Watts AERCO Benchmark 2.0LN User Manual Download

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APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS

PR2: 04/22/13 Page

155

158

Benchmark 2.0LN Dual-Fuel Low NOx Boiler

Operation and Maintenance Manual

OMM-0052_0E

GF-127

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

•

Ph: 800-526-0288

Figure K-2: Ball Valve Positions for

PROPANE

Gas Operation

Figure K-3: Ball Valve Positions for

NATURAL GAS

Gas Operation

TO AIR/FUEL

VALVE

CLOSE

NATURAL
GAS

BALL

VALVE

OPEN

PROPANE

GAS

BALL VALVE

NATURAL GAS
INLET

PROPANE

INLET

TO AIR/FUEL

VALVE

OPEN

NATURAL

GAS

BALL

VALVE

CLOSE

PROPANE

GAS

BALL VALVE

NATURAL GAS
INLET

PROPANE

INLET

Summary of Contents for AERCO Benchmark 2.0LN

Page 1: ...ernational Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 USER MANUAL Modulating Condensing Forced Draft Hot Water Boiler 2 000 000 BTU H Input Applicable for Serial Numbers G 11 2402 and above...

Page 2: ...t 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...

Page 3: ...PIPING 14 Exhaust Manifold Condensate Drain 15 2 6 1 2 7 GAS SUPPLY PIPING 16 Gas Supply Specifications 17 2 7 1 Manual Gas Shutoff Valve 17 2 7 2 IRI Gas Train Kit 17 2 7 3 2 8 AC ELECTRICAL POWER WI...

Page 4: ...MENUS 31 Menu Processing Procedure 31 3 3 1 3 4 OPERATING MENU 32 3 5 SETUP MENU 33 3 6 CONFIGURATION MENU 34 3 7 TUNING MENU 35 3 8 COMBUSTION CAL MENU 35 3 9 START SEQUENCE 36 3 10 START STOP LEVEL...

Page 5: ...ystem Setup and Startup 62 5 7 2 CHAPTER 6 SAFETY DEVICE TESTING 63 6 1 TESTING OF SAFETY DEVICES 63 6 2 NATURAL GAS LOW GAS PRESSURE FAULT TEST 63 6 3 PROPANE LOW GAS PRESSURE FAULT TEST 64 6 4 NATUR...

Page 6: ...Using PuTTY 98 9 1 3 9 2 RS232 COMMUNICATION SETUP 99 9 3 MENU PROCESSING UTILIZING RS232 COMMUNICATION 99 9 4 DATA LOGGING 100 Fault Log 100 9 4 1 Operation Time Log 100 9 4 2 Sensor Log 101 9 4 3 A...

Page 7: ...anging from 100 000 BTU hr to 2 000 000 BTU hr The output of the boiler is a function of the unit s firing rate and return water temperature Output ranges from 99 000 BTU hr to 1 933 000 BTU hr depend...

Page 8: ...PR2 04 22 13 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 This page left intent...

Page 9: ...lowed in all cases Authorities having jurisdiction should be consulted before installations are made IMPORTANT This Instruction Manual is an integral part of the product and must be maintained in legi...

Page 10: ...UTION DO NOT use this boiler if any part has been under water Call a qualified service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs...

Page 11: ...n 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 deliveri...

Page 12: ...ces these codes shall supersede AERCO s requirements Minimum acceptable clearances required are Sides 24 inches Front 24 inches Rear 30 inches Top 18 inches All gas piping water piping and electrical...

Page 13: ...R USING THE GAS TRAIN OR BLOWER WHEN USING THE LIFTING TABS ENSURE THERE IS NO LOAD PLACED ON THE GAS TRAIN OR BLOWER LIFTING TABS 2 Figure 2 2 Partial Top View Showing Lifting Tab Location In multipl...

Page 14: ...NSATE DRAIN AND PIPING The Benchmark 2 0LN Boiler is designed to condense water vapor from the flue products Therefore the installation must have provisions for suitable condensate drainage or collect...

Page 15: ...nd other prevailing conditions at the site However the following guidelines must be observed to ensure proper condensate trap operation The condensate trap inlet Figure 2 5 must be level with or lower...

Page 16: ...ere with removal of any covers inhibit service maintenance or restrict access between the unit and walls or another unit Benchmark 2 0LN Dual Fuel units contain two 2 inch gas inlet connections on the...

Page 17: ...ropane The gas supply pressure to the unit must be of sufficient capacity to provide 800 cfh while maintaining the gas pressure at 4 0 W C for FM or 5 0 W C for IRI gas trains The maximum static press...

Page 18: ...OF FRONT PANEL TERMINAL BLOCK Figure 2 7 AC Input Terminal Block Location Electrical Power Requirements 2 8 1 The AERCO Benchmark 2 0LN Boiler accepts 120 VAC single phase 60 Hz 20A The Power Box cont...

Page 19: ...terminal strips shown in Figure 2 9 loosen the four cover screws and remove the cover All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings pro...

Page 20: ...485 Modus signaling connections are made from the BMS BMS II ACS 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 AERC...

Page 21: ...1 data sheet BMS 168 applications GF 131 and TAG 0050 ACS applications Figure 2 10 I O Box Terminal Locations and Functions 2 10 I O BOX CONNECTIONS The types of input and output signals and devices t...

Page 22: ...en in the Operating Menu The sensor must be wired to the positive and negative terminals of the AIR TEMP SENSOR and must be similar to AERCO BALCO wire sensor Part No 12449 A resistance chart for this...

Page 23: ...ch In 11 2 10 10 These terminals permit an external exhaust switch to be connected to the exhaust manifold of the boiler The exhaust switch should be a normally open type switch such as AERCO Part No...

Page 24: ...ust be consulted before any flue gas vent or inlet air venting is designed or installed U L listed positive pressure watertight vent materials as specified in AERCO s GF 2050 must be used for safety a...

Page 25: ...ing the total maximum allowable venting run See the AERCO Benchmark Venting and Combustion Air Guide GF 2050 When using the boiler in a sealed combustion air configuration each unit must have a minimu...

Page 26: ...f pump valve load exceeds the above contact ratings use a separate contact relay See Diagrams 2 1a and 2 1b To identify if the boiler is equipped with the BMK Pump Relay Option part no 69102 look for...

Page 27: ...ANT All of the installation procedures in Chapter 2 must be completed before attempting to start the unit WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460 208 AND 24 VOLTS AC IT MUST BE SERV...

Page 28: ...N Page 28 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Figu...

Page 29: ...Deadband Mode 3 VFD Display Vacuum Fluorescent Display VFD consists of 2 lines each capable of displaying up to 16 alphanumeric characters The information displayed includes Startup Messages Fault Mes...

Page 30: ...menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 press...

Page 31: ...nitiating each menu and option is accomplished using the Menu Keys shown in Figure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps before attempting to pe...

Page 32: ...ailed descriptions of each menu option Refer to Appendix B for listings and descriptions of displayed startup status and error messages 3 4 OPERATING MENU The Operating Menu displays a number of key o...

Page 33: ...port A view only software version display is also provided to indicate the current Control Box software version NOTE The Outdoor Temp display item shown with an asterisk in Table 3 2 will not be displ...

Page 34: ...itions no changes will be required Table 3 4 Configuration Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Internal Setpt Lo Temp Limit Hi Temp Limit 130 F Unit Type KC Boil...

Page 35: ...ting 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...

Page 36: ...95 Vdc CAL Voltage 45 25 Vdc 10 0 Vdc 3 00 Vdc CAL Voltage 60 25 Vdc 10 0 Vdc 3 00 Vdc CAL Voltage 80 25 Vdc 10 0 Vdc 4 45 Vdc CAL Voltage 91 25 Vdc 10 0 Vdc 8 20 Vdc SET Valve Position 0 91 0 Blower...

Page 37: ...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 Figure 3 3 SSOV Locations 4...

Page 38: ...Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 c The gas Safety Shut Off Valve SSOV is energized opened allowing gas to f...

Page 39: ...he current date and time will be displayed in place of the flame strength 8 With the unit firing properly it will be controlled by the temperature controller circuitry The boiler s VALVE POSITION will...

Page 40: ...uel Valve position Refer to Table 3 8 for the relationship between the energy input and Air Fuel Valve position for a unit running on natural gas Table 3 8 Relationship Between Air Fuel Valve Position...

Page 41: ...flue gas emissions Initial unit start up is to 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...

Page 42: ...nd plastic tubing 1 4 NPT to barbed fittings for use with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive Installing Gas Supply Manometer 4 2 2 The gas...

Page 43: ...he SSOV during Combustion Calibration paragraph 4 5 and 4 6 remove the 1 4 NPT plug from the appropriate leak detection ball valve natural gas or propane on the downstream side of the SSOV as shown in...

Page 44: ...ation It is important to perform the following procedure as outlined This will keep readjustments to a minimum and provide optimum performance 1 Open the water supply and return valves to the unit and...

Page 45: ...C 12 Increase the valve position to 100 and verify that the gas pressure downstream of the SSOV remains at 7 2 W C Readjust pressure if necessary 13 With the valve position at 100 insert the combustio...

Page 46: ...on the front panel of the C MORE and access the Setup menu Enter password 6817 and then press the ENTER key 18 Press the MENU key on the front panel of the C MORE until Combustion Cal Menu appears on...

Page 47: ...ion reads 60 and press the ENTER key 30 Press the down arrow key until CAL Voltage 60 is displayed 31 Press the CHANGE key CAL Voltage 60 will begin to flash 32 The oxygen level at the 60 valve positi...

Page 48: ...flash 48 The oxygen level at the 30 valve position should be as shown below Also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown Table 4 5 Combustion...

Page 49: ...of initial start up is necessary due to changes in the local altitude gas BTU content gas supply piping and supply regulators Factory Test Data sheets are shipped with each unit These sheets must be...

Page 50: ...for a 91 Valve Position Oxygen 0 2 Carbon Monoxide NOx 5 3 150 ppm 100 ppm 15 If necessary adjust the iris air damper shown in Figure 4 5 until the oxygen level is within the range specified above 16...

Page 51: ...on appears on the C MORE display 28 Press the CHANGE key SET Valve Position will begin to flash 29 Press the arrow key until the SET Valve Position reads 60 and press the ENTER key 30 Press the down a...

Page 52: ...TER key 46 Press the arrow key until CAL Voltage 30 is displayed 47 Press the CHANGE key CAL Voltage 30 will begin to flash 48 The oxygen level at the 30 valve position should be as shown below Also e...

Page 53: ...the vent hole Replace the NPT plug in the vent hole using a suitable pipe joint compound 6 Replace the unit s side panels and front door 4 6 OVER TEMPERATURE LIMIT SWITCHES The unit contains three 3...

Page 54: ...Switch and Fuel Selector Locations Digital Alarm Switch Checks and Adjustments 4 6 1 The digital alarm switch settings can be checked or adjusted using the controls and display on the front panel of...

Page 55: ...over temperature alarm setting press the or arrow button to change the display to the desired temperature setting 5 Once the desired over temperature alarm setting 210 F is displayed press the SET but...

Page 56: ...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 Building Reference Temperature...

Page 57: ...13 Press ENTER to save the change Refer to paragraph 3 3 for detailed instructions on menu changing 5 3 CONSTANT SETPOINT MODE The Constant Setpoint mode is used when a fixed header temperature is des...

Page 58: ...Remote Setpoint Mode the 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 paragra...

Page 59: ...0 mA 1 5 Vdc With this setting 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 sign...

Page 60: ...EMOTE LED will again light and the MANUAL LED will go off 5 6 BOILER MANAGEMENT SYSTEM BMS NOTE BMS Model 168 can utilize either pulse width modulation PWM or RS485 Modbus signaling to the Boiler The...

Page 61: ...ay Panel optional depending on applications are necessary to configure this system Typically an adequate number of boilers are installed to cover the space heating load on the design day however one o...

Page 62: ...settings in the Configuration Menu MENU OPTION SETTINGS BMS 168 Applications ACS Applications Boiler Mode Combination Combination Remote Signal BMS PWM Input Network RS485 Internal Setpt 40 F to 240 F...

Page 63: ...EM MAY INCLUDE 120 AND 24 VOLTS AC POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 6 2 NATURAL GAS LOW GAS PRESSURE FAULT TEST Refer...

Page 64: ...d adjust the valve position to 34 6 While the unit is firing slowly close the external manual gas shut off valve 7 The unit should shut down and display a LOW GAS PRESSURE fault message at approximate...

Page 65: ...fault message should clear and the FAULT indicator should go off The unit should restart 11 Upon test completion close the leak detect ion ball valve and remove the manometer Replace the 1 4 plug rem...

Page 66: ...return piping to the unit 9 Open the water supply shut off valve to the unit to refill 10 After the shell is full press the LOW WATER LEVEL RESET button to reset the low water cutoff 11 Press the CLE...

Page 67: ...m the factory jumpered closed However each of these interlocks may be utilized in the field as a remote stop and start an emergency cut off or to prove that a device such as a pump gas booster or louv...

Page 68: ...OFF position 2 Place the unit in the Manual Mode and set the valve position to 34 3 Close the manual gas shutoff valve located between the Safety Shut Off Valves SSOVs and the Air Fuel Valve see Figu...

Page 69: ...isable the blower output drive voltage as follows a Press the MENU key until CONFIGUR ATION MENU is displayed b Press the arrow key until the ANA LOG OUTPUT function is displayed then press the CHANGE...

Page 70: ...ton The unit should restart 10 Next check the Blocked Inlet Switch by first noting the current position of the Iris Air Damper and then closing the Damper to position 8 11 The unit should shut down an...

Page 71: ...e 6 6 5 Initiate a unit start sequence 6 The unit should begin it s start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION 7 Replace the wire on the Ignition Switch and press th...

Page 72: ...M 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Figure 6 5 Air Fuel Valve Cover Location Figure 6 6 Air Fuel Valve Purge and Ignition Switch Locations 6 14 SA...

Page 73: ...also includes the items contained in the Annual Maintenance Kit Therefore only Kit Part No 58025 06 is required when performing the waterside fireside inspections Appendix K contains recommended spar...

Page 74: ...ector flame detector and other related components 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...

Page 75: ...r injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector should be replaced If carbon build up is present clean the com...

Page 76: ...of the unit see Figures 7 1 and 7 2 The flame detector may be hot Allow the unit to cool sufficiently before removing the flame detector To inspect or replace the flame detector 1 Set the ON OFF switc...

Page 77: ...ults of the tests should be recorded in a log book See Chapter 6 Safety Device Testing Procedures 7 6 BURNER ASSEMBLY INSPECTION The burner assembly part no 24176 is located at the top of the unit s h...

Page 78: ...niter injector 7 Using a 7 16 open end wrench disconnect the compression nut securing the gas injector tube of the igniter injector to the elbow of the staged ignition assembly see Figure 7 2 Disconne...

Page 79: ...r gasket which will be replaced with a new gasket 16 Remove the eight 8 3 8 16 nuts from the burner flange Figure 7 5 using a 9 16 wrench BLOWER PROOF SWITCH BLOCKED INLET SWITCH AIR FUEL VAVLE STAGED...

Page 80: ...t types of condensate traps that may be used in your configuration an older style without an inlet adapter and a newer style with a built in inlet adapter see Figure 7 5 Maintenance is the same except...

Page 81: ...to the OFF position to shut down the boiler s operating controls 2 Disconnect AC power from the unit 3 Close the water supply and return valves to isolate boiler 4 Close external gas supply valve 5 Op...

Page 82: ...age 82 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This pa...

Page 83: ...32 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 RS232 communication set up an...

Page 84: ...witch and inspect for signs of blockage clean or replace as necessary 4 Remove the blocked air inlet switch and inspect for signs of blockage clean or replace as necessary 5 Measure the Blower proof s...

Page 85: ...to the combustion blower for signs of blockage 5 Measure for 24 VAC during start sequence from each side of the switch to ground If 24VAC is not present refer to qualified service personnel 6 See CORR...

Page 86: ...oked up Hook up if not installed If installed check polarity Measure signal level Check continuity of wiring between source and boiler 2 Check signal at source to ensure it is isolated 3 Check DIP swi...

Page 87: ...he valve is correct 3 Check combustion calibration Adjust as necessary 4 Remove the burner and inspect for any carbon or debris Clean and reinstall 5 Remove blockage in condensate drain HEAT DEMAND FA...

Page 88: ...the current readings then reset them to the default values 3 Using the resistance charts in the Appendix C Measure the resistance of Shell sensor and BTU sensor at a known water temperature 4 If unit...

Page 89: ...tch is wired correctly correct wire numbers on the normally open terminals If the switch is wired correctly replace the switch 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON repl...

Page 90: ...rect supply gas pressure 2 Defective Low Pressure Gas Switch 1 Measure gas pressure upstream of the supply gas regulator with the unit firing Refer to paragraph 2 7 1 to ensure that the gas pressure i...

Page 91: ...he 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 ser...

Page 92: ...rd 2 The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two Normally this measurement should be near zero or no more than a few millivol...

Page 93: ...essage being displayed TABLE 8 2 BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light Off 1 Staged Ignition Ball Valve closed 2 Clogged...

Page 94: ...essure Switch Snubber Locatio STAGED IGNITION ASSEMBLY IGNITOR INJECTOR BURNER PLATE BURNER Figure 8 2 Staged Ignition Solenoid Location NATURAL GAS SSOV PROPANE SSOV PROPANE LOW GAS PRESSURE SWITCH N...

Page 95: ...PR2 04 22 13 Page 95 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Figur...

Page 96: ...IDE Page 96 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Th...

Page 97: ...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 Log...

Page 98: ...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...

Page 99: ...An asterisk prompt should appear 3 At the prompt enter the valid RS232 password jaguar in lower case letters and press Enter 4 Welcome to Aerco will appear in the laptop or dumb terminal display with...

Page 100: ...are provided in the following paragraphs The basic procedure for accessing each data log is described in paragraph 9 3 step 7 Fault Log 9 4 1 The C More Control Panel logs the last 20 faults 0 19 sta...

Page 101: ...Fault Log Display No Fault Message Cycle Date Time 0 Direct Drive Signal Fault 609 1 10 02 8 42am 1 Low Gas Pressure 366 7 04 01 5 29pm 2 Loss of Power 0 1 01 01 11 50am Table 9 2 Sample Operation Tim...

Page 102: ...Page 102 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This...

Page 103: ...is value is the setpoint equivalent to the remote analog signal supplied to the unit When in the Outdoor Reset Mode this is the derived value from the charts in Appendix D Air Temp Air Temp is the air...

Page 104: ...ammable password Baud Rate Allows communications Baud Rate to be set 2400 to 19 2K Default is 9600 Software Version Identifies the current software version of the control box Ver 0 0 to Ver 9 9 CONFIG...

Page 105: ...Hi Limit This is the maximum allowable outlet temperature 40 to 210 F Any temperature above this setting will turn off the unit The temperature must then drop 5 below this setting to allow the unit to...

Page 106: ...of one minute When this entry is set to zero the unit will turn on again as soon as the Valve Position in reaches the Start Level value There will not be a one minute delay when firing at the 29 Valv...

Page 107: ...the actual error is less than the proportional band setting 1 to 120 F the fire rate will be less than 100 If the error is equal to or greater than the proportional band setting the fire rate will be...

Page 108: ...IONS Page 108 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288...

Page 109: ...nit 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 plac...

Page 110: ...he Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when commanded HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switc...

Page 111: ...D DURING IGNITION The Purge Position Limit Switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN DURING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REM...

Page 112: ...ESSAGES Page 112 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 02...

Page 113: ...ge Chart Balco TEMP F RES OHMS VOLTS 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956...

Page 114: ...TANCE Page 114 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288...

Page 115: ...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 D 2 Header Tem...

Page 116: ...137 149 161 173 185 197 209 0 104 117 130 143 156 169 182 195 208 5 107 121 135 149 163 177 191 205 219 10 110 125 140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Tab...

Page 117: ...35 147 159 171 183 195 207 219 10F 114 127 140 153 166 179 192 205 218 5F 117 131 145 159 173 187 201 215 0F 120 135 150 165 180 195 210 5F 123 139 155 171 187 203 219 10F 126 143 160 177 194 211 15F...

Page 118: ...01 102 80F 96 98 100 102 104 106 108 110 112 114 75F 99 102 105 108 111 114 117 120 123 126 70F 102 106 110 114 118 122 126 130 134 138 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126...

Page 119: ...e BMK Boiler Dual Unit Size 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 Bldg Ref Temp If Boiler Mode Out...

Page 120: ...0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Table E 1 Boiler Default Settings Continued MENU OPTION FACTORY DEFAULT Configuration Menu Continued Network Timeout...

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Page 122: ...D DIMENSIONAL DRAWINGS Page 122 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 1091...

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Page 126: ...D DIMENSIONAL DRAWINGS Page 126 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 1091...

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Page 132: ...D DIMENSIONAL DRAWINGS Page 132 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 1091...

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Page 134: ...D DIMENSIONAL DRAWINGS Page 134 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 1091...

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Page 136: ...Page 136 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This page intenti...

Page 137: ...GS PR2 04 22 13 Page 137 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 AP...

Page 138: ...PIPING DRAWINGS Page 138 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 80...

Page 139: ...PIPING DRAWINGS PR2 04 22 13 Page 139 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 80...

Page 140: ...PIPING DRAWINGS Page 140 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 80...

Page 141: ...PIPING DRAWINGS PR2 04 22 13 Page 141 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 80...

Page 142: ...PIPING DRAWINGS Page 142 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 80...

Page 143: ...Page 143 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 APPENDIX H WIRING...

Page 144: ...S Page 144 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Thi...

Page 145: ...PR2 04 22 13 Page 145 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288...

Page 146: ...IRING SCHEMATICS Page 146 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 8...

Page 147: ...IRING SCHEMATICS PR2 04 22 13 Page 147 of 158 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 8...

Page 148: ...IRING SCHEMATICS Page 148 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 8...

Page 149: ...nt stack or intake air duct Monthly Operator Visually inspection condition and check for obstructions Spark Igniter Weekly Operator See paragraph 7 2 Air Fuel Valve position Weekly Operator Check posi...

Page 150: ...CHECK LIST Page 150 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526...

Page 151: ...2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 APPENDIX J BENCHMARK CONTROL PANEL FEATURES...

Page 152: ...ATURES Page 152 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 028...

Page 153: ...key Password will begin to flash 8 Using the arrow key increment the display and stop at 159 9 Press the ENTER key to store the displayed password 10 Password 1 will be displayed indicating that the...

Page 154: ...Page 154 of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Figur...

Page 155: ...nal Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Figure K 2 Ball Valve Positions for PROPANE Gas Operation Figure K 3 Ball Valve Positions for NATURAL GAS Gas Operation TO AIR FUEL VALVE CLOSE...

Page 156: ...arrow keys scroll through the Configuration Menu and stop at Max Valve Position 13 Press the CHANGE key The Max Valve Position will begin to flash 14 Press the arrow key and increase the Max Valve Pos...

Page 157: ...Actuator Regulator Combo Used on ALL FM gas train models Downstream SSOV of IRI gas train models 64048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 6903...

Page 158: ...of 158 PR2 04 22 13 Benchmark 2 0LN Dual Fuel Low NOx Boiler Operation and Maintenance Manual OMM 0052_0E GF 127 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 This page left...

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