Aerco Benchmark BMK 2500 User Manual Download Page 112

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Benchmark 2500 - 3000 Boilers

CHAPTER 8 – TROUBLESHOOTING GUIDE

Page

112

204

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0094_0E

03/20/2014

Ph.: 800-526-0288

GF-137

Figure 8-1: Staged Ignition Connection to Gas Injector Tube

Figure 8-2: 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 TERMINAL

BRASS HEX HEAD

(Remove to access

the Gas Pressure

Adjustment Screw).

DAMPING ORIFICE

Summary of Contents for Benchmark BMK 2500

Page 1: ... Oritani Dr Blauvelt NY 10913 Page 1 of 204 GF 137 Ph 800 526 0288 03 20 2014 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 14 0304 and Above Latest Update 03 20 2014 ...

Page 2: ...he 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 occurri...

Page 3: ...as Supply Regulator 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 OUT Air Sensor Common COM 27 2 10 2 COMBUSTION AIR Terminal 27 2 10 3 O2 SENSOR O2 O2 28 2 10 4 SPARK SIGNAL FLW FLW 28 2 10 5 Analog In 28 2 10 6 B M S PWM In BMS BMS 28 2 10 7 Shield SHLD SHLD 28 2 10 8 Analog Output 28 2 10 9 RS 485 Comm GND 29 2 10 ...

Page 4: ...OF OPERATION 63 5 1 INTRODUCTION 63 5 2 INDOOR OUTDOOR RESET MODE 63 5 2 1 Reset Ratio 63 5 2 2 Building Reference Temperature 63 5 2 3 Outdoor Air Temperature Sensor Installation 63 5 2 4 Indoor Outdoor Startup 63 5 3 CONSTANT SETPOINT MODE 64 5 3 1 Setting the Setpoint 64 5 4 REMOTE SETPOINT MODES 65 5 4 1 Remote Setpoint Field Wiring 65 5 4 2 Remote Setpoint Startup 66 5 5 DIRECT DRIVE MODES 66...

Page 5: ...n a Remote Machine Using PuTTY 114 9 2 RS 232 COMMUNICATION SETUP 115 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION 115 9 4 DATA LOGGING 116 9 4 1 Fault Log 117 9 4 2 Operation Time Log 117 9 4 3 Sensor Log 118 CHAPTER 10 BOILER SEQUENCING TECHNOLOGY 119 10 1 INTRODUCTION 119 10 2 AERCO BST QUICK START CHART 120 10 3 BST IMPLEMENTATION INSTRUCTION 121 10 3 1 Option 1 Constant Setpoint with DI...

Page 6: ... 20 2014 Ph 800 526 0288 GF 137 APPENDIX F INDOOR OUTDOOR RESET RATIO CHARTS 149 APPENDIX G DIMENSIONAL DRAWING 153 APPENDIX H CLEARANCE DRAWINGS 154 APPENDIX I PARTS LIST DRAWINGS 155 APPENDIX J C MORE WIRING DIAGRAMS 171 APPENDIX K PIPING DRAWINGS 191 APPENDIX L C MORE CONTROL PANEL VIEWS 199 APPENDIX M RECOMMENDED SPARES 201 APPENDIX N LIMITED WARRANTY 203 ...

Page 7: ...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 and BMK 3000 offer the maximum...

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

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

Page 10: ...nym Meaning SSOV Safety Shut Off Valve TEMP Temp Temperature Terminating Resistor A resistor placed at each end of a daisy chain or multi drop network in order to prevent reflections that may cause invalid data in the communication uA Microamp 0 000001 amp one millionth of an amp VAC Volts Alternating Current VDC Volts Direct Current VFD Vacuum Fluorescent Display or Variable Frequency Drive W Wat...

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 DO NOT USE MATCHES CANDL...

Page 12: ...o 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 3 PROLONGED SHUTDOWN Aft...

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: ...tor 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 materials ...

Page 16: ...nchmark Model 2500 and 3000 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 req...

Page 17: ... plumber or gas fitter licensed within the Commonwealth of Massachusetts In addition the installation must comply with all requirements specified in Chapter 1 Safety Precautions 2 4 2 Setting the Unit The unit must be installed on a concrete housekeeping pad a minimum of 4 inches and a maximum of 8 inches thick to ensure proper condensate drainage If anchoring the unit refer to Figure 2 1b for anc...

Page 18: ...O MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER Figure 2 2 Boiler Lifting Provisions In multiple unit installations it is important to plan the position of each unit in advance Sufficient space for piping connections and future service maintenance requirements must also be taken into consideration All piping must include ample provisions for expansion If installing a Combination Control Pane...

Page 19: ...ting 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 installed on the hot water outlet of the boiler as shown in Figure 2 4 A suitable pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any joint compound into the valve body The relief valve must be pipe...

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: ...ap outlet and 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 GPH The condensate drain trap associated fittings and drain line must be removable for routine maintenance Use PVC stainless steel aluminum or polypropylene for con...

Page 22: ...n 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 piping isolate the unit from the gas...

Page 23: ...d as shown in Figure 2 7 The gas supply regulator must be properly vented to 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 gas pressure a separate external gas supply regulator as shown in Figure 2 7 is highly recom...

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 THE POWER BREAKER SHOWN IN FIGURE 2 9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS Figure 2 9 Power Box Internal Comp...

Page 25: ...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 NOT attach the switch to sheet ...

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: ...ensor may be wired up to 200 feet from the boiler It is connected to the OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I O 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 ...

Page 28: ...l supplied signals must be floating ungrounded signals Connections between the source and the boiler s I O PCB Figure 2 12 must be made using twisted shielded pair of 18 22 AWG wire such as Belden 9841 Polarity must be maintained and the shield must be connected only at the source end and must be left floating not connected at the Boiler s I O PCB Whether using voltage or current for the drive sig...

Page 29: ...d the Remote Interlock and Delayed Interlock REMOTE INTL K IN and DELAYED INTL K IN in Figure 2 12 Both interlocks described below are factory wired in the closed position using jumpers NOTE Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to fire 2 10 12 1 Remote Interlock In OUT IN The remote interlock circuit is provided to remotely start enable and st...

Page 30: ...11 FLUE GAS VENT INSTALLATION AERCO Gas Fired Venting and Combustion Air Guide GF 2050 must be consulted before any flue or combustion air venting is designed or installed Suitable U L approved positive pressure watertight vent materials MUST be used for safety and UL certification Because the unit is capable of discharging low temperature exhaust gases the flue must be pitched back towards the un...

Page 31: ...to the requirements specified in CSA B149 1 10 sections 8 4 1 and 8 4 3 2 12 2 Combustion Air from Inside the Building When combustion air is provided from within the building it must be supplied through two permanent openings in an interior wall Each opening must have a free area of not less than one square inch per 1000 BTUH of total input or 3000 square inches of free area The free area must ta...

Page 32: ...ed cable 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 valve to operate normally Find the free end of this cable inside the unit s enclosure Figure 2 14 Sequencing Valve Installed 3 Remove the jumper...

Page 33: ... 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 start the unit 3 2 CONTR...

Page 34: ...nt View NOTE If there is a requirement to use the RS232 port Item 4 on the C More controller front panel contact AERCO to purchase the RS232 Adaptor Cable P N 124675 which is designed for this purpose This cable features a DB9 connector for connection to older computers with serial ports or can be used with a Serial to USB adaptor for use in modern computer USB ports 3 1 8 9 10 11 7 6 5 4 12 2 ...

Page 35: ... 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 connector ...

Page 36: ...menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key is pressed the...

Page 37: ...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 38: ... Ph 800 526 0288 GF 137 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 39: ... 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 Menu Table 3...

Page 40: ...0 C More Alpha A Z A IP Address Software Ver 0 00 Ver 9 99 3 6 CONFIGURATION MENU The Configuration Menu shown in Table 3 4 permits adjustment of the Internal Setpoint Setpt temperature regardless of whether the valid password has been entered Setpt is required for operation in the Constant Setpoint mode The remaining options in this menu require the valid password to be entered prior to changing ...

Page 41: ...0 MBH 1500 MBH 2000 MBH 2500 MBH 3000 MBH 6000 MBH 2500 MBH or 3000 MBH Fuel Type Natural Gas or Propane Natural Gas Boiler Mode Constant Setpoint Remote Setpoint Direct Drive Combination Outdoor Reset Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V 0 20 mA 0 5V PWM Input Legacy BMS Network 4 20 mA 1 5V Outdoor Sensor Enabled or Disabled Disabled Bl...

Page 42: ... Network Timeout 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 DO NOT CHANGE the Analog Output Menu Item from its Default setting Valve Position 0 10V 3 7 TUNING MENU The Tuning Menu items in Table 3 5 are Factory set for each individual unit Do not change these menu entries unless specifically requested to do so by factory trained pers...

Page 43: ...ge 14 CAL Voltage 30 CAL Voltage 30 CAL Voltage 40 CAL Voltage 40 CAL Voltage 50 CAL Voltage 50 CAL Voltage 70 CAL Voltage 70 CAL Voltage 100 CAL Voltage 100 SET Valve Position SET Valve Position Blower Output Blower Output Set Stdby Volt Set Stdby Volt 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 Ena...

Page 44: ...Fire Rate BST Outdoor Temp NA Outdoor Temp F Units Available 0 8 Units Present Units Ignited 0 8 Units firing BST Valve State 0 CLOSED 1 OPEN 0 1 Comm Errors 8 0 9 0 1 BST Units 8 0 see table 0 see table 0 BST SETUP MENU Disabled Enabled Disabled BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt Head Temp Source Network FFWD Temp FFWD Temp Header Temp Addr 0 255 240 ...

Page 45: ...Off Delay 0 15 min 1 min BST Sequencing Run Hours Unit Size Select Lead Run Hours Select Lead Unit 0 127 0 Select Lag Unit 0 127 0 Lead Lag Hours 25 hours 225 hours 72 hours BST TEMP CTRL MENU Disabled Enabled Disabled BST Temp Hi Limit 40 F 210 F 210 F BST Setpt Lo Limit 40 F BST Setpt HI Limit 60 F BST Setpt HI Limit BST Setpt Lo Limit 220 F 195 F BST Prop Band 1 F 120 F 100 F BST Intgral Gain 0...

Page 46: ... 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 occur NOTE If any of the Pre Purge safety device switches are open the appro...

Page 47: ...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 NATURAL GAS INLET TO AIR FUEL VALVE HIGH GAS PRESSURE SWITCH SSOV TO AIR FUEL VALVE MANUAL SHUT OFF VALVE LOW GAS ...

Page 48: ...d time of the purge cycle in seconds Figure 3 5 Blower Proof Switch 5 Upon completion of the purge cycle the Control Box initiates an ignition cycle and the following events occur a The Air Fuel Valve rotates to the low fire Ignition Position 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 p...

Page 49: ... present 3 seconds into the IGNITION TRIAL the C More will abort the Ignition Cycle and shut down the boiler Refer to Chapter 8 Troubleshooting for guidance if this occurs Figure 3 6 Air Fuel Valve In Ignition Position 6 Up to 4 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected 7 After 2 seconds of continuous flame Flame Pro...

Page 50: ... input and Air Fuel Valve position for a BMK 2500 MBH boiler 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 14 Stop Level 200 000 6 7 20 320 000 11 30 690 000 23 40 1 110 000 37 50 1 530 000 51 60 1 820 000 61 70 2 210 000 74 80 2 49...

Page 51: ...emissions Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this Chapter it will be necessary to perform the Safety Device Testing procedures specified in Chapter 6 to complete all initial unit start up requirements An AERCO Gas Fired Startup Sheet included with each Benchmark must be completed for each ...

Page 52: ...se 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 location sh...

Page 53: ...s the 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 t...

Page 54: ...TION 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 BMK Boiler Model Nominal Gas Pressure BMK 2500 2 0 W C 0 2 W C BMK 3000 2 1 W C 0 2 W C Recalibration as part of initial start up is necessary due to changes in the local altitude gas BTU content gas supply piping and supply...

Page 55: ... 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 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 C Readjust the gas press...

Page 56: ...l 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 Position a...

Page 57: ...bustion 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 see Fi...

Page 58: ...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 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 Compare the oxygen readings on...

Page 59: ...ears 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 the 70 ...

Page 60: ...C 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 procedures 4 4 REASSEMBLY Once the combustion calibration adj...

Page 61: ...adjustable from xxx to yyy ºF This switch allows the boiler to restart once the temperature drops below the selected temperature setting on the dial Set the dial on this over temperature switch to the desired setting The digital alarm switch shown in Figures 4 5 and 4 6 is preset at the factory to 210ºF and should not be changed If an over temperature condition is detected this switch automaticall...

Page 62: ...ture 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 display The switch comes from the f...

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

Page 64: ...ess 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 This completes 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is desired Common uses of this mode of operation include water source heat pump loops and indirect heat exchangers for potable hot wa...

Page 65: ...he following menu setting must be made in the Configuration Menu Menu Option Setting Boiler Mode Remote Setpoint Remote Signal 4 20mA 1 5V 0 20mA 0 5V or Network Refer to section 3 3 for detailed instructions on changing menu options If the Network setting is selected for RS 485 Modbus operation a valid Comm Address must be entered in the Setup Menu Refer to Modbus Communication Manual GF 114 for ...

Page 66: ...etting a 4 to 20 mA signal sent by an EMS or BAS is used to change the unit s valve position from 0 to 100 A 4 mA 1V signal is equal to a 0 valve position while a 20 mA 5V signal is equal to a 100 valve position When a 0 20 mA 0 5 Vdc signal is used zero is equal to a 0 valve position In addition to the current and voltage signals described above the Direct Drive mode can also be driven by a RS 48...

Page 67: ...ange back to the Direct Drive mode simply press the AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 6 AERCO CONTROL SYSTEM ACS NOTE ACS is for installations with 9 or more boilers It utilizes only RS 485 signaling to the boiler Installations with 1 to 8 boilers can use BST see Chapter 10 The ACS mode of operation is used in conjunction with an AERCO Control System ...

Page 68: ...at water is then circulated through a heat exchanger in a domestic hot water storage tank Only the AERCO Control System ACS is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water However the ACS Relay Panel is required in combination with the ACS when there are up to two isolation valves boiler interlocks and or a Domestic Hot Water ...

Page 69: ...in the I O Box Wire the units using a shielded twisted pair of 18 to 22 AWG wire When wiring multiple units each unit s wiring must conform to the above 5 7 2 Combination Control System Setup and Startup Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode remote signal type and setpoint The setpoint is adjustable from 40 F to 190 F Enter the followi...

Page 70: ...nchmark 2500 3000 Boilers CHAPTER 5 MODE OF OPERATION Page 70 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 71: ...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 72: ...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 73: ...ve 6 The unit should shut down and display a GAS PRESSURE fault message at approximately 3 6 W C for for BMK 2500 and 2 6 W C 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 remove the manometer...

Page 74: ...he 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 for BMK 2500 and 3 5 W C 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 within the range of 2 0 W C 0 2 W C for BMK 2500 and 2 3 W C 0 2 W C ...

Page 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ... 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 81: ...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 4a to any bare metal surface or ground The C More display should now show FLAME PROVEN and ...

Page 82: ... 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 6 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure switch circuit 6 The unit should fault and display SSOV SWITCH OPEN 7 Replace wire 148 and press the CLEAR button 8 Set the ON OFF switch to the ON position ...

Page 83: ...n During Purge 1 Set the unit s ON OFF switch to the OFF position Place the unit in manual mode and set the valve position between 25 and 30 2 Remove the Air Fuel Valve cover by rotating the cover counterclockwise to unlock it see Figure 6 7 3 Remove one of the two wires 171 or 172 from the Purge Switch Figure 6 7 4 Initiate a unit start sequence 5 The unit should begin its start sequence then shu...

Page 84: ... in Manual Mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 6 7 by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove one of the two wires 169 or 170 from the Ignition Switch Figure 6 8 5 Initiate a unit start sequence 6 The unit should begin its start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION 7 Repla...

Page 85: ...6 0288 03 20 2014 Figure 6 8 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 ...

Page 86: ...hmark 2500 3000 Boilers CHAPTER 6 SAFETY DEVICE TESTING Page 86 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 87: ...ce Kit 58025 01 Therefore only Kit Part No 58025 10 is required when performing the waterside fireside inspections Refer to Appendix M 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 SHUT OFF VALV...

Page 88: ...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 89: ...p 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 ero...

Page 90: ... 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 part no 66020 is located on the burner plate at the top of the unit see Figures 7 1 and 7 2 The fla...

Page 91: ...or 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 loosen...

Page 92: ...ce the burner assembly proceed as follows Burner Assembly Inspection and Maintenance Procedures 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit and turn off the gas supply 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 ...

Page 93: ...at the LOWER RELEASE GASKET has tabs which the others do not NOTE During reassembly apply a light coating of high temperature anti seize lubricant to the threads of the igniter injector and grounding screw Also ensure that the igniter injector is properly positioned as indicated in Figure 7 3 Torque the igniter injector to 170 180 in lbs 15 Beginning with the burner assembly reinstall all the comp...

Page 94: ...ails BMK 2500 Shown NOTE The BMK 2500 bare boiler image in Figure 7 4a and 7 4b may be used to refer to the BMK 3000 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 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each BLOWER PLENUM GAS TRAIN AIR FILTER A F VALVE PLENUM BLOWER BURNER PLATE 3 8 16 HEX NUTS 8 each A...

Page 95: ...cation 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 BURNER INSTALLED IN HEAT EXCHANGER ASSY IMPORTANT Use ALL THREE gaskets provided ...

Page 96: ...rap shown in Figure 7 6 3 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover 4 Remove the float from the condensate trap 5 Remove the O ring and orifice gaskets from the trap AERCO recommends that these items be replaced annually 6 Thoroughly clean the trap and float Also inspect the drain piping for blockage If the trap cannot be thoroughly cleaned replace th...

Page 97: ... 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 d...

Page 98: ...ing 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 10 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 in Service After Long Shutdown 1 Review insta...

Page 99: ...232 communication feature permits service personnel to view menu items and data logs which can be useful in isolating faults Refer to Chapter 9 of this manual for detailed RS 232 communication set up and procedures When a fault occurs in the unit proceed as follows to isolate and correct the fault Fault Correction 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fau...

Page 100: ...ark 2500 3000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE Page 100 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This page left intentionally blank ...

Page 101: ... 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 102: ...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 103: ...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 104: ...tion 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 inspe...

Page 105: ...al 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 default values 3 ...

Page 106: ... 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 107: ...e 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 5 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 3 6 W C for BMK 2500 and 2 6 W C for BMK 3000 measure continuity across the switch and ...

Page 108: ...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 109: ...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 110: ...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 111: ... 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...

Page 112: ...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 TERMINAL BRASS HEX HE...

Page 113: ...oad the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it Logging on to a Remote Machine Using PuTTY 1 1 1 To use PuTTY to logon to a remote machine bring up the Pu...

Page 114: ...achine Using PuTTY PuTTY may also be used to run some command residing on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open depending on how you configure the session Here are the steps ...

Page 115: ...00 o 9600 Default o 19 2K Data Format The program must be set for o 8 data bits o 1 stop bit o no parity o either Xon Xoff or No flow control 9 3 MENU PROCESSING UTILIZING RS 232 COMMUNICATION Viewing data logs and viewing or changing Control Panel menu options using RS 232 communication is accomplished as follows Menu Processing Utilizing Rs 232 Communication 1 Start the emulator software program...

Page 116: ...nu m5 Diagnostic Menu 8 To change a value or setting for a displayed menu option proceed as follows a Enter C followed by the number to the right of the displayed option to be changed and then press Rtn b Enter the desired value or setting for the option and press Rtn Refer to Chapter 3 Tables 3 2 through 3 5 for allowable entry ranges and settings for the Operating Setup Configuration and Tuning ...

Page 117: ... memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate or flame strength must change by more than 5 or the run mode must change At steady state the run length is allowed to reach a ...

Page 118: ...ostics Menu The log interval can vary from once every minute to once every day Table 9 3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN...

Page 119: ... 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 s...

Page 120: ...ion 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 121: ...der 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 ...

Page 122: ...ield 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 ...

Page 123: ...r 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 124: ... 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 Out...

Page 125: ...sor 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 AW...

Page 126: ... 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 ...

Page 127: ...round for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Direct Wired 0 20ma or 4 20ma Wiring 1 Connect the 4 20ma or 0 20ma terminals from the Direct Drive source to the Ain and Ain terminals on the Master Unit s I O Box NOTE Shielded pair 18 22 AWG cable is recommended for this connection Polarity must be observed The gr...

Page 128: ...header Shielded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure and Connect the SSD Device ProtoNode per the AERCO Manual GF129 Step 3 Configure ALL C More Units On ALL Boi...

Page 129: ...2 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 LA...

Page 130: ...ve 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 He...

Page 131: ... for the shield is at the SHLD terminal in the I O the Box The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoint with Network 1 Configure and Connect the ...

Page 132: ... 2500 3000 Boilers CHAPTER 10 BOILER SEQUENCING TECHNOLOGY Page 132 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 133: ... 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 Desired input valve pos...

Page 134: ... communications 0 to 127 Default address is 0 RS 232 should have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Min Upload Timer Mandatory for AERCO OnAER Remote Data Collection ORDC This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds The COMM LED will light during the upload U...

Page 135: ...re to be set when operating a boiler in the Outdoor Reset Mode Default is 70 F Reset Ratio If Boiler Mode Outdoor Reset Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode Reset Ratio is adjustable from 0 1 to 9 9 Default is 1 2 Outdoor Sensor Allows outdoor sensor function to be enabled or disabled Default is disabled System Start Tmp If Outdoor Sensor is Enabled If out...

Page 136: ...imit Band The Setpoint Limit Band can be set from 0 to 10 The default setting is 5 Network Timeout Specifies the timeout value seconds before a Modbus fault is declared Available settings range from 5 to 999 seconds Default is 30 seconds Shutoff Dly Temp This feature delays the shutdown of a boiler in order to reduce excessive cycling This specifies the temperature value the Outlet Temperature is ...

Page 137: ... the Outlet Temperature remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections Setting range is 0 to 25 Default is 2 for both Deadband High and Deadband Low IGST Version Displays...

Page 138: ...ain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 1 00 Default is 1 0 Derivative Time This value 0 0 to 2 0 min responds to the rate of change of the setpoint error This is the time that this action advances the output WARMUP The feature embodied in the next three menu items eli...

Page 139: ...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 140: ...ND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The Exhaust Temperature has exceeded 200 F HIGH GAS PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is open I...

Page 141: ...rge 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 during standby SSOV...

Page 142: ...2500 3000 Boilers APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 142 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 143: ...art Balco TEMP F RES OHMS VOLTS 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 1364 2 1391 0 1418 2 1445 7 1 93 1 96 1 99 2 02 2 05 2 07 2 10 2 12 2 15 2 17 2 20 2 23 2 25...

Page 144: ...500 3000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 144 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Is Intentionally Blank ...

Page 145: ...rnal Setpt 130 F Unit Type BMK Boiler LN Unit Size 2500 MBH or 3000 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 Lim...

Page 146: ...094_0E 03 20 2014 Ph 800 526 0288 GF 137 Appendix D Boiler Default Settings MENU OPTION FACTORY DEFAULT Configuration Menu Continued Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min ...

Page 147: ...ly inspection 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 sh...

Page 148: ...000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING Page 148 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 boiler operation This page intentionally blank ...

Page 149: ...50 160 170 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 F 2 Header Temperature for a Building Reference Temperature of 60F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 60F 60 60 60 60 60 60 60 60 60 60 55F 63 64 65 66 67 68 69 70 71 72 50F 66 68 70 72 74...

Page 150: ... 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 F 4 Header Temperature for a Building Reference Temperature of 70F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70F 70 70 70 70 70 70 70 70 70 70 65F 73 74 75 76 77 78 79 80 81 82 60F 76 78 80 82 84 86 88...

Page 151: ...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 F 6 Header Temperature for a Building Reference Temperature of 80F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 80F 80 80 80 80 80 80 80 80 80 80 75F 83 84 85 86 87 88 89 90 91 ...

Page 152: ...2 104 106 108 110 112 114 75F 99 102 105 108 111 114 117 120 123 126 70F 102 106 110 114 118 122 126 130 134 138 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126 132 138 144 150 156 162 55F 111 118 125 132 139 146 153 160 167 174 50F 114 122 130 138 146 154 162 170 178 186 45F 117 126 135 144 153 162 171 180 189 198 40F 120 130 140 150 160 170 180 190 200 210 35F 123 134 145 156 167...

Page 153: ...0 Boilers APPENDIX G DIMENSIONAL DRAWING OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 204 GF 137 Ph 800 526 0288 03 20 2014 APPENDIX G DIMENSIONAL DRAWING Drawing Number AP A 900 rev C ...

Page 154: ...00 Boilers APPENDIX H CLEARANCE DRAWINGS Page 154 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 APPENDIX H CLEARANCE DRAWINGS Drawing Number SD A 898 rev C ...

Page 155: ...80 BURNER GASKET 46 1 65128 3 POLE 20A 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 43091 AIR FUEL VALVE PLENUM 49 1 93359 THERMOWELL 15 1 24311 AIR FUEL VALVE KIT 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 53...

Page 156: ... PANEL ASSEMBLY OTHER ACCESSORIES PARTS 72 1 30115 BACK PANEL LEFT 84 1 39164 AIR INLET ADAPTER 73 1 30116 BACK PANEL RIGHT 85 2 38034 AIR INLET COVER PANEL 74 2 35022 TOP RAIL 87 1 SEE TABLE A PRESSURE TEMP GAUGE 75 1 25068 ASSEMBLY FRONT FRAME 88 1 SEE TABLE A PRESSSURE RELIEF VALVE KIT 76 1 25078 FRONT PANEL ASSY 89 1 123540 EXT MANUAL SHUT OFF VALVE 77 1 72068 DOME LABEL 90 1 69126 LOW WATER C...

Page 157: ...DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 204 GF 137 Ph 800 526 0288 03 20 2014 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 158: ...ernational Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 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 ...

Page 159: ... 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 160: ...DRAWINGS Page 160 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 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 161: ...94_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 204 GF 137 Ph 800 526 0288 03 20 2014 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 162: ...EDUCING 1 2 X 1 4 NPT 12 1 124136 VALVE SSOV 2 NPT 13 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 14 2 9 22 PIPE PLUG 1 4 NPT STEEL 15 1 123547 NIPPLE 2 NPT TBE X 2 00 LG 16 1 94027 144 NIPPLE 2 NPT TBE X 36 LG 17 1 93384 2 TEE 18 1 93382 2 NPT CAP 19 1 9 4 ELBOW 90 2 NPT 20 2 99017 SNUBBER PRESSURE 1 4 21 1 61002 16 HIGH GAS PRESSURE SWITCH 3 5 W C 22 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 23 1 97...

Page 163: ...ARTS LIST DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 204 GF 137 Ph 800 526 0288 03 20 2014 AERCO International Inc Blauvelt NY 10913 Benchmark 3000 FM Gas Train 07 15 2013 22171 rev F Page 2 of 2 ...

Page 164: ...W O P O C SWITCH 17 1 99015 DAMPING ORIFICE SSOV 18 1 124862 RESISTOR ASSY 19 1 123769 VALVE SOLENOID N O 1 NPT 20 2 9 222 ELBOW 90 MOD DEG 1 NPT M I 21 1 94028 24 00 NIPPLE 1 NPT TBE X 24 LG 22 2 94028 2 00 NIPPLE 1 NPT TBE X 2 00 LG 23 1 94028 11 00 NIPPLE 1 NPT TBE X 11 LG 24 4 12951 2 BUSHING CONTROL BOX 25 1 123311 BUSHING REDUCING 1 2 NPT X 1 4 NPT 26 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 27 ...

Page 165: ...RTS LIST DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 204 GF 137 Ph 800 526 0288 03 20 2014 AERCO International Inc Blauvelt NY 10913 Benchmark 3000 DBB Gas Train 07 15 2013 22173 rev G Page 2 of 2 ...

Page 166: ...1 2 NPT X 3 50 LG 13 1 93456 TEE REDUCING 2x1 5x2 14 1 94027 12 NIPPLE 2 NPT TBE X 3 00 LG 15 1 93382 2 NPT CAP 16 1 94027 144 NIPPLE 2 NPT TBE X 36 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 LG 20 1 124084 ELBOW 1 4 NPT 150 M I 21 2 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 22 1 124083 TEE 1 4 NPT 150 23 2 123536 BUSHING REDUCING 1 4 X ...

Page 167: ...ARTS LIST DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 167 of 204 GF 137 Ph 800 526 0288 03 20 2014 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 FM Gas Train 10 31 2013 22190 rev B Page 2 of 2 ...

Page 168: ...NG FLEXIBLE GAS 12 18 1 124084 ELBOW 1 4 NPT 150 M I 19 1 124088 NIPPLE 1 4 NPT C S 2 1 2 LONG 20 2 123536 BUSHING REDUCING 1 4 X 1 8 NPT 21 1 61002 11 LOW GAS PRESSURE SWITCH 3 6 W C 22 3 92077 1 4 NPT MXF BRASS BALL VALVE OPEN 23 2 9 22 PIPE PLUG 1 4 NPT STEEL 24 3 93290 TEE MXFXF BLACK IRON 1 4 NPT 25 4 12951 2 BUSHING CONTROL BOX 26 1 99017 SNUBBER PRESSURE 1 4 27 1 61002 3 HIGH GAS PRESSURE S...

Page 169: ...RTS LIST DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 204 GF 137 Ph 800 526 0288 03 20 2014 AERCO International Inc Blauvelt NY 10913 Benchmark 2500 DBB Gas Train 10 31 2013 22211 rev B Page 2 of 2 ...

Page 170: ...chmark 2500 3000 Boilers APPENDIX I PARTS LIST DRAWINGS Page 170 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This page intentionally blank ...

Page 171: ...s APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 204 GF 137 Ph 800 526 0288 03 20 2014 APPENDIX J C MORE WIRING DIAGRAMS Drawing Number 68040 rev E Sheet 1 of 2 ...

Page 172: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 172 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 173: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68040 rev E Sheet 2 of 2 ...

Page 174: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 174 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 175: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68041 rev E Sheet 1 of 2 ...

Page 176: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 176 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 177: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 177 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68041 rev E Sheet 2 of 2 ...

Page 178: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 178 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 179: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 179 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68060 rev B Sheet 1 of 2 ...

Page 180: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 180 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 181: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 181 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68060 rev B Sheet 2 of 2 ...

Page 182: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 182 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 183: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 183 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68062 rev B Sheet 1 of 2 ...

Page 184: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 184 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 185: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 185 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68062 rev B Sheet 2 of 2 ...

Page 186: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 186 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 187: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 187 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68063 rev A Sheet 1 of 2 ...

Page 188: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 188 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 189: ... 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 189 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number 68063 rev A Sheet 2 of 2 ...

Page 190: ...hmark 2500 3000 Boilers APPENDIX J C MORE WIRING DIAGRAMS Page 190 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This Page Intentionally Blank ...

Page 191: ... 3000 Boilers APPENDIX K PIPING DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 191 of 204 GF 137 Ph 800 526 0288 03 20 2014 APPENDIX K PIPING DRAWINGS Drawing Number SD A 957 rev A ...

Page 192: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS Page 192 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Drawing Number SD A 958 rev A ...

Page 193: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 193 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number SD A 959 rev A ...

Page 194: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS Page 194 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Drawing Number SD A 960 rev A ...

Page 195: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 195 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number SD A 961 rev A ...

Page 196: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS Page 196 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 Drawing Number SD A 962 rev A ...

Page 197: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS OMM 0094_0E AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 197 of 204 GF 137 Ph 800 526 0288 03 20 2014 Drawing Number SD A 963 rev A ...

Page 198: ...enchmark 2500 3000 Boilers APPENDIX K PIPING DRAWINGS Page 198 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This page intentionally blank ...

Page 199: ...8 FRONT FACE PLATE BENCHMARK P N 124949 FISH PAPER INSULATOR P N 124960 ENCLOSURE P N 124951 V F D DISPLAY MODULE P N 124527 DISPLAY BOARD P N 124365 PMC BOARD P N 124364 LOW WATER CUTOFF BOARD P N 124363 CONNECTOR BOARD P N 124366 IGNITION STEPPER BOARD P N 124361 POWER SUPPLY BOARD P N 124362 GREEN LED P N 124948 ROCKER SWITCH P N 124947 PUSH BUTTON SWITCHES P N 124954 BENCHMARK CONTROL PANEL EX...

Page 200: ... 03 20 2014 Ph 800 526 0288 GF 137 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 L 2 Benchmark Control Panel Rear View ...

Page 201: ...SCRIPTION 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 IRI gas train models 69005 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset 123552 Table M 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER 12 Month Maint...

Page 202: ...mark 2500 3000 Boilers APPENDIX M RECOMMENDED SPARES Page 202 of 204 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0094_0E 03 20 2014 Ph 800 526 0288 GF 137 This page left intentionally blank ...

Page 203: ... such claim Any claims relating to this product shall be limited to the sale price of the product at the time of sale The sale of the product is specifically conditioned upon acceptance of these terms CONDITIONS OF WARRANTY Should an AERCO gas fired natural gas propane and natural gas propane dual fuel only boiler fail for any of the above reasons within the specified time period from the date of ...

Page 204: ...netic PIR 934 14 Corrected labels of Blower Proof and Blocked Inlet switches in diagrams in chapter 7 PIR 942 Replaced 460 V Power Box label in section 2 9 PIR 934 24 Increased max height of housekeeping pad to 8 inch Chapter 2 PIR 981 Modified formatting of Table A in Appendix F Part List PIR 960 Addition of two sub sections in 2 10 12 addition of section 2 15 Sequencing Valve Installation additi...

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Aerco Benchmark BMK 2500, User Manual

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