure 7 10 Connecting Ohmmeter between LWCO Probe Shell Harness Cable Unplug S...

Page 101: ...ard Low Water Cutoff C More Test 1 Turn the AC power to the unit to the ON position 2 Press the TEST switch on the C More controller and confirm that the blinking Low Water Level message appears on the C More display within 4 seconds 3 Press the RESET key followed by the Clear button and confirm that the Low Water Level message is cleared 7 10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIM...

Page 102: ...1034 evaluates the strength of the current between the ignition transformer and igniter injector Wire 140 connected to the ignition transformer see Figure 7 11 passes through the monitor s orifice If an adequate AC current is not detected in the wire during ignition the unit automatically shuts down The monitor s wires are connected to the I O board s Spark Signal terminals see section 2 10 4 Figu...

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Page 104: ......

Page 105: ... and correct the fault Fault Correction 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication 4 Perform the checks and procedures listed i...

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Page 107: ... 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 an errati...

Page 108: ...twork leading up to the combustion blower for signs of blockage 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not present refer fault to qualified service personnel 6 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 2 Blocked ...

Page 109: ...rent 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 LOSS DURING IGN 1 Worn ...

Page 110: ... 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 Chapter 4 4 Remove the burner and inspect f...

Page 111: ...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 1 Test the temperature switch to insure it trips at its actual water temperature setting 2 Check PID settings against menu default settings in Appendix D If the settings have been changed record the current readings then reset them to the def...

Page 112: ... correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace Power Supply Board 5 Check Heartbeat LED DS1 and verify it is blinking ON OFF every second If not replace IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 2 Defective ignitio...

Page 113: ...tch 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 996 and 3487 Pa For DBB gas trains ensure it is between 4 5 W C and 14 W C 1121 and 3487 Pa see section 4 3 2 Measure gas pressure at the Low Gas Pressure switch If it is greater than 3 6 W C 897 Pa for BMK 2500 or 2 6 W C 648 Pa for BMK 3000 measure continuity ...

Page 114: ...PEN 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 qualified se...

Page 115: ...ent 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 2 Gas Shut Off Valve downstream of SSOV Figure 2 7 Install a manometer or gauge at...

Page 116: ...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 Defective Air Fuel Valve...

Page 117: ... Figure 8 1 and inspect Gas Injector to ensure it is not clogged or damaged 2 Close the 2 Manual Shutoff Valve Attempt to start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into unit is fluctuating 2 Dampin...

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Page 119: ...2 SSOV Actuator With Gas Pressure Adjustment STAGED IGNITION SOLENOID FLAME DETECTOR GASKET FLAME OBSERVATION PORT INJECTOR IGNITOR ASSEMBLY O2 SENSOR WASHER INDEXING CLOCKING WASHERS 0 3 as needed STAGED IGNITION FLEX GAS HOSE NIPPLE STAGED IGNITION COMPRESSION FITTING ELBOW BURNER PLATE FLANGE BLOWER PLENUM GAS INJECTOR TUBE IGNITOR CABLE TERMINAL O2 SENSOR CABLE TERMINAL FLAME DETECTOR HARNESS ...

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Page 121: ...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 122: ...dy installed you must physically disconnect it from the Modbus network in I O board b Make sure that the Modbus load and bias resistors are properly configured for the system to operate without the ProtoNode installed c Temporarily set the BST system for Constant Setpoint mode of operation see below d Turn on and completely test the installation to verify that it is operating proper e Once the ins...

Page 123: ...ption 1 or 2 Option 1 Direct Wired Header Complete section 9 3 1 OR Option 2 Modbus Header Complete section 9 3 2 Outdoor Reset choose option 3 or 4 Option 3 Direct Wired Header AND Direct Wired Outdoor Air Complete section 9 3 3 OR Option 4 Modbus Header AND Modbus Outdoor Air Complete section 9 3 4 Remote Setpoint choose option 5 through 8 Option 5 4 20ma Drive AND Direct Wired Header Complete s...

Page 124: ...8 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 item and set the BST Menu item to Enabled 2 Go to the Boiler Sequencing Menu item and set the BST ...

Page 125: ... I O the Box The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 2 Configure ALL C More Units On ALL Boilers 1 Go to the Configuration menu item and set the...

Page 126: ...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 P N 123525 to the OUT and COM terminals in the I O Box ...

Page 127: ...nu item 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 O...

Page 128: ...nstalled between 2 and 10 feet 0 61 and 3 1m 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 A...

Page 129: ...he 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 Enable...

Page 130: ... the terminal block labeled Header Temp sensor in the I O Box NOTES The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m 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 th...

Page 131: ...he Boiler Sequencing Menu item 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 M...

Page 132: ...ir 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Step 3 Configure ALL C More Units On ALL Boilers 1 Go to the C...

Page 133: ...le connect the Modbus Header Temperature Sensor P N 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 0 61 and 3 1m downstream of the LA...

Page 134: ...lave 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 ...

Page 135: ... 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 P N 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...

Page 136: ...ST 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 Heade...

Page 137: ...he input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed 4 Outdoor Temp Outdoor temperature is displayed in ºF or ºC only if outdoor temperature sensor is installed and enabled 5 Valve Position In Desired input valve position This would normally be the same as the fire valve position shown on the bar graph valve position out when the boiler is ope...

Page 138: ...ermits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C 6 Comm Address For RS 485 communications 0 to 127 RS232 should have its own programmable password 7 Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 8 OnAER Mode Allows selection of either Ethernet or SD Card 9 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC...

Page 139: ...rect Drive or Combination Used to set the type of external signal which will be used when operating in the Remote Setpoint Direct Drive or Combination Mode 7 Outdoor Sensor Allows outdoor sensor function to be set to Enabled or Disabled 8 Bldg Ref Temp Only available if Boiler Mode Outdoor Reset Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode 9...

Page 140: ... or Disabled 21 Setpt Limit Band The Setpoint Limit Band can be set from 0 F to 10 F 0 C to 5 5 C 22 Network Timeout Specifies the timeout value in seconds before a Modbus fault is declared up to 999 seconds 23 Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temperature value the Outlet Temperature is permitted to rise above set...

Page 141: ...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 F 0 C to 25 F 13 75 C Default is 5 F 2 75 C for both Deadband High and Deadband Low 27 IGST Version Displays the version of the IGST Board installed 28 IGN Time...

Page 142: ...be 100 2 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 3 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 menu ite...

Page 143: ...BUSTION CAL MENU MENU OPTION DESCRIPTION 1 CAL Voltage 14 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 2 CAL Voltage 30 3 CAL Voltage 45 4 CAL Voltage 65 5 CAL Voltage 85 6 CAL Voltage 100 7 Set Valve Position Permits s...

Page 144: ...rk 2500 3000 Boilers APPENDIX A BOILER MENU DESCRIPTIONS Page 144 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 145: ...t 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 during startup Th...

Page 146: ...er 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 activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F GAS PRESSURE FAULT The High Gas Pressure Limit switch is open or the Low Gas Pressure Limit switch is open HIGH WATER TEMPERATURE The temperature measured by the ...

Page 147: ...LET TEMPERATURE display Opn indicates sensor is open circuited PRG SWTCH CLOSED DURING 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 se...

Page 148: ...2500 3000 Boilers APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 148 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 149: ...80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 40 34 4 28 9 23 3 17 2 12 2 6 7 1 1 4 4 10 15 5 21 1 26 7 32 2 37 8 43 3 48 9 54 4 60 65 6 71 1 76 7 82 2 87 8 93 3 98 9 104 4 110 115 6 121 1 779 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 14...

Page 150: ...500 3000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 150 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 151: ...tion condition and check for obstructions Spark Igniter Injector Weekly Operator See section 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial section 3 11 SSOV Leakage test Annually Service Technician Check for leakage in accordance with the SSOV manufacturer s Siemens recommendations Flame failure Weekly Operator Close manual gas shutoff valve and check safety shutdown Se...

Page 152: ...rk 2500 3000 Boilers APPENDIX D RECOMMENDED PERIODIC TESTING Page 152 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This page intentionally blank ...

Page 153: ...94 105 116 127 138 149 160 171 182 10 23 3 86 98 110 122 134 146 158 170 182 194 15 26 1 89 102 115 128 141 154 167 180 193 206 20 28 9 92 106 120 134 148 162 176 190 204 218 Table E 2 Header Temperature for a Building Reference Temperature 60 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 60 15 6 60 60 60 60 60 60 60 60 60 60 55 12 8 63 64 65 66 67 68 69 70 71 72 50 10 0 66 68...

Page 154: ...7 130 143 156 169 182 195 208 5 20 6 107 121 135 149 163 177 191 205 219 10 23 3 110 125 140 155 170 185 200 215 15 26 1 113 129 145 161 177 193 209 20 28 9 116 133 150 167 201 218 Table E 4 Header Temperature for a Building Reference Temperature 70 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 70 21 1 70 70 70 70 70 70 70 70 70 70 65 18 3 73 74 75 76 77 78 79 80 81 82 60 15 6...

Page 155: ...140 153 166 179 192 205 218 5 15 0 117 131 145 159 173 187 201 215 0 17 8 120 135 150 165 180 195 210 5 20 6 123 139 155 171 187 203 219 10 23 3 126 143 160 177 194 211 15 26 1 129 147 165 183 201 219 Table E 6 Header Temperature for a Building Reference Temperature 80 F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 F C 80 26 7 80 80 80 80 80 80 80 80 80 80 75 23 9 83 84 85 86 87 88...

Page 156: ... 114 75 23 9 99 102 105 108 111 114 117 120 123 126 70 21 1 102 106 110 114 118 122 126 130 134 138 65 18 3 105 110 115 120 125 130 135 140 145 150 60 15 6 108 114 120 126 132 138 144 150 156 162 55 12 8 111 118 125 132 139 146 153 160 167 174 50 10 0 114 122 130 138 146 154 162 170 178 186 45 7 2 117 126 135 144 153 162 171 180 189 198 40 4 4 120 130 140 150 160 170 180 190 200 210 35 1 7 123 134...

Page 157: ...0 Boilers APPENDIX F DIMENSIONAL DRAWING OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 207 GF 137 Ph 800 526 0288 09 30 2015 APPENDIX F DIMENSIONAL DRAWING Drawing Number AP A 900 rev C ...

Page 158: ...00 Boilers APPENDIX F CLEARANCE DRAWINGS Page 158 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 APPENDIX G CLEARANCE DRAWINGS Drawing Number SD A 898 rev C ...

Page 159: ...A BREAKER 12 1 81173 RELEASE GASKET 47 2 124512 FUSE 4 AMP 13 1 81185 LOWER RELEASE GASKET 48 1 123449 SENSOR TEMPERATURE 14 1 43090 AIR FUEL VALVE PLENUM 49 1 58132 THERMOWELL 15 1 24220 AIR FUEL VALVE 50 1 63105 I O SENSOR COMM HARNESS 51 1 63104 I O INTERLOCK HARNESS HOSES GASKETS INSULATION 52 2 69141 DIN RAIL MOUNT END STOP 16 1 97005 9 FLEX TUBE 48 1 2 m LG 53 1 124310 TRANSFORMER 460V 17 1 ...

Page 160: ...n Item Qty Part Description SHEET METAL PANEL ASSEMBLY OTHER ACCESSORIES PARTS 72 1 30115 BACK PANEL LEFT 85 2 38034 AIR INLET COVER PANEL 73 1 30116 BACK PANEL RIGHT 87 1 SEE TABLE A PRESSURE TEMP GAUGE 74 2 35022 TOP RAIL 88 1 SEE TABLE A PRESSSURE RELIEF VALVE KIT 75 1 25072 FRONT FRAME ASSEMBLY 89 1 123540 EXT MANUAL SHUT OFF VALVE 76 1 25078 FRONT PANEL 90 1 69126 LOW WATER CUTOFF CAPACITOR A...

Page 161: ...DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 207 GF 137 Ph 800 526 0288 09 30 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 02 10 2014 Whole Boiler 28536 1 28382 1 Sheet 3 of 7 ...

Page 162: ...ational Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 02 10 2014 Whole Boiler 28536 1 28382 1 Sheet 4 of 7 Benchmark 2500 3000 Burner Air Fuel Valve Assembly P N 26015 26014 26 26 ...

Page 163: ... FM Gas Train P N 22171 See full drawing below Benchmark 3000 Double Block Bleed Gas Train P N 22173 See full drawing below 4 4 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 02 10 2014 Whole Boiler 28536 1 28382 1 Sheet 5 of 7 Benchmark 2500 Standard FM Gas Train P N 22190 See full drawing below Benchmark 2500 Double Block Bleed Gas Train P N 22211 See full drawing below ...

Page 164: ...DRAWINGS Page 164 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 02 10 2014 Whole Boiler 28536 1 28382 1 Sheet 6 of 7 ...

Page 165: ...94_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 207 GF 137 Ph 800 526 0288 09 30 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 3000 Part List 02 10 2014 Whole Boiler 28536 1 28382 1 Sheet 7 of 7 Power I O Box P N 24353 2 97 ...

Page 166: ... 22 PIPE PLUG 1 4 NPT STEEL 5 1 123540 VALVE BALL 2 FULL PORT 18 1 93382 2 NPT CAP 7 1 99015 DAMPING ORIFICE SSOV 20 1 99017 SNUBBER PRESSURE 1 4 9 1 69005 ACTUATOR SSOV W REGULATOR 21 1 61002 16 HIGH PRESSURE SWITCH 3 5 W C 12 1 124136 VALVE SSOV 2 NPT 23 1 97087 12 FLEX TUBING 12 13 3 92077 1 4 NPT MXF BRASS BALL VALVE 26 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 7 1 5 21 12 9 18 23 AERCO Inter...

Page 167: ...CH 7 1 123540 VALVE BALL 2 FULL PORT 17 1 99015 DAMPING ORIFICE SSOV 9 2 95030 FLANGE SSOV 2 NPT 19 1 123769 VALVE SOLENOID N O 1 NPT 10 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 32 1 99017 SNUBBER PRESSURE 1 4 13 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 28 1 93382 2 NPT CAP 14 1 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 34 2 9 22 PIPE PLUG 1 4 NPT STEEL 15 1 69005 ACTUATOR SSOV W REGULATOR 37 1 970...

Page 168: ... 8 9 cm LG 13 1 93456 TEE REDUCING 2x1 5x2 14 1 94027 12 NIPPLE 2 NPT TBE X 3 0 7 6 cm LG 15 1 93382 2 NPT CAP 16 1 94027 144 NIPPLE 2 NPT TBE X 36 91 4 cm LG 17 1 93035 ELBOW STREET 1 4 NPT 18 3 99014 NIPPLE HEX 1 4 NPT X 3 8 NPT 19 1 97005 2 TUBE FLEXIBLE GAS 12 30 5 cm LG 20 1 124084 ELBOW 1 4 NPT 150 M I 21 2 124088 NIPPLE 1 4 NPT C S 2 1 2 6 35 cm LG 22 1 124083 TEE 1 4 NPT 150 23 2 123536 BU...

Page 169: ...ARTS LIST DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 207 GF 137 Ph 800 526 0288 09 30 2015 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 FM Gas Train 10 31 2013 22190 rev B Page 2 of 2 ...

Page 170: ... 99015 DAMPING ORIFICE SSOV 9 1 69005 ACTUATOR SSOV W REGULATOR 31 1 124137 VALVE SSOV DOUBLE BODY 1 1 2 NPT 13 1 93382 2 NPT CAP 32 2 95029 FLANGE SSOV 1 1 2 NPT 17 1 97005 2 TUBING FLEXIBLE GAS 12 33 1 69038 ACTUATOR SSOV W O P O C SWITCH 21 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 34 1 122774 VALVE VENT 3 4 NPT 22 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 41 1 124094 UNION 3 4 NPT 150 23 2 9 ...

Page 171: ...s APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 207 GF 137 Ph 800 526 0288 09 30 2015 APPENDIX I C MORE WIRING DIAGRAMS Drawing Number 68040 rev F Sheet 1 of 2 ...

Page 172: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 172 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 173: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68040 rev F Sheet 2 of 2 ...

Page 174: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 174 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 175: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68041 rev F Sheet 1 of 2 ...

Page 176: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 176 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 177: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68041 rev E Sheet 2 of 2 ...

Page 178: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 178 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 179: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68060 rev C Sheet 1 of 2 ...

Page 180: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 180 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 181: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 181 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68060 rev C Sheet 2 of 2 ...

Page 182: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 182 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 183: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 183 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68062 rev C Sheet 1 of 2 ...

Page 184: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 184 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 185: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68062 rev C Sheet 2 of 2 ...

Page 186: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 186 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 187: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 187 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68063 rev B Sheet 1 of 2 ...

Page 188: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 188 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 189: ... 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 189 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number 68063 rev B Sheet 2 of 2 ...

Page 190: ...hmark 2500 3000 Boilers APPENDIX I C MORE WIRING DIAGRAMS Page 190 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 191: ... 3000 Boilers APPENDIX J PIPING DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 207 GF 137 Ph 800 526 0288 09 30 2015 APPENDIX J PIPING DRAWINGS Drawing Number SD A 957 rev A ...

Page 192: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS Page 192 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 Drawing Number SD A 958 rev A ...

Page 193: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number SD A 959 rev A ...

Page 194: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS Page 194 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 Drawing Number SD A 960 rev A ...

Page 195: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 195 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number SD A 961 rev A ...

Page 196: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS Page 196 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 Drawing Number SD A 962 rev A ...

Page 197: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS OMM 0094_0F AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 197 of 207 GF 137 Ph 800 526 0288 09 30 2015 Drawing Number SD A 963 rev A ...

Page 198: ...enchmark 2500 3000 Boilers APPENDIX J PIPING DRAWINGS Page 198 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This page intentionally blank ...

Page 199: ... Series Control Panel Exploded View ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 FISH PAPER INSULATOR P N 124960 V F D DISPLAY MODULE P N 124527 FRONT FACE PLATE BENCHMARK P N 124949 VERTICAL OVERLAY BENCHMARK P N 124718 PUSH BUTTON SWITCHES P N 124954 ROCKER SWITCH P N 124947 GREEN LED P N 124948 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW WATER CUTOF...

Page 200: ...M 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 Figure K 2 Benchmark Control Panel Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR 24 PIN TO INPUT OUTPUT I O BOX GAS TRAIN HARNESS CONNECTOR 9 PIN SHELL HARNESS CONNECTOR 19 PIN INTERLOCK HARNESS CONNECTOR 16 PIN TO INPUT OUTPUT I O BOX ...

Page 201: ...TION PART NUMBER 208 230 VAC or 460 VAC Blower 24351 or 24350 SSOV Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of DBB gas train models 69005 SSOV Actuator Without Proof of Closure switch Used on Upstream SSOV of DBB gas train models 69038 Temperature switch Manual Reset 123552 Table L 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER 12 Month Maintenanc...

Page 202: ...hmark 2500 3000 Boilers APPENDIX L RECOMMENDED SPARES Page 202 of 207 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0F 09 30 2015 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 203: ...3 Page 203 of 207 GF 137 Ph 800 526 0288 09 30 2015 APPENDIX M KOREAN GAS TRAINS The information in this appendix applies only to units shipped to Korea It includes diagrams parts lists and schematics for the following gas trains 22215 Benchmark 3000 22244 Benchmark 2500 Figure M 1 Gas Train Schematic P N 22215 and P N 22244 ...

Page 204: ... FLANGE SSOV 2 NPT 31 1 64083 REGULATOR GAS 9 1 124142 VALVE SSOV DOUBLE BODY 2 NPT 32 1 124866 SOLENOID VALVE 1 4 NPT 12 1 61002 1 PRESSURE SWITCH 2 6 W C FALL N O 33 1 67006 GAGE LOW PRESSURE 0 10 in H2O 13 1 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 35 1 60020 SWITCH GAS PRESSURE 2 20 W C 15 1 99015 DAMPING ORIFICE SSOV 43 1 124138 ACTUATOR SSOV 21 1 93382 2 NPT CAP 44 1 9 294 UNION 2 NPT 300 2...

Page 205: ...0 1 97005 2 TUBING FLEXIBLE 12 8 1 93382 2 NPT CAP 36 1 92006 7 VALVE BALL BRASS 1 1 2 NPT 11 1 99017 SNUBBER PRESSURE 1 4 37 1 9 294 UNION 2 NPT 300 15 1 67007 GAGE LOW PRESSURE 0 15 in H2O 38 2 95029 FLANGE SSOV 1 1 2 NPT 16 1 64083 REGULATOR GAS PRESSURE 41 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 17 1 124866 SOLENOID VALVE 1 4 NPT 43 1 124138 ACTUATOR SSOV 18 1 67006 GAGE LOW PRESSURE 0 10 i...

Page 206: ......

Page 207: ...2 1 Replaced old style Condensate trap 20460 with new style 24441 in section 7 7 1000 P N 61026 now labeled Lean Oxygen Sensor 64081 now named ECU 1011 Changed Blocked Inlet switch pressure from 8 0 to 4 5 in Appendix A 934 65 Added explanatory paragraph to section 2 15 Sequencing Isolation Valve Installation 1028 Replace fuel rod 66020 with 66034 934 79 Warranty revision dated 6 11 14 replaced wa...

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