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APPENDIX K

K-2

PROPANE

CLOSED

NAT. GAS

FUEL IN

FRONT OF UNIT

DIVERTER VALVE HANDLE

PROPANE POSITION

DIVERTER VALVE HANDLE

NATURAL GAS POSITION

DIVERTER VALVE HANDLE

CLOSED POSITION

FIGURE 1. DUAL-FUEL DIVERTER VALVE

PARTIAL TOP VIEW SHOWING DUAL FUEL BURNER

DUAL FUEL

BENCHMARK

BURNER

AIR

INJECTION

TUBE

OPEN POSITION

(HANDLE IN LINE

WITH TUBE)

AIR INJECTION

VALVE

FIGURE 2. DUAL-FUEL AIR INJECTION VALVE

Summary of Contents for AERCO Benchmark 2.0

Page 1: ...chmark 2 0 Gas Fired Boiler USER MANUAL Applicable for Serial Numbers G 02 533 thru G 10 1060 Benchmark 2 0 Gas Fired Boiler System Condensing Modulating Forced Draft Hot Water Boiler 2 000 000 BTU H...

Page 2: ...ation contained in this operation and maintenance manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including bu...

Page 3: ...iary Relay Contacts 2 9 2 9 Flue Gas Vent Installation 2 9 2 10 Combustion Air 2 10 Chapter 3 CONTROL PANEL COMPONENTS AND OPERATING PROCEDURES 3 1 Para Subject Page 3 1 Introduction 3 1 3 2 Control P...

Page 4: ...Interlock Tests 6 2 6 7 Flame Fault Test 6 3 Para Subject Page 6 8 Air Flow Fault Test 6 4 6 9 SSOV Proof of Closure Switch 6 4 6 10 Purge Switch Open During Purge 6 5 6 11 Ignition Switch Open Durin...

Page 5: ...istance Chart C 1 D Indoor Outdoor Reset Ratio Charts D 1 E Boiler Default Settings E 1 App Subject Page F Dimensional and Part Drawings F 1 G Piping Drawings G 1 H Wiring Schematics H 1 I Recommended...

Page 6: ...the Benchmark ideally suited for modern low temperature as well as conventional heating systems Whether used in singular or modular arrangements the Benchmark offers the maximum flexibility in ventin...

Page 7: ...r by the installer and kept in a safe place for future reference WARNINGS MUST BE OBSERVED TO PREVENT SERIOUS INJURY WARNING BEFORE ATTEMPTING TO PER FORM ANY MAINTENANCE ON THE UNIT SHUT OFF ALL GAS...

Page 8: ...low preventer must be installed upstream of the Fill Makeup Valve The vent termination must be located a minimum of 4 feet above grade level If side wall venting is used the installation must conform...

Page 9: ...orizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisio...

Page 10: ...nclude a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instruction...

Page 11: ...should also be made clear to the delivering carrier 2 2 UNPACKING Carefully unpack the unit taking care not to damage the unit jacket when cutting away packaging materials A close inspection of the u...

Page 12: ...sate drainage If anchoring the unit see the dimensional drawings in Appendix F for anchor location Lifting lugs are provided for moving the unit when it has been removed from the shipping skid See Fig...

Page 13: ...cure both ends of the hose with clamps Drainage from the condensate drain trap outlet must be by gravity to a nearby floor drain via a polypropylene hose or suitable piping If a floor drain is not ava...

Page 14: ...and should have no more than 1 droop from minimum to full fire Propane for Dual Fuel Unit The maximum static pressure to the unit must be no more than 14 W C Minimum operating gas pressure for propan...

Page 15: ...AL BLOCK Figure 2 6 AC Input Terminal Location 2 5 1 ELECTRICAL REQUIREMENTS The Benchmark Boiler is available in one three different AC power configurations 220 Vac 1 Phase 60 Hz 20 amps 208 Vac 3 Ph...

Page 16: ...ion concerning field wiring is provided in paragraphs 2 7 1 through 2 7 9 For additional information on modes of operation refer to Chapter 5 LOWER RIGHT CORNER OF FRONT PANEL TERMINAL STRIPS Figure 2...

Page 17: ...signaling connections are made from the BMS to the RS485 COMM terminals on the I O Box terminal strip Polarity must be maintained and the shield must be connected only at the AERCO BMS The boiler end...

Page 18: ...lding where an aver age outside air temperature is expected The sensor must be shielded from direct sunlight as well as impingement by the elements If a shield is used it must allow for free air circu...

Page 19: ...junction with the auxiliary relay described in paragraph 2 8 This interlock circuit is located in the purge section of the start string It can be connected to the proving device end switch flow switch...

Page 20: ...ll be attached at the blower suction and the knockout at the top of the unit will be and should remain in place The more common methods of supplying combustion air are outlined below For more informat...

Page 21: ...TRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460 220 120 AND 24 VOLTS AC IT MUST NOT BE SERVICED OR ACCESSED BY OTHER THAN FACTORY CERTIFIED SERVICE TECHNICIANS WARNING DO NOT ATTEMPT TO DRY FIRE THE BO...

Page 22: ...ying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Messages Operating Status Messages Menu Selection 4 RS 232 Port Port permits a Laptop Computer or Extern...

Page 23: ...e 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 an...

Page 24: ...s in the Operating Menu 2 Press the MENU key The display will show the Setup Menu which is the next menu category shown in Figure 3 2 This menu contains the Password option which must be entered if ot...

Page 25: ...ime language to be used for display messages units of temperature measurements and entries required for external communication and control of the unit via the RS 232 port A view only software version...

Page 26: ...ximum Default Internal Setpt Lo Temp Limit Hi Temp Limit 130 F Unit Type Boiler Water Heater Boiler Unit Size 0 5 MBTU 1 0 MBTU 1 5 MBTU 2 0 MBTU 2 5 MBTU 3 0 MBTU 1 0 MBTU Boiler Mode Constant Setpoi...

Page 27: ...ure POC switch Low Water Level switch High Water Temperature switch High Gas Pressure switch Low Gas Pressure switch If all of the above switches are closed the READY light above the ON OFF switch wil...

Page 28: ...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 and c...

Page 29: ...The blower relay will be deactivated and the Air Fuel Valve will be closed Standby will be displayed 3 9 START STOP LEVELS The start and stop levels are the fire rate percentages that start and stop...

Page 30: ......

Page 31: ...THE BOILER WITHOUT FULL WATER LEVEL THIS CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE THIS IS NOT COVERED BY WARRANTY CAUTION All installation procedures in Chapt...

Page 32: ...al pressure regulator see Figure 4 3 2 Place the gasket from the regulator cap onto the regulator adjustment tool 3 Prior to installing the tool on the regulator pull up the screwdriver blade of the t...

Page 33: ...ensure that the system pumps are running 2 Open the natural gas supply valve s to the unit 3 Using the 16 manometer ensure that there is adequate supply gas pressure If using a non lock up regulator...

Page 34: ...ure should still be 7 0 for FM gas trains and 7 4 W C for IRI gas trains If it is not readjust as necessary 14 Allow the combustion analyzer to settle Compare the measured oxygen level with the levels...

Page 35: ...tic supply gas pressure for approximately 9 WC 6 Set the ON OFF switch to the OFF position Turn on AC power to the unit The display will show LOSS OF POWER and the time and date 7 Set the unit to the...

Page 36: ...at it is still within the range specified in Table 4 19 Continue this procedure until oxygen levels at 40 24 and 100 firing rates are within the ranges specified in Tables 4 5 and 6 20 Set the ON OFF...

Page 37: ...ed manual reset switch that will shutdown and lock out the boiler if the water temperature reaches 210 F The other is an adjustable auto reset switch which allows the boiler to restart once the temper...

Page 38: ......

Page 39: ...increasing its temperature For instance if a reset ratio of 1 6 is used and we select a building reference temperature of 70 F then at an outside temperature of 69 F the supply header temperature will...

Page 40: ...ttings must be made in the Configuration Menu MENU OPTION SETTING Boiler Mode Constant Setpoint Internal Setpt Select desired setpoint using and arrow keys 40 F to 240 F Refer to paragraph 3 3 for det...

Page 41: ...signal is present To operate the unit in the Manual mode press the AUTO MAN switch The REMOTE LED will go off and the MANUAL LED will light To change back to the Remote Setpoint mode simply press the...

Page 42: ...he BMS mode is used when it is desired to operate multiple units in the most efficient manner possible The BMS can control up to 40 boilers 8 via pulse width modulation PWM and up to 32 via Modbus RS4...

Page 43: ...d When the combo units are satisfying the domestic load they are in constant setpoint mode of operation When the combo units switch over to space heating their mode of operation changes to the BMS mod...

Page 44: ......

Page 45: ...TRICAL SHOCK 6 2 LOW GAS PRESSURE FAULT TEST 1 Referring to Figure 6 1 ensure that the 1 4 leak detection valve located at the high gas pressure switch is closed 2 Remove the 1 4 plug from the 1 4 lea...

Page 46: ...unit is now ready for operation 6 5 WATER TEMPERATURE FAULT TEST 1 In the normal operating mode allow the unit to stabilize at its setpoint 2 Lower the adjustable temperature limit switch setting to...

Page 47: ...rminals remove one side of the jumper If the interlock is connected to a proving switch of an external device disconnect one of the wires leading to the proving switch 4 The unit should shut down and...

Page 48: ...wn and display AIRFLOW FAULT DURING RUN 4 Replace the wire previously removed from the blower proof switch and depress the CLEAR button The unit should restart HARNESS 155 C NO 154 TO FRAME A F VALVE...

Page 49: ...DURING IGNITION 1 Set the unit s ON OFF switch to the off position Place the unit in manual mode and set the fire rate between 25 and 30 2 Remove the air fuel valve cover Fig 6 7 by rotating the cover...

Page 50: ......

Page 51: ...r and pull the igniter bushing from the burner shell 4 Insert the igniter removal tool into the burner shell where the igniter bushing was removed Fit the hexagonal end of the tool over the igniter Se...

Page 52: ...cool sufficiently before removing the flame detector To inspect or replace the flame detector 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remo...

Page 53: ...el Valve See Fig 7 3 NOTE Do not remove the gas inlet pipe from the Burner Assembly See Fig 7 3 7 Remove the six 6 5 16 16 bolts from the burner flange See Fig 7 3 BURNER 5 16 16 BOLTS 6 HOSE CLAMP GA...

Page 54: ...trap should be inspected and if necessary cleaned to ensure proper operation Proceed as follows 1 Disconnect the external condensate trap by loosening the hose clamps between the trap and the condens...

Page 55: ...ernal gas supply valve 5 Open relief valve to vent water pressure 7 9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN After a prolonged shutdown a year or more the following procedures m...

Page 56: ......

Page 57: ...on No 1 etc When a fault occurs in the Benchmark Boiler proceed as follows to isolate and correct the fault 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indic...

Page 58: ...relay is okay check the blower 2 Start the unit If the blower runs check the airflow switch for continuity Replace the switch if there is no continuity 3 Remove the air flow switch and inspect for sig...

Page 59: ...rrectly for the type of signal being sent Check control signal type set in Configuration Menu FLAME LOSS DURING IGN 1 Burner Ground Screw not installed or loose 2 Worn flame detector 3 No spark from S...

Page 60: ...fault persists replace Ignition Stepper IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Defective exhaust sensor 2 Carboned heat exchanger due to incorrect combustion calib...

Page 61: ...easure the resistance of Shell sensor and BTU sensor at a known water temperature 4 If unit is in Manual Mode switch to Auto Mode 5 Check setpoint of unit and setpoint of Temperature Switch Ensure tha...

Page 62: ...ion 2 Defective ignition switch 3 Defective Power Supply Board or fuse 4 Defective IGST Board 1 Start the unit The Air Fuel Valve should rotate to the purge open position then back to ignition positio...

Page 63: ...Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons Replace water level circuitry if it does not respond 3 Check continuity of probe end to the shell change...

Page 64: ...sor 1 Inspect Outdoor Temperature sensor for loose or broken wiring 2 Check resistance of sensor to determine if it is within specification 3 Ensure that the correct sensor is installed REMOTE SETPT S...

Page 65: ...ve power from the unit Refer fault to qualified service personnel 3 Remove the electrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve clos...

Page 66: ...APPENDIX C C 1 Temperature Sensor Resistance Chart Balco...

Page 67: ...F 89 102 115 128 141 154 167 180 193 206 20F 92 106 120 134 148 162 176 190 204 218 Header Temperature for a Building Reference Temperatrure of 60F RESET RATIO Air Temp 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0...

Page 68: ...25 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 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...

Page 69: ...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 Header Temperature for a Building Reference Temperature of 80F RESET RATIO Air Temp 0 6...

Page 70: ...22 126 130 134 138 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 1...

Page 71: ...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...

Page 72: ...PLATE EXHAUST PLENUM 8 INLET ADAPTOR OFFSET REDUCER COVER POLY BLOWER INLET DUCT 19 20 18 96004 2 123990 123681 201216 201283 123612 CONDENSATE TRAP ASSEMBLY 24060 12820 11 1 1 2 NPT DRAIN BALL VALVE...

Page 73: ...43 44 32 31 4 15 23 37 38 34 41 49 50 35 10 BENCHMARK 2 0 BOILER SH 2 OF 3 PL A 140 INTERNATIONAL INC NORTHVALE NJ 07647 041304 AERCO PARTS LIST K DWN BY APPD SCALE CZ DATE DATE 22 40 52 52 14 51 23 1...

Page 74: ...SEMBLY RIGHT REAR PANEL LEFT REAR PANEL 201127 1 201126 1 TOP PANEL 181144 4 161463 2 DESCRIPTION FRONT DOOR ASSEMBLY FRONT PANEL ENCLOSURE TOP RAIL 161464 2 201120 1 201113 1 QTY PL A 140 SH 3 OF 3 D...

Page 75: ...E B PV CODE SECTION IV STAMP H 240 210 PSIG TEST PRESS TEMP F MAXIMUM MAX WORKING PRESS PSIG 160 HEAT EXCHANGER COMBUSTION CHAMBER DESIGN STANDARDS HT G SURFACE SQ FT 95 MIN RELIEF VA CAPACITY MBH 200...

Page 76: ...APPENDIX F F 5...

Page 77: ...OF OF CLOSURE SWITCH P N 69038 2 NPT DIFFERENTIAL GAS PRESSURE REGULATOR P N 123541 VENT TO ATMOSPHERE PER ANSI Z223 1 NFPA54 NTS BOILER BOUNDARY TO AIR FUEL VALVE ASS Y F SSOV 1 SSOV 2 TEST COCK LOW...

Page 78: ...HIGH GAS PRESS SWITCH P N 122412 1 1 4 NPT PROPANE DIFFERENTIAL PRESSURE REGULATOR P N 122415 E AP A 744 APPD CHKD INTERNATIONAL INC NORTHVALE NJ 07647 BENCHMARK DUAL FUEL GAS TRAIN AERCO DATE SIZE DW...

Page 79: ...VALVE P N 124274 VENT TO ATMOSPHERE PER ANSI Z223 1 NFPA54 NTS BOILER BOUNDARY TO AIR FUEL VALVE ASS Y SSOV 1 SSOV 2 TEST COCK LOW GAS PRESS SWITCH P N 123866 HIGH GAS PRESS SWITCH P N GP 122412 2 NPT...

Page 80: ...APPENDIX F F 9...

Page 81: ...APPENDIX F F 10...

Page 82: ...MAINTAIN A REGULATED 7 W C PRESSURE AT MAXIMUM BTU HR INPUT 2 MANUAL SHUTOFF VALVE GAS SUPPLY TO THE BOILER SEE DIMENSIONAL DRAWING AP A 739 2 SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARR...

Page 83: ...URE REGULATOR MAINTAIN A REGULATED 7 W C PRESSURE AT MAXIMUM BTU HR INPUT 2 MANUAL SHUTOFF VALVE GAS SUPPLY DIRT TRAP TO THE BOILER SEE DIMENSIONAL DRAWING AP A 739 2 SHELL DRAIN VALVE AND CONDENSATE...

Page 84: ...DWN BY SCALE DATE DATE CZ NTS 072701 AERCO SD A 594 D REV TEMPERATURE GAUGE P T PRESSURE BALANCING VALVE ISOLATION VALVE UNION Y STRAINER LEGEND BENCHMARK 2 MIL BTU GAS FIRED BOILER THREE UNIT INSTALL...

Page 85: ...RELIEF VALVE SHOULD BE PIPED VERTICALLY 1 FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER 3 ALL ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY CONNECTIONS TO THE BOILER SEE DIMENSIONAL DRA...

Page 86: ...APPENDIX G G 7...

Page 87: ...L1 GN D POWER BOX MOTOR BLOWER 230 VAC 3O 60 HZ 300 261 262 205 301 302 210 RELAY 260 262 261 206 206 300 NEU 200 GROUND BLOCK SHEET 1 OF 2 320 321 TO CONTROL BOX ADDED GROUND WIRES 320 321 FYP B 1007...

Page 88: ...485 IN A 1 2 4 3 7 8 6 5 9 10 12 11 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 12 11 10 9 13 14 15 231 234 232 233 238 236 235 237 239 INPUT OUTPUT BOX 220 VAC 1 PHASE LS2 1 LS1 LS4 LS3 J3 J2 J1 SHEET 2 OF 2 AS...

Page 89: ...POWER BOX 120 VAC MOTOR BLOWER 230 VAC 3O 60 HZ 300 261 262 L1 L2 263 205 L3 A1 T1 MCR T2 T1 T2 301 95 NC T3 A2 303 T3 302 210 RELAY WITH OVERLOAD 260 263 262 261 206 206 300 NEU 200 GROUND BLOCK SHEE...

Page 90: ...485 IN A 1 2 4 3 7 8 6 5 9 10 12 11 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 12 11 10 9 13 14 15 231 234 232 233 238 236 235 237 239 INPUT OUTPUT BOX 230 VAC 3 PHASE LS2 1 LS1 LS4 LS3 J3 J2 J1 SHEET 2 OF 2 AS...

Page 91: ...2 313 308 318 L3 A1 T1 MCR T2 T1 T2 301 95 NC T3 A2 303 T3 302 316 RELAY WITH OVERLOAD CONTROL TRANSFORMER 310 H2 308 300 BAR GROUND H1 309 H4 460VAC H3 X2 X1 4 AMPS XF 315 FUSE 120VAC 205 317 260 313...

Page 92: ...485 IN A 1 2 4 3 7 8 6 5 9 10 12 11 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 12 11 10 9 13 14 15 231 234 232 233 238 236 235 237 239 INPUT OUTPUT BOX 460 VAC 3 PHASE LS2 1 LS1 LS4 LS3 J3 J2 J1 AS FOLLOWS UNLE...

Page 93: ...monthly Operator Visual inspection for condition or obstructions Igniter Weekly Operator see section 7 2 main fuel valve valve position Weekly Operator Check position indicator leakage test annually...

Page 94: ...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 GRE...

Page 95: ...IN 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 P...

Page 96: ...ss the Calibration Menu by pressing the MENU key four times 8 Press the arrow key one time Start Level 20 should be displayed indicating that it is currently set for Natural Gas operation 9 Press the...

Page 97: ...IVERTER VALVE HANDLE NATURAL GAS POSITION DIVERTER VALVE HANDLE CLOSED POSITION FIGURE 1 DUAL FUEL DIVERTER VALVE PARTIAL TOP VIEW SHOWING DUAL FUEL BURNER DUAL FUEL BENCHMARK BURNER AIR INJECTION TUB...

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