Benchmark BMK 1500 User Manual Download Page 168

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Benchmark 1500 - 2000 Boilers

APPENDIX I – WIRING DIAGRAMS

Page

168

184

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0097_0C

Ph.: 800-526-0288

GF-142

(This page intentionally blank)

Summary of Contents for BMK 1500

Page 1: ...100 Oritani Dr Blauvelt NY 10913 Page 1 of 184 GF 142 Ph 800 526 0288 USER MANUAL Installation Operation and Maintenance BENCHMARK 1500 2000 Gas Fired Boilers Natural Gas Modulating Condensing Hot Wa...

Page 2: ...ormation contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implie...

Page 3: ...y 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 2...

Page 4: ...ION 61 5 2 INDOOR OUTDOOR RESET MODE 61 5 2 1 Reset Ratio 61 5 2 2 Building Reference Temperature 61 5 2 3 Outdoor Air Temperature Sensor Installation 61 5 2 4 Indoor Outdoor Startup 61 5 3 CONSTANT S...

Page 5: ...UIDE 95 8 1 INTRODUCTION 95 8 2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES 107 CHAPTER 9 RS 232 COMMUNICATION 109 9 1 INTRODUCTION 109 9 1 1 Acquiring the PuTTY Application 109 9 1 2 Running a...

Page 6: ...rk 1500 2000 Boilers Installation Operation Maintenance Manual IOMM Page 6 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally...

Page 7: ...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 wit...

Page 8: ...MS or BMS II AERCO Boiler Management Systems BLDG Bldg Building 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...

Page 9: ...dth 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 Nationa...

Page 10: ...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 invali...

Page 11: ...ld 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 i...

Page 12: ...ect 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 th...

Page 13: ...ide detector with an alarm is installed 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...

Page 14: ...he venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVI...

Page 15: ...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 p...

Page 16: ...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 requir...

Page 17: ...pter 1 Safety Precautions pages 11 and 12 2 4 2 Setting the Unit The unit must be installed on a 4 inch to 6 inch thick housekeeping pad to ensure proper condensate drainage If anchoring the unit refe...

Page 18: ...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...

Page 19: ...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...

Page 20: ...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...

Page 21: ...tlet 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 maxi...

Page 22: ...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 approve...

Page 23: ...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 I...

Page 24: ...ont 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 intern...

Page 25: ...gure 2 10 Power Box Cover Labels 120VAC 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 b...

Page 26: ...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...

Page 27: ...ensor is DISABLED To enable the sensor and or select an enable disable outdoor temperature see the Configuration Menu in Chapter 3 The outdoor sensor may be wired up to 200 feet from the boiler It is...

Page 28: ...changed to 0 to 20 mA 0 to 5 VDC using the Configuration Menu described in Chapter 3 If voltage rather than current is selected as the drive signal a DIP switch must be set on the PMC Board located i...

Page 29: ...he VFD Blower terminals is disabled 2 10 12 Interlocks The unit offers two interlock circuits for interfacing with Energy Management Systems and auxiliary equipment such as pumps or louvers or other a...

Page 30: ...llow for proper drainage While there is a positive flue pressure during operation the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet or 0 8 W C Fittings...

Page 31: ...K 2000 The free area must take into account restrictions such as louvers and bird screens For Canada installations refer to the requirements specified in CSA B149 1 10 sections 8 4 1 and 8 4 3 2 12 2...

Page 32: ...Benchmark 1500 2000 Boilers CHAPTER 2 INSTALLATION Page 32 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 33: ...D 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 R...

Page 34: ...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 c...

Page 35: ...cters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection 4 RS 232 Port Port permits a Laptop Computer or External Modem to be connected to the...

Page 36: ...em 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...

Page 37: ...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...

Page 38: ...IN THIS O M SEE GF 112 FOR MENU ITEM DESCRIPTIONS LEVEL 2 PWD LEVEL 1 PWD DIAGNOSTICS NOT USED IN THIS O M SEE GF 112 FOR MENU ITEM DESCRIPTIONS Figure 3 2 Menu Structure NOTE The following sections...

Page 39: ...door 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...

Page 40: ...re 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 whethe...

Page 41: ...500 MBH 2000 MBH 2500 MBH 3000 MBH 6000 MBH 1500 MBH or 2000 MBH Fuel Type Natural Gas or Propane Natural Gas Boiler Mode Constant Setpoint Remote Setpoint Direct Drive Combination Outdoor Reset Const...

Page 42: ...rk 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...

Page 43: ...r 4 The valve positions and default drive voltages are listed in Table 3 6 Table 3 6 Combustion Cal Menu Menu Item Display BMK 1500 BMK 2000 CAL Voltage 16 CAL Voltage 14 CAL Voltage 30 CAL Voltage 30...

Page 44: ...cator will light 2 The unit checks to ensure that the Proof of Closure POC switch in the downstream Safety Shut Off Valve SSOV is closed See Figure 3 3 for SSOV location Figure 3 3 BMK 1500 2000 SSOV...

Page 45: ...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 rotate...

Page 46: ...nt 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 Ignit...

Page 47: ...d Air Fuel Valve position for a BMK 1500 MBH boiler running on natural gas Table 3 7a BMK 1500 Relationship Between Air Fuel Valve Position and Energy Input Running On Natural Gas Air Fuel Valve Posit...

Page 48: ...Benchmark 1500 2000 Boilers CHAPTER 3 OPERATION Page 48 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally Blank...

Page 49: ...ns 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 Saf...

Page 50: ...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...

Page 51: ...OV as shown in Figure 4 1 4 Install a NPT to barbed fitting into the tapped plug port 5 Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 W C manometer 4 2 3 Acces...

Page 52: ...en the natural gas supply valve to the unit 3 Set the control panel ON OFF switch to the OFF position 4 Turn on external ac power to the unit The display will show loss of power and the time and date...

Page 53: ...on analyzer to stabilize following each adjustment Clockwise rotation reduces the oxygen level while counterclockwise rotation increases the oxygen level 16 Once the oxygen level is within the specifi...

Page 54: ...ll readings on the Combustion Calibration Sheets provided 28 Repeat steps 20 through 27 for valve positions of 60 45 30 and 16 The oxygen O2 nitrogen oxide NOx and carbon monoxide CO should remain wit...

Page 55: ...RCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 55 of 184 GF 142 Ph 800 526 0288 Figure 4 3 Gas Pressure Adjustment Screw Location Figure 4 4 TAC Valve Adjust Idle Screw BRASS HEX HEAD Rem...

Page 56: ...s 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 3 9 W C 0 2 W C 11 Using the arrow key increase t...

Page 57: ...within the range of 50 F to 100 F If NOx readings exceed the target values shown increase the O2 level up to 1 higher than the listed calibration range Record the increased O2 value on the Combustion...

Page 58: ...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 14 valve position is too high and the Blower voltage is at the minimum value you can adjust the...

Page 59: ...able from xxx to yyy F 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 desire...

Page 60: ...arm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210 F is displayed press the SET button to store the se...

Page 61: ...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...

Page 62: ...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 Con...

Page 63: ...owing 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 instruction...

Page 64: ...g 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 po...

Page 65: ...ain light and the MANUAL LED will go off 5 6 AERCO CONTROL SYSTEM ACS NOTE ACS can utilize only RS 485 signaling to the boiler The ACS mode of operation is used in conjunction with an AERCO Control Sy...

Page 66: ...red in combination with the ACS when there are up to two isolation valves boiler interlocks and or a Domestic Hot Water DHW pump in a Combination heating plant where AERCO boilers are being used for b...

Page 67: ...he 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 set...

Page 68: ...Benchmark 1500 2000 Boilers CHAPTER 5 MODE OF OPERATION Page 68 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally Blank...

Page 69: ...g 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...

Page 70: ...owly open the ball valve near the low gas pressure switch 5 Place the unit in Manual Mode and adjust the Air Fuel Valve position open between 25 and 30 6 While the unit is firing slowly close the exte...

Page 71: ...manometer installed in step 2 and record the gas pressure reading 7 Slowly increase the gas pressure using the adjustment screw on the SSOV see Figure 4 3 8 The unit should shut down and display a HI...

Page 72: ...e 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 an...

Page 73: ...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 s...

Page 74: ...tween 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...

Page 75: ...e located between the Safety Shut Off Valve SSOV and the Air Fuel Valve see Figure 6 3 4 Set the ON OFF switch to the ON position to start the unit 5 The unit should purge and light the Pilot Flame th...

Page 76: ...itani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Figure 6 3 Bare Boiler Partial View BMK 1500 2000 BLOWER HEAT EXCHANGER BLOWER PROOF SWITCH AIR FUEL VALVE BLOCKED INLET SWITCH AIR FILTER...

Page 77: ...e 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...

Page 78: ...efer to Figure 6 1 and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 5 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 fr...

Page 79: ...ng 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 countercl...

Page 80: ...ual Mode and set the valve position between 25 and 30 3 Remove the Air Fuel Valve cover Figure 6 6 by rotating the cover counterclockwise to unlock and lift up to remove 4 Remove one of the two wires...

Page 81: ...00 526 0288 Figure 6 7 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vesse...

Page 82: ...Benchmark 1500 2000 Boilers CHAPTER 6 SAFETY DEVICE TESTING Page 82 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally Blank...

Page 83: ...58025 09 Therefore only Kit Part No 58025 10 is required when performing the waterside fireside inspections Refer to Appendix L for recommended spare TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE...

Page 84: ...1 Benchmark 1500 2000 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 af...

Page 85: ...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 lo...

Page 86: ...ver 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 ignit...

Page 87: ...aintenance 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 st...

Page 88: ...urner 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...

Page 89: ...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 A...

Page 90: ...00 526 0288 GF 142 Burner Assembly Inspection and Maintenance Procedure Cont Figure 7 4a Burner Assembly Mounting Details 5 16 x 1 3 4 BOLTS 5 16 WASHERS NYLOCK NUTS 4 each BLOWER PLENUM GAS TRAIN AIR...

Page 91: ...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...

Page 92: ...crews 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...

Page 93: ...ng 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 screwdrive...

Page 94: ...ntrols 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 BO...

Page 95: ...munication 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 pro...

Page 96: ...enchmark 1500 2000 Boilers CHAPTER 8 TROUBLESHOOTING GUIDE Page 96 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page left intentionally blank...

Page 97: ...essary 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 i...

Page 98: ...eading 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 qu...

Page 99: ...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...

Page 100: ...urner 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...

Page 101: ...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...

Page 102: ...t 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 Chec...

Page 103: ...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 6 0 W C and 14 W C For DBB gas trains ensure it is between 6...

Page 104: ...ive 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 cont...

Page 105: ...eck 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 Valv...

Page 106: ...ectrical 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 o...

Page 107: ...e 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 mak...

Page 108: ...1 Igniter Injector Flame Detector Mounting Details Figure 8 2 SSOV Actuator with Gas Pressure Adjustment BRASS HEX HEAD Remove to access the Gas Pressure Adjustment Screw DAMPING ORIFICE STAGED IGNIT...

Page 109: ...an 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...

Page 110: ...d 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 Her...

Page 111: ...d rate and data formats have been entered 2 Press the Enter key on the laptop An asterisk prompt should appear 3 At the prompt enter the valid RS 232 password jaguar in lower case letters and press En...

Page 112: ...ption which was just changed in step 5 enter D and press Rtn 10 To display the Fault F Log Sensor S Log or Time T Line Log press F S or T followed by Rtn Refer to section 9 4 for descriptions and samp...

Page 113: ...record is logged This means that no more than 30 minutes of data can be lost if the unit loses power Table 9 2 shows a sample Operation Time Log for a boiler The Operation Time Log can only be access...

Page 114: ...nt 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...

Page 115: ...e derived value from the charts in Appendix D Inlet Water Temp Displays the inlet water temperature in F Air Temp Air Temp is the air temperature at the input to the Air Fuel Valve This reading is one...

Page 116: ...uld have its own programmable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Unit Alpha Displays the first alphabetical character of the boiler serial numbe...

Page 117: ...f Temp Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode Default is 70 F Reset Ratio Permits setting of Reset Ratio when operating boiler in the Out...

Page 118: ...Specifies the timeout value seconds before a Modbus fault is declared Available settings range from 5 to 999 seconds Default is 30 seconds HI DB Setpt EN Operating at a Valve Position below this value...

Page 119: ...BAND 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 corre...

Page 120: ...4 of this Manual CAL Voltage 14 CAL Voltage 30 CAL Voltage 40 CAL Voltage 50 CAL Voltage 70 CAL Voltage 100 Displays the default DC drive voltage provided to the blower at each of the Air Fuel Valve p...

Page 121: ...isabled 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 flam...

Page 122: ...LURE 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 Sw...

Page 123: ...ition 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 Remo...

Page 124: ...ark 1500 2000 Boilers APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 124 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally...

Page 125: ...lco 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 3 100...

Page 126: ...ark 1500 2000 Boilers APPENDIX C SENSOR RESISTTANCE VOLTAGE CHART Page 126 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally...

Page 127: ...etpt 130 F Unit Type BMK Boiler LN Unit Size 1500 MBH or 2000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V Bld...

Page 128: ...3 OMM 0097_0C Ph 800 526 0288 GF 142 Appendix D Boiler Default Settings MENU OPTION FACTORY DEFAULT Configuration Menu Cont Setpt Limit Band If Setpt Limiting Enabled 5 F Network Timeout 30 seconds Hi...

Page 129: ...dition 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 9 SSOV Leakage test Annually Se...

Page 130: ...hmark 1500 2000 Boilers APPENDIX E RECOMMENDED PERIODIC TESTING Page 130 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally B...

Page 131: ...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 Temperatur...

Page 132: ...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...

Page 133: ...9 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...

Page 134: ...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 1...

Page 135: ...PPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 135 of 184 GF 142 Ph 800 526 0288 Appendix G DIMENSIONAL AND CLEARANCE DRAWINGS D...

Page 136: ...ark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS Page 136 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Drawing Number AP A 995...

Page 137: ...ark 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 137 of 184 GF 142 Ph 800 526 0288 Drawing Number AP A 898...

Page 138: ...rk 1500 2000 Boilers APPENDIX G DIMENSIONAL AND CLEARANCE DRAWINGS Page 138 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionall...

Page 139: ...I O SENSOR COMM HARNESS 13 2 81183 BURNER RELEASE GASKET 51 1 63104 I O INTERLOCK HARNESS 14 1 43090 AIR FUEL VALVE PLENUM 52 1 63090 HARNESS ASSY TEMP LIM CONT PWR 15 1 24220 3 AIR FUEL VALVE ASSY B...

Page 140: ...23 12 69087 3 58088 W125 125 PSI KIT WATTS 92023 13 69087 3 58088 W150 150 PSI KIT WATTS 92023 14 69087 4 58088 W160 160 PSI KIT KUNKLE 92023 15 69087 4 Benchmark 1500 2000 Kits Available Part Descrip...

Page 141: ...ART DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 141 of 184 GF 142 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 10 31 2...

Page 142: ...l Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Benchmark 1500 2000 Burner Air Fuel Valve Assembly P N 24378 24388 See full part lists below AERCO International Inc Blauvelt...

Page 143: ...Page 143 of 184 GF 142 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 10 31 2013 29313 rev B 29337 rev B Sheet 5 of 7 Benchmark 1500 2000 Standard FM Gas Train...

Page 144: ...ART DRAWINGS Page 144 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 10 31 2...

Page 145: ...MM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 145 of 184 GF 142 Ph 800 526 0288 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Part List 10 31 2013 29313 rev...

Page 146: ...PLE 1 1 2 NPT X 8 00 LG 8 1 9 43 BUSHING REDUCING 1 2 X 1 4 NPT 25 2 9 323 ELBOW 90 DEGREE 1 1 2 9 3 92077 1 4 NPT MXF BRASS BALL VALVE 26 1 124150 VALVE SSOV 1 1 2 NPT 10 3 9 22 PIPE PLUG 1 4 NPT STE...

Page 147: ...63109 GAS TRAIN HARNESS BMK 3000 35 1 124024 HARNESS WIRING IRI 12 1 124862 RESISTOR ASSY 36 2 95029 FLANGE SSOV 1 1 2 NPT 13 3 93035 ELBOW STREET 1 4 NPT 37 2 123533 NIPPLE CLOSE 1 8 14 1 9 420 TEE...

Page 148: ...H PART DRAWINGS Page 148 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 DBB Gas Train...

Page 149: ...GASKET BLOWER 23 1 81048 GASKET FLAME ROD LOW NOX 6 1 43095 BLOWER PLENUM 24 1 66020 FLAME DETECTOR 7 10 55025 BOLT LOCKING 1 4 20 X 1 00 LG 25 1 59104 OBSERVATION PORT 8 1 59138 FILTER AIR 6 26 1 811...

Page 150: ...ional Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 AERCO International Inc Blauvelt NY 10913 Benchmark 1500 2000 Burner Assembly 10 18 2013 24378 24388 rev A Sheet 2 of 1 24...

Page 151: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 151 of 184 GF 142 Ph 800 526 0288 Appendix I WIRING DIAGRAMS...

Page 152: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 152 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 153: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 184 GF 142 Ph 800 526 0288 Drawing Number 68050 page 1 of 2...

Page 154: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 154 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 155: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 155 of 184 GF 142 Ph 800 526 0288 Drawing Number 68050 page 2 of 2...

Page 156: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 156 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 157: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 157 of 184 GF 142 Ph 800 526 0288 Drawing Number 68060 rev A page 2 of 2...

Page 158: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 158 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 159: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 184 GF 142 Ph 800 526 0288 Drawing Number 68061 rev A page 1 of 2...

Page 160: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 160 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 161: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 184 GF 142 Ph 800 526 0288 Drawing Number 68061 rev A page 2 of 2...

Page 162: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 162 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 163: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 184 GF 142 Ph 800 526 0288 Drawing Number 68062 rev A page 1 of 2...

Page 164: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 164 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 165: ...nchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 165 of 184 GF 142 Ph 800 526 0288 Drawing Number N 68062 rev A page 2 of...

Page 166: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 166 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 167: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 167 of 184 GF 142 Ph 800 526 0288 Drawing Number 68063 rev A page 1 of 2...

Page 168: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 168 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This page intentionally blank...

Page 169: ...enchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 169 of 184 GF 142 Ph 800 526 0288 Drawing Number 68063 rev A page 2 of 2...

Page 170: ...Benchmark 1500 2000 Boilers APPENDIX I WIRING DIAGRAMS Page 170 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 This Page Is Intentionally Blank...

Page 171: ...1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 171 of 184 GF 142 Ph 800 526 0288 Appendix J PIPING DRAWINGS Drawing Number SD A...

Page 172: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 172 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Drawing Number SD A 990 rev A...

Page 173: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 173 of 184 GF 142 Ph 800 526 0288 Drawing Number SD A 991 rev A...

Page 174: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 174 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Drawing Number SD A 992 rev A...

Page 175: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS OMM 0097_0C AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 175 of 184 GF 142 Ph 800 526 0288 Drawing Number SD A 993 rev A...

Page 176: ...Benchmark 1500 2000 Boilers APPENDIX J PIPING DRAWINGS Page 176 of 184 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0097_0C Ph 800 526 0288 GF 142 Drawing Number SD A 994 rev A...

Page 177: ...T 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 C...

Page 178: ...7_0C Ph 800 526 0288 GF 142 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 CONNE...

Page 179: ...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...

Page 180: ...the technical ref docs tables drawings diagrams And etc Revised pressure regulator requirements Curtis Harvey 11 21 2013 Rev C 934 5 Revised the regulator requirements 934 2 revised Analog Output VFD...

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