Watts AERCO Benchmark 2.0LN Operating & Maintenance Instructions Download Page 2

Page: 2 / 101

Printed in U.S.A.

REVISED

JANUARY,

2009

GF-110LN

OMM-0023_0A

Benchmark 2.0LN Low NOx Gas-Fired Boiler

USER MANUAL

Telephone Support

Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through Friday)

(800) 526-0288

AERCO International, Inc.

100 Oritani Drive

Blauvelt, NY 10913

www.aerco.com

The information contained in this installation, 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

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 occurring in connection with the

furnishing, performance, or use of this material.

Summary of Contents for AERCO Benchmark 2.0LN

Page 1: ...MM 0023_0A Benchmark 2 0LN Low NOx Gas Fired Boiler USER MANUAL Applicable To Serial Numbers G 05 1393 and above Benchmark 2 0LN Gas Fired Low NOx Boiler System Condensing Modulating Forced Draft Hot Water Boiler 2 000 000 BTU H Input Patent 2 155 12 ...

Page 2: ...08 The information contained in this installation 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 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 ...

Page 3: ...7 I O Box Connections 2 7 2 8 Auxiliary Relay Contacts 2 8 2 9 Flue Gas Vent Installation 2 9 2 10 Combustion Air 2 9 Chapter 3 CONTROL PANEL COMPONENTS AND OPERATING PROCEDURES 3 1 Para Subject Page 3 1 Introduction 3 1 3 2 Control Panel Description 3 1 3 3 Control Panel Menus 3 3 3 4 Operating Menu 3 5 3 5 Setup Menu 3 5 Para Subject Page 3 6 Configuration Menu 3 6 3 7 Tuning Menu 3 7 3 8 Start ...

Page 4: ...6 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 During Ignition 6 5 6 12 Safety Pressure Relief Valve Test 6 5 Chapter 7 MAINTENANCE REQUIREMENTS 7 1 Para Subject Page 7 1 Maintenance Schedule 7 1 7 2 Spark Igniter 7 1 7 3 Flame Detector 7 2 7 4 Combus...

Page 5: ... Messages B 1 C Temperature Sensor Resistance Chart C 1 D Indoor Outdoor Reset Ratio Charts D 1 App Subject Page E Boiler Default Settings E 1 F Dimensional and Part Drawings F 1 G Piping Drawings G 1 H Wiring Schematics H 1 I Recommended Periodic Testing Checklist I 1 J Benchmark Control Panel Views J 1 ...

Page 6: ...uction Manual the Benchmark 2 0 LN Boiler complies with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Texas Commission on Environmental Quality TCEQ Title 30 Chaptr 117 Rule117 465 Whether used in singular or modular arrangements the Benchmark 2 0 LN offers the maximum flexibility in venting with minimum installation space requirements The Be...

Page 7: ...ence WARNINGS MUST BE OBSERVED TO PREVENT SERIOUS INJURY WARNING BEFORE ATTEMPTING TO PER FORM ANY MAINTENANCE ON THE UNIT SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT WARNING THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A POSITIVE PRESSURE AND THERE FORE MUST BE COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES WARNING DO NOT USE MATCHES CANDLES FLAMES OR OT...

Page 8: ... 1 3 PROLONGED SHUTDOWN After prolonged shutdown it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 6 of this manual be performed to verify all system operating parameters If there is an emergency turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit The installer must identify the ...

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Page 10: ... materials 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 unit should be made to determine if there has been any damage not indicated by the Tip N Tell The freight carrier should be notified immediately if any damage is detected The following access...

Page 11: ...as been removed from the shipping skid See Fig 2 2 USE ONLY THE LIFTING LUGS TO MOVE THE UNIT Remove the rear top panel from the unit to provide access to the lifting lugs Remove the four 4 lag screws securing the boiler to the shipping skid Lift the unit off the shipping skid and position it on to the 4 to 6 inch housekeeping concrete pad required in the desired location In multiple unit installa...

Page 12: ...rap associated fittings and drain line must be removable for routine maintenance Do Not hard pipe EXHAUST MANIFOLD 1 2 NPT CONDENSATE DRAIN CONNECTION 3 4 NPT CONDENSATE TRAP Figure 2 4 Condensate Drain Connection Location CONDENSATE TRAP CLAMPS CLAMP TO FLOOR DRAIN 1 I D HOSE 1 I D HOSE 3 4 NPT NIPPLES CONDENSATE DRAIN CONNECTION EXHAUST MANIFOLD Figure 2 5 Condensate Trap Installation 2 4 GAS SU...

Page 13: ... MANUAL GAS SHUTOFF VALVE A 2 manual gas shut off valve is furnished with each unit The valve should be positioned on the inlet to the unit as shown in Figure 2 5 NATURAL GAS SUPPLY 2 MANUAL SHUT OFF DIRT TRAP Figure 2 5 Manual Shut Off Valve Location 2 4 3 IRI GAS TRAIN KIT The IRI gas train is an optional gas train required in some areas by code or for insurance purposes The IRI gas train is fac...

Page 14: ...C 3 PHASE 460 VAC 3 Phase Figure 2 7 AC Terminal Block Configurations 2 6 MODE OF OPERATION and FIELD CONTROL WIRING The Benchmark Boiler is available in several different modes of operation While each unit is factory configured and wired for a particular mode some field wiring may be required to complete the installation This wiring is typically run to the Input Output I O Box located on the fron...

Page 15: ...ected between the BMS Panel and each Boiler s I O Box terminal strip Figure 2 9 Twisted shielded pair wire from 18 to 22 AWG must be utilized for the connections The BMS Mode can utilize either pulse width modulation PWM signaling or RS485 Modbus signaling For PWM signaling connections are made from the AERCO Boiler Management System to the B M S PWM IN terminals on the I O Box terminal strip For ...

Page 16: ...200 feet from the boiler It is connected to the OUTDOOR SENSOR IN and SENSOR COMMON terminals in the I O box see Figs 2 8 and 2 9 Wire the sensor using a twisted shielded pair cable of 18 22 AWG wire There is no polarity when terminating the wires The shield is to be connected only to the terminals labeled SHEILD in the I O box The sensor end of the shield must be left free and ungrounded When mou...

Page 17: ... labeled REMOTE INTL K IN and DELAYED INTL K IN Both interlocks described below are factory wired in the closed position NOTE Both the Delayed Interlock and Remote Interlock must be in the closed position to allow the unit to fire 2 7 9 1 REMOTE INTERLOCK IN The remote interlock circuit REMOTE INTL K IN is provided to remotely start enable and stop disable the Boiler if desired The circuit is 24 V...

Page 18: ... sealed combustion and can be ordered with a sealed combustion option or can be installed using room air as long as there is an adequate supply See paragraph 2 10 3 for more information concerning sealed combustion air If the sealed combustion air option is not being used an inlet screen will be attached at the blower suction and the knockout at the top of the unit will be and should remain in pla...

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Page 20: ...CTRICAL 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 BOILER STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN PERSONNEL INJURY OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY 3 2 CONTROL PANEL DESCRIPTI...

Page 21: ...aying 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 External Modem to be connected to the boiler Control Panel 5 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm condition occurs An alarm message will appear in the VFD 6 CLEAR Key Turns of...

Page 22: ...he arrow key will increment the selected setting DOWN Arrow When in one of the main menu categories Figure 3 2 pressing this key will select the displayed menu category If the CHANGE key was pressed and the menu item is flashing pressing the arrow key will decrement the selected setting CHANGE Permits a setting to be changed edited When the CHANGE key is pressed the displayed menu item will begin ...

Page 23: ...ms 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 other menu options will be changed 3 Continue pressing the MENU key until the desired menu is displayed 4 With the desired menu displayed press the or arrow key The first option in the selected menu wi...

Page 24: ...time 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 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 displayed unless the Outdoor Sensor fu...

Page 25: ...aximum 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 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 BMS PWM Input Network 4 20 mA 1...

Page 26: ...Closure 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 will light and the unit will be in the Standby mode When there is a demand for heat the following events will occur NOTE If any of the Pre Purge safety device switches are open the appropriate fault ...

Page 27: ... and the following events occur a The Air Fuel Valve rotates to the low fire ignition 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 position b Simultaneously the ignition transformer and the staged ignition solenoid valve will be activated The ignition trans former provides ignition spark ...

Page 28: ...el Valve In Ignition Position Once the demand for heat has been satisfied the Control Box will turn off the gas valve 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 the unit based on load These levels are Factory preset as follows Start Level 20 St...

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Page 30: ...T 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 Chapter 2 must be completed before attempting to start the unit 4 2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION To properly perform combustion calibration the proper instruments and tools must be used and correctl...

Page 31: ...he differential 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 tool Then thread the tool into the regulator and hand tighten 4 Engage the tool s screwdriver blade into the regulator s adjustment screw slot Figure 4 3 Differential Regulator Adjustment ...

Page 32: ...tment using a flat tip screwdriver to obtain 4 8 W C see Figure 4 4 For Benchmark 2 0 Low NOx boilers configured for De Rated capacity see para 2 4 1 the gas pressure downstream of the SSOV must be 3 7 W C for both FM and IRI gas trains at a 100 firing rate CAUTION Turn the gas regulator adjustment screw very slowly Unlike ordinary regulators this adjustment is very sensitive REGULATOR ADJUSTMENT ...

Page 33: ...ory if the oxygen or carbon monoxide levels are not within the specified range NOTE If the port being used to sample combustion products at 16 is too far from the unit the readings may be shifted Table 2 Combustion Oxygen Levels for a 16 Firing Rate 20 Raise the firing rate to 100 Gas pressure should still be 4 8 W C If it is not readjust as necessary For Benchmark 2 0 Low NOx boilers configured f...

Page 34: ...compound 5 Remove the combustion analyzer probe from the tapped hole in the exhaust manifold Replace the NPT plug previously removed in para 4 2 3 step 1 6 Replace the unit s panels 4 5 OVER TEMPERATURE LIMIT SWITCH The over temperature limit switches are located on the plate to the left of the boiler shell One is a fixed manual reset switch that will shutdown and lock out the boiler if the water ...

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Page 36: ...gin 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 increase by 1 6 to 71 6 F 5 2 3 Outdoor Air Temperature Sensor Installation The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outsi...

Page 37: ...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 detailed instructions on changing menu options 5 4 REMOTE SETPOINT MODES The unit s setpoint can be remotely controlled by an Energy Management System EMS or Building Automation System BAS The Remote Set...

Page 38: ...l 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 AUTO MAN switch The REMOTE LED will again light and the MANUAL LED will go off 5 5 DIRECT DRIVE MODES The unit s fire rate can be changed by a remote signal which is typically sent from an Energy Ma...

Page 39: ...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 RS485 network communication For BMS programming and operation see GF 108M BMS Model 168 and GF 124 BMS II Model 5R5 384 BMS Operations Guides For operation via an RS485 Modbus network refer to Modbus Communicat...

Page 40: ...ad 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 mode For more information concerning the operation of the Combination Control Panel see the AERCO CCP 1 literature 5 7 1 Combination Control System Field Wiring Wiring for this system is between the BMS...

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Page 42: ...e SSOV is closed located at low gas pressure switch 2 Remove the 1 8 plug from the ball valve upstream of the safety shutoff valve SSOV 3 Install a 0 16 W C manometer or W C gauge where the 1 8 plug was removed 4 Slowly open the 1 8 ball valve upstream of the SSOV 5 Place the unit in Manual Mode and fire the unit at a firing rate between 25 and 30 6 While the unit is firing slowly close the Man ua...

Page 43: ...he 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 match the displayed OUTLET TEMPERATURE See Fig 6 2 RESET BUTTON FOR MANUAL RESET TEMPERATURE LIMIT SWITCH HIGH LIMIT ADJUSTABLE TEMPERATURE LIMIT SWITCH MOUNTING PLATE ON SHELL Figure 6 2 Temperatur...

Page 44: ...tton The unit should start 6 7 FLAME FAULT TEST 1 Place the ON OFF switch in the OFF posi tion 2 Place the unit in the Manual Mode and set the firing rate between 25 and 30 3 Close the manual gas valve located between the SSOV and the Air Fuel Valve see Fig 6 3 and the 1 4 ball valve downstream of the SSOV Figure 6 3 Manual Gas Shut Off Valve Location 4 Place the ON OFF switch in the ON position t...

Page 45: ...eplace the wire previously disconnected and depress the CLEAR button 6 Start the unit 7 Disconnect the wire again when the unit reaches the purge cycle 8 The unit should shut down and display SSOV FAULT DURING PURGE 9 Replace the wire previously disconnected and depress the CLEAR button The unit should restart SSOV ACTUATOR COVER SSOV ACTUATOR COVER SCREW Figure 6 5 SSOV Actuator Cover Screw Locat...

Page 46: ...e rate between 25 and 30 2 Remove the air fuel valve cover Fig 6 8 by rotating the cover counterclockwise to unlock it then pulling it towards you 3 Disconnect one of the two wires from the ignition position switch Fig 6 7 and start the unit 4 The unit should begin to start then shut down and display IGN SWITCH OPEN DURING IGNITION 5 Replace the wire on the ignition switch and depress the CLEAR bu...

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Page 48: ...ce the Igniter 1 Set the ON OFF switch on the control panel to the OFF position Disconnect AC power from the unit 2 Remove the side and top panels from the unit 3 Disconnect the igniter cable from the igniter 4 Using a 15 16 wrench unscrew the igniter from the burner head Remove the igniter from the burner shell by grasping the contact end of the igniter FLAME DETECTOR IGNITER CONTACTOR BURNER Fig...

Page 49: ...ector 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 Remove the top panels from the unit 3 Disconnect the flame detector lead wire Unscrew the flame detector and remove it See Fig 7 2 4 Inspect the detector thoroughly If eroded the detector should be replaced Otherwise clean the detector with a fine emer...

Page 50: ... burner Separate the gas injector and gasket from the burner 6 Disconnect the burner housing from the venturi by removing the six 6 1 4 20 screws Fig 7 3 using a 3 8 wrench 7 Remove the eight 8 3 8 16 nuts from the burner flange see Fig 7 3 using a 9 16 wrench NOTE The burner housing is heavy weighing approximately 20 pounds 8 Remove the burner housing from burner flange by pulling straight up 9 R...

Page 51: ...ce gasket and float in the condensate trap and replace the trap cover 9 Reassemble all piping and hose connections to the condensate trap inlet and outlet Reconnect trap to condensate drain connection on the exhaust manifold FLOAT THUMB SCREWS 4 3 4 NPT PORT INLET OUTLET 3 4 NPT PORT COVER GASKET ORIFICE GASKET Figure 7 4 External Condensate Trap 7 8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD...

Page 52: ...s follows to isolate and correct the fault 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best describes the existing conditions 3 Proceed to the Probable Cause column and start with the first item 1 listed for the Fault Indication 4 Perform the checks and procedures liste...

Page 53: ... 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 signs of blockage clean or replace as necessary 4 Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage 5 Measure for 24 VAC during ...

Page 54: ...wiring between source and boiler 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 Burner Ground Screw not installed or loose 2 Worn flame detector 3 No spark from Spark Plug 4 Defective Ignition Transformer 5 Defective Ignition...

Page 55: ...5 Remove blockage in condensate drain HEAT DEMAND FAILURE 1 The Heat Demand Relays on the Ignition Stepper board failed to activate when commanded 2 Relay is activated when not in Demand 1 Press CLEAR button and restart the unit If the fault persists replace Ignition Stepper IGST Board 2 Defective relay Replace IGST Board HIGH EXHAUST TEMPERATURE 1 Defective exhaust sensor 2 Carboned heat exchange...

Page 56: ...ature setting 2 Check PID settings against Menu Default settings in the Appendix If the settings have been changed record 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 is in Manual Mode switch to Auto Mode 5 Check setpoint of unit and setpoint of...

Page 57: ...e IGST Board IGN SWTCH OPEN DURING IGNITION 1 Air Fuel Valve not rotating to ignition position 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 position towards closed during the ignition cycle If the valve does not rotate back to the ignition position check t...

Page 58: ...easure continuity across the switch and replace if necessary For Benchmark 2 0 Low NOx boilers configured for De Rated capacity see para 2 4 1 if measured gas pressure at the low gas pressure switch is greater than 3 6 W C measure continuity across the switch and replace if necessary LOW WATER LEVEL 1 Insufficient water level in system 2 Defective water level circuitry 3 Defective water level prob...

Page 59: ...ck the 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 service personnel 3 Check to ensure that the switch is wired correctly correct wire numbers on the normally open terminals 4 Check DS1 DS2 LEDs on Power Supply Board If they are not steady ON replace...

Page 60: ...oard SSOV SWITCH OPEN 1 Actuator not allowing for full closure of gas valve 2 SSOV powered when it should not be 3 Defective Switch or Actuator 4 Incorrectly wired switch 1 Observe operation of the Safety Shut Off Valve SSOV through indicator on the Valve actuator and ensure that the valve is fully and not partially closing 2 If the SSOV never closes it may be powered continuously Close the gas su...

Page 61: ...closed 2 Clogged damaged Gas Injector Figure 8 2 3 Defective Staged Ignition Solenoid figure 8 2 1 Open the 1 4 Ball Valve downstream of the SSOV 2 Remove and inspect Gas Injector to ensure it is not clogged or damaged 3 Close the 2 Ball Valve downstream of the Differential Regulator and the 1 4 Ball Valve downstream of the SSOV Start the unit and listen for a clicking sound that the Staged Igniti...

Page 62: ... HIGH GAS PRESSURE SWITCH Figure 8 1 High Pressure Gas Switch Gas Pressure Snubber Locations BURNER HOUSING STAGED IGNITION SOLENOID GAS INJECTOR Figure 8 2 Staged Ignition Solenoid Location DAMPING ORIFICE Figure 8 3 Damping Orifice Location ...

Page 63: ... signal supplied to the unit When in the Outdoor Reset Mode this is the derived value from the charts in Appendix D Aux Temp For monitoring purposes only Outdoor Temp Displayed only if an outdoor sensor is installed and enabled in the Configuration Menu Fire Rate In Indicates desired input fire rate This will normally be the same as the fire rate shown on the bar graph fire rate out when the boile...

Page 64: ...ions Baud Rate to be set 2400 to 19 2K Default is 9600 Software Version Identifies the current software version of the control box CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of Boiler or Water Heater Default is Boiler Unit Size Sets unit size from 0 5 to 3 0 MBTUs Default is 1 0 MBTU Boiler Mode It allows selection of Constan...

Page 65: ...e 40 F to 240 F Any temperature above this setting will turn off the unit The temperature must then drop 5 F below this setting to allow the unit to run Default Temp Hi Limit is 210 F Max Fire Rate Sets the maximum allowable fire rate for the unit 40 to 100 Default is 100 Pump Delay Timer Specifies the amount of time 0 to 30 min to keep the pump running after the unit turns off Default is zero Aux...

Page 66: ...rror 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 100 Default is 70 F Integral Gain This sets the fraction of the output due to setpoint error to add or subtract from the output each minute to move towards the setpoint Gain is adjustable from 0 00 to 2 00 Defaul...

Page 67: ...sec Displayed if Demand Delay is active PURGING XX sec Displayed during the purge cycle during startup The duration of the purge cycle counts up in seconds IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5...

Page 68: ... air fuel valve closed during purge PRG SWTCH CLOSED DURING IGNITION The Purge Position Limit switch on the air fuel valve closed during ignition AIRFLOW FAULT DURING IGN The Blower Proof Switch opened during ignition AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run SSOV SWITCH OPEN The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during purge ...

Page 69: ...setpoint signal is not present or is out of range OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range OUTLET TEMP SENSOR FAULT The temperature measured by the Outlet Sensor is out of range FFWD TEMP SENSOR FAULT The temperature measured by the FFWD Sensor is out of range HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp ...

Page 70: ...APPENDIX C C 1 Temperature Sensor Resistance Chart Balco ...

Page 71: ...5F 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 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 76 78 80 82 84 45F 69 72 75 78 81 84 87 90 93 96 40F 72 76 80 84 88 92 96 100 104 108 35F 75 80 85 90 9...

Page 72: ...125 140 155 170 185 200 215 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 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 90 92 94 55F 79 82 85 88 91 94 97 100 103 106 50F 82 86 90 94 98 102 106 110 114 118 45F 85 90 95...

Page 73: ...0 135 150 165 180 195 210 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 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 92 70F 86 88 90 92 94 96 98 100 102 104 65F 89 92 95 98 101 104 107 110 113 116 60F 92 96 100 104 ...

Page 74: ...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 123 134 145 156 167 178 189 200 30F 126 138 150 162 174 186 198 210 25F 129 142 155 168 181 194 207 20F 132 146 ...

Page 75: ... 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 Limit 200 F Temp Hi Limit 215 F Max Fire Rate 100 Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown mA Output Off Lo Fire Timer 2 sec Setpt Limit...

Page 76: ...TION 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 112 MIN RELIEF VA CAPACITY MBH 2000 CONTROL PANEL DISPLAY 14 1 30 9 71 1 140 9 58 4 21 6 6 0 5 7 174 0 69 2 38 6 33 5 18 2 58 4 31 1 17 1 LIFTING LUGS 2 RELIEF VALVE AND CONDENSATE TRAP ARE INCLUDED SEPARATELY IN SHIPMENT 3 4 ELECTRICAL CONDUIT CON...

Page 77: ...APPENDIX F F 2 ...

Page 78: ...APPENDIX F F 3 ...

Page 79: ...APPENDIX F F 4 ...

Page 80: ...124136 2 SAFETY SHUT OFF VALVE ACTUATOR w REGULATOR P N 64048 2 NPT DIFFERENTIAL GAS PRESSURE REGULATOR P N 123541 NTS TO AIR FUEL VALVE ASS Y B TEST COCK LOW GAS PRESS SWITCH P N 61002 8 HIGH GAS PRESS SWITCH P N 61002 9 1 8 NPT PLUG INSTALL MANOMETER HERE FULL PORT BALL VALVE 2 NPT P N 123540 ENTIRE BMK 2 0 LN FM GAS TRAIN P N 24024 1 BOILER BOUNDARY BENCHMARK2 0 LOW NOx ...

Page 81: ... BALL VALVE 2 NPT P N 123540 C NTS REV DATE SCALE SIZE DWN BY CHKD APPD 020706 CZ AP A 796 BENCHMARK2 0 LOW NOx AERCO INTERNATIONAL INC NORTHVALE NJ 07647 IRI GAS TRAIN SAFETY SHUT OFF VALVE ACTUATOR P N 69038 2 DOUBLE BODY CONNECTING FLANGE P N 124156 2 SAFETY SHUT OFF DOUBLE BODY GAS VALVE P N 124142 LOW GAS PRESS SWITCH P N 61002 8 SAFETY SHUT OFF VALVE ACTUATOR w REGULATOR P N 64048 1 8 NPT PL...

Page 82: ... P N 64048 2 NPT DIFFERENTIAL GAS PRESSURE REGULATOR P N 123541 NTS TO AIR FUEL VALVE ASS Y B TEST COCK HIGH GAS PRESS SWITCH P N 61002 12 1 8 NPT PLUG INSTALL MANOMETER HERE FULL PORT BALL VALVE 2 NPT P N 123540 BOILER BOUNDARY DE RATED OPTION 1 75 MIL BTU HR INPUT FM GAS TRAIN BENCHMARK2 0 LOW NOx 2 SAFETY SHUT OFF GAS VALVE P N 124136 LOW GAS PRESS SWITCH P N 61002 11 ...

Page 83: ...TE SCALE SIZE DWN BY CHKD APPD 020706 CZ AP A 801 AERCO INTERNATIONAL INC NORTHVALE NJ 07647 SAFETY SHUT OFF VALVE ACTUATOR P N 69038 2 DOUBLE BODY CONNECTING FLANGE P N 124156 2 SAFETY SHUT OFF DOUBLE BODY GAS VALVE P N 124142 LOW GAS PRESS SWITCH P N 61002 11 SAFETY SHUT OFF VALVE ACTUATOR w REGULATOR P N 64048 1 8 NPT PLUG INSTALL MANOMETER HERE TEST COCK HIGH GAS PRESS SWITCH P N 61002 12 DE R...

Page 84: ...SKET BURNER HOUSING VENTURI ASSY BMK 2 0 LOW NOX SCREW MACH 10 32 X 3 8 LG OBSERVATION PORT 1 2 NPT FLAME ROD BMK 2 0 LOW NOX BURNER BMK 2 0 LOW NOX 55025 81019 6 1 24026 GP 122377 1 1 9 75 59029 2 1 66006 46012 1 1 PLUG 1 NPT HOUSING BURNER LOW NOX GASKET BURNER 9 65 DIA LOW NOX 81030 43016 2 1 PL A 147 CZ DWN BY APPD SCALE 031606 DATE DATE BURNER ACCESSORIES BENCHMARK 2 0 LOW NOx REV A INTERNATI...

Page 85: ... 1 46 1 1 1 1 1 3 4 150 PSI RELIEF VALVE SETTING 3 75 AND 100 PSI RELIEF VALVE SETTING 2 2 30 AND 50 PSI RELIEF VALVE SETTING 1 NOT SHOWN IN THE DRAWING 124310 50 460 V TRANSFORMER 1 PART NO 27003 1 ITEM 14 DESCRIPTION COMBUSTION AIR BLOWER SINGLE PHASE QTY 1 BLOWER PART NO ITEM DESCRIPTION QTY CONTROL S 161577 161558 34 POWER BOX ASS Y 208 230V 3 PH 1 POWER BOX ASS Y 220V SINGLE PH PRESSURE RELIE...

Page 86: ... LOW NOx SH 2 OF 3 PL A 146 INTERNATIONAL INC NORTHVALE NJ 07647 031406 AERCO BOILER PARTS LIST E DWN BY APPD SCALE CZ DATE DATE VIEW A A SEE SH 1 OF 3 14 23 24 24 41 13 19 31 18 30 35 44 36 43 20 29 27 1 0 5 6 2 3 1 54 37 38 34 26 ...

Page 87: ...7 62 181144 60 1 1 4 NORTHVALE NJ 07647 DATE CZ 031406 DATE SH 3 OF 3 PL A 146 BENCHMARK 2 0 LOW NOx BOILER PARTS LIST E BENCHMARK SHEET METAL ENCLOSURE PARTS LIST FRONT PANEL ENCLOSURE FRONT DOOR ASSEMBLY 58 161464 161463 201120 57 2 TOP RAIL TOP PANEL 2 1 201113 56 PART NO 1 QTY DESCRIPTION 56 57 60 59 58 63 63 BMK2 0 LOW NOX LOGO 74002 1 ...

Page 88: ... BACKFLOW PREVENTER DIAPHRAGM TYPE EXPANSION TANK WATER SUPPLY CONDENSATE DRAIN TRAP P T RELIEF VALVE TYP PRESSURE REDUCING FILL VALVE HEATING SYSTEM RETURN CHECK VALVE TYP HEATING SYSTEM SUPPLY SYSTEM PUMP AT MAXIMUM BTU HR INPUT MAINTAIN MINIMUM GAS PRESSURE AT 5 3 W C FM GAS TRAIN 5 5 W C IRI MAX GAS PRESSURE 2 0 PSIG SEE NOTE 6 2 MANUAL SHUTOFF VALVE DIRT TRAP GAS SUPPLY FREELY BY GRAVITY TO A...

Page 89: ...UCING FILL VALVE CHECK VALVE TYP HEATING SYSTEM SUPPLY SYSTEM PUMP P T RELIEF VALVE TYP HEATING SYSTEM RETURN 2 MANUAL SHUTOFF VALVE GAS SUPPLY DIRT TRAP 2 SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY BY GRAVITY TO A 4 LOCATE WATER INLET AND OUTLET FITTINGS i e UNIONS ELBOWS ETC A MINIMUM OF 6 FROM BOILER NORTHVALE NJ 07647 INTERNATIONAL INC A...

Page 90: ... ETC A MINIMUM OF 6 FROM BOILER NORTHVALE NJ 07647 INTERNATIONAL INC APPD DWN BY SCALE DATE DATE CZ NTS 021506 AERCO SD A 674 TEMPERATURE GAUGE P T PRESSURE BALANCING VALVE ISOLATION VALVE UNION Y STRAINER LEGEND BENCHMARK 2 MIL BTU LOW NOx GAS FIRED BOILER 3 UNIT INSTALLATION 2 ZERO SIDE 1 SEPARATE CONDENSATE DRAIN TRAP 1 1 2 NPT DRAIN CONN BACKFLOW PREVENTER DIAPHRAGM TYPE EXPANSION TANK LINE SI...

Page 91: ...VALVE SHOULD BE PIPED VERTICALLY TO A HEIGHT 18 ABOVE FLOOR 1 FOR ACTUAL SIZES AND LOCATIONS OF PIPING AND OTHER CONNECTIONS TO THE BOILER SEE DIMENSIONAL DRAWING AP A 739 3 ALL ITEMS ARE INCLUDED SEPARATELY IN SHIPMENT FROM FACTORY 2 SHELL DRAIN VALVE AND CONDENSATE DRAIN TRAP SHOULD BE ARRANGED TO PERMIT THE FLUIDS TO DRAIN FREELY BY GRAVITY TO A NOTES DATE DATE AERCO BENCHMARK 2 MIL BTU LOW NOx...

Page 92: ...APPENDIX G G 5 ...

Page 93: ... 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 100703 JM AS FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX 015 XXX 005 FRACTIONS 1 32 ANGLES 1 PERPENDICULARITY PARALLELISM FLATNESS 003...

Page 94: ... 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 FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX 015 XXX 005 FRACTIONS 1 32 ANGLES 1 PERPENDICULARITY PARALLELISM FLATNESS 003 TOTAL DI...

Page 95: ... 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 SHEET 1 OF 2 GND 321 321 320 TO CONTROL BOX B ADDED GROUND WIRES 320 321 FYP 100703 JM AS FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX ...

Page 96: ... 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 FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX 015 XXX 005 FRACTIONS 1 32 ANGLES 1 PERPENDICULARITY PARALLELISM FLATNESS 003 TOTAL DI...

Page 97: ...46 145 147 136 137 209 208 L3 L2 L1 GND 200 210 203 314 315 POWER BOX 120 VAC MOTOR BLOWER 460VAC 3O 60 HZ 300 L1 L2 L3 A1 T1 MCR T2 T1 T2 301 95 NC T3 A2 303 T3 302 RELAY WITH OVERLOAD CONTROL TRANSFORMER H2 316 H1 317 H4 460VAC H3 X2 X1 4 AMPS XF 315 FUSE 120VAC 205 260 263 262 261 260 GROUND BLOCK AS FOLLOWS UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL ...

Page 98: ... 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 UNLESS OTHERWISE SPECIFIED THIRD ANGLE PROJECTION ALL DIMENSIONS ARE IN INCHES AND ALL TOLERANCES ARE XX 015 XXX 005 FRACTIONS 1 32 ANGLES 1 PERPENDICULARITY PARALLELISM FLATNESS 003 TOTAL DIAMETERS ON A COMM...

Page 99: ...t 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 Service technician Close manual fuel supply valve and test for pressure on down stream valve port Combustion safety flame failure weekly Operator Close manual fuel supply valve check safety shutdown ...

Page 100: ... 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 EXPLODED VIEW BENCHMARK CONTROL PANEL EXPLODED VIEW ...

Page 101: ...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 BENCHMARK CONTROL PANEL REAR VIEW ...

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