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Benchmark 750 – 1000 Boiler User Manual - INTERNATIONAL

APPENDIX G – PART LIST DRAWINGS

Page

152

170

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

OMM-0119_0A

11/03/2016

Ph.: 800-526-0288

GF-130-I

Benchmark 750 - 1000 Part List –

Continued

Item # Qty Part #

Description

Item # Qty Part #

Description

SHEET METAL/PANEL ASSEMBLY

OTHER ACCESSORIES & PARTS

37110

PANEL: LEFT

37111

PANEL: RIGHT



123675-5

PRESS./TEMP GAUGE

37114

COVER ASSY



92023-8

PRESSURE RELIEF VALVE KIT

25068

FRONT FRAME ASSEMBLY



92006-5

VALVE: BALL 1" NPT

25078

FRONT PANEL ASSEMBLY

122843

LOW WATER CUTOFF

74042

LABEL: DOME

123863

VALVE: BALL 1/8" NPT

59179

HANDLE: CONCEALED PULL

92094

VALVE: 3/4 BOILER DRAIN MNPT x

GHT

59133

LATCH: COMPRESSION



59043

CONDENSATE FLOAT

50010

LATCH: DRAW



24441

COND. TRAP ASSEMBLY

50011

KEEPER: DRAW LATCH

59178

VENT: AIR 1/8 NPT

74039

BMK LOGO LABEL

124008

NIPPLE: 1/8 NPT X 3.0" (7.6 cm) LG

100



92084-6

MOTORIZED SEQUENCING ISOLATION

VALVE (OPTIONAL)

123621

BOLT, HEX HD 1/4-20 X .50 (1.27cm ) LG.

101



63150

HARNESS: FLAME ROD

39125

6" AIR INLET ADAPTER



Not shown on drawing

AERCO

International, Inc.

Blauvelt, NY 10913

Benchmark 750-1000 Part List

03/11/2016

Whole Boiler: BMK 750 – 28321-CHI

BMK 1000 – 28253-CHI

Sheet 2 of 6

Summary of Contents for Aerco Benchmark 750

Page 1: ...ge 1 of 170 GF 130 I Ph 800 526 0288 11 03 2016 USER MANUAL Installation Operation and Maintenance BENCHMARK 750 and 1000 Gas Fired Boilers Natural Gas Modulating Condensing Hot Water Heating Boiler M...

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

Page 3: ...2 8 3 External Gas Supply Regulator 22 2 9 AC ELECTRICAL POWER WIRING 22 2 9 1 Electrical Power Requirements 24 2 10 FIELD CONTROL WIRING 25 2 10 1 Outdoor Air In OUT Air Sensor Common COM 26 2 10 2...

Page 4: ...itch Checks and Adjustments 63 CHAPTER 5 MODE OF OPERATION 65 5 1 INTRODUCTION 65 5 2 INDOOR OUTDOOR RESET MODE 65 5 2 1 Reset Ratio 65 5 2 2 Building Reference Temperature 65 5 2 3 Outdoor Air Temper...

Page 5: ...Notes 114 9 2 AERCO BST QUICK START CHART 115 9 3 BST IMPLEMENTATION INSTRUCTION 116 9 3 1 Option 1 Constant Setpoint with DIRECT Wired Header Sensor 116 9 3 2 Option 2 Constant Setpoint with MODBUS...

Page 6: ...O International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I APPENDIX G PART LIST DRAWINGS 151 APPENDIX H WIRING DIAGRAMS 159 APPENDIX I PIPING DRAWINGS 163 APP...

Page 7: ...000 50 000 14 6 kW 1 000 000 293 kW 48 300 14 15 kW 968 000 284 kW The output of the boiler is a function of the unit s firing rate valve position and return water temperature When installed and opera...

Page 8: ...long BMK Benchmark AERCO s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems BLDG Bldg Building BST AERCO on board Boiler Sequencing Technology BTU British Thermal Unit A unit of...

Page 9: ...products IP Internet Protocol ISO International Organization for Standardization Lbs Pounds 1 lb 0 45 kg LED Light Emitting Diode LN Low Nitrogen Oxide MA mA Milliampere 1 thousandth of an ampere MAX...

Page 10: ...plex FDX transmission of data based on the RS422 Standard RS485 or EIA 485 A standard for serial half duplex HDX transmission of data based on the RS485 Standard RTN Rtn Return SETPT Setpt Setpoint Te...

Page 11: ...should be carefully followed 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 mus...

Page 12: ...qualified service technician to inspect and replace any part that has been under water 1 2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off close the manual gas shutoff va...

Page 13: ...ide during shipment If the Tip N Tell indicator is tripped do not sign for the shipment Note the information on the carrier s paperwork and request a freight claim and inspection by a claims adjuster...

Page 14: ...an enclosure having identical exterior dimensions The unit must be installed with the prescribed clearances for service as shown in Figure 2 1a The minimum clearance dimensions required by AERCO are...

Page 15: ...1b Benchmark 750 1000 Anchor Bolt Locations Remove the four 4 lag screws securing the unit to the shipping skid The boiler can be lifted and moved by inserting forklift tines in the front slots provid...

Page 16: ...roperly set on the pad detach the lifting bar and replace the shroud on the top of the unit 6 Retain the lifting bar for possible reuse at the installation site Figure 2 2 Heating Boiler Lifting Provi...

Page 17: ...ld even greater efficiency gains The maximum temperature differential across the Heating Boiler s heat exchanger is 100 F 55 C To use the secondary inlet pipe the warmer return water to the secondary...

Page 18: ...on the hot water outlet of the boiler as shown in Figure 2 4 A suitable pipe joint compound should be used on the threaded connections Any excess should be wiped off to avoid getting any joint compou...

Page 19: ...nage The condensate trap inlet Figure 2 6 must be level the exhaust manifold drain port The base of the condensate trap must be supported to ensure that it is level horizontal The trap must be removab...

Page 20: ...ndensate drain piping Figure 2 6 Do NOT use carbon or copper components Figure 2 6 Sample Condensate Trap Installation Right Side View EXHAUST MANIFOLD DRAIN PORT COMBUSTION ANALYZER PROBE PORT EXHAUS...

Page 21: ...tall any flexible connectors or unapproved gas fittings Piping must be supported from the floor ceiling or walls only and must not be supported by the unit A suitable piping compound approved for use...

Page 22: ...external gas supply regulator as shown in Figure 2 7 is highly recommended No regulator is required for gas pressures below 7 W C 1 74 kPa of pressure Consult the local gas utility for detailed requir...

Page 23: ...cover and remove cover to access the internal connections shown in Figure 2 8 Figure 2 8 Power Box Location with Cover Closed WARNING The power breaker shown in figure 2 9 does NOT remove power from...

Page 24: ...ontains terminal blocks as shown in Figure 2 9 A label showing the required AC power connections is provided on the front cover of the Power Box as shown in Figure 2 10 Figure 2 10 Power Box Cover Lab...

Page 25: ...ated in the upper left portion on the front of the unit as shown in Figure 2 11 The I O board terminal strip connections are shown in Figure 2 11 All field wiring is installed from the rear of the pan...

Page 26: ...the outdoor sensor 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 61m from...

Page 27: ...o 5 VDC or a 0 to 20 mA 0 to 5 VDC signal may be used to vary the set point or air fuel valve position The factory default setting is for 4 to 20 mA 1 to 5 VDC however this may be changed to 0 to 20 m...

Page 28: ...ing an isolation valve shorting jumper JP2 on the I O Board MUST be installed 3 When the 4 20mA is selected for the Analog Output the 0 10VDC is disabled at the VFD Blower terminals and the selected o...

Page 29: ...guration menu Chapter 3 2 10 13 Fault Relay NC COM NO The fault relay is a single pole double throw SPDT relay having a normally open and normally closed set of relay contacts that are rated for 5 amp...

Page 30: ...oors for the protection and longevity of the equipment and warranty validation For combustion air supply from ducting see section 2 12 below and consult the AERCO GF 2055 Gas Fired Venting and Combust...

Page 31: ...ler load is satisfied the isolation valve opens for a programmed interval default 1 minute before closing When the system load is satisfied the BST system will open the isolation valves for all of the...

Page 32: ...Isolation Valve Installed 3 Remove the jumper wire from the Molex connector and then plug it into the sequencing isolation valve s connector 2 15 BENCHMARK PUMP RELAY Benchmark 750 and 1000 models shi...

Page 33: ...contact ratings use a separate contact relay as shown in Figure 2 17 Figure 2 17 Schematic System Pump Start using a Separate Contact Relay The Benchmark pump relay SPDT contact is rated for 10 A Res...

Page 34: ...000 Boiler User Manual INTERNATIONAL CHAPTER 2 INSTALLATION Page 34 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page left inten...

Page 35: ...IS SYSTEM INCLUDE 220 120 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY FACTORY CERTIFIED SERVICE TECHNICIANS DO NOT ATTEMPT TO DRY FIRE THE UNIT STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUS...

Page 36: ...ser Manual INTERNATIONAL CHAPTER 3 OPERATION Page 36 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I Figure 3 1 Control Panel Front View...

Page 37: ...shes shows header temperature 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 Me...

Page 38: ...ed 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 pressing this key will select the displayed me...

Page 39: ...n 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 perform specific menu procedure...

Page 40: ...11 03 2016 Ph 800 526 0288 GF 130 I Only if BST is enabled see Chapter 9 Figure 3 2 Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu Refer t...

Page 41: ...lay the menu items in reverse order Bottom Up Table 3 2 Operating Menu Menu Item Display Available Choices or Limits Minimum Maximum 1 Active Setpoint 40 F 4 4 C 240 F 116 C 2 Inlet Temp 40 F 4 4 C 14...

Page 42: ...pm 4 Date 01 01 00 12 31 99 5 Unit of Temp Fahrenheit or Celsius Fahrenheit 6 Comm Address 0 127 0 7 Baud Rate 2400 4800 9600 19 2K 9600 8 OnAER Mode Ethernet or SD Card Ethernet 9 Min Upload Timer 0...

Page 43: ...Constant Setpoint 6 Remote Signal If Mode Remote Setpoint Direct Drive or Combination 4 20 mA 1 5V 0 20 mA 0 5V PWM Input Legacy BMS Network 4 20 mA 1 5V 7 Outdoor Sensor Enabled or Disabled Disabled...

Page 44: ...F 13 75 C 10 F 5 5 C 24 Demand Offset 0 F 0 C 25 F 13 75 C 0 F 0 C 25 Deadband High 0 F 0 C 25 F 13 75 C 5 F 2 75 C 26 Deadband Low 0 F 0 C 25 F 13 75 C 5 F 2 75 C 27 IGST Version V2 00 or Lower V2 02...

Page 45: ...817 which must be entered to view or change the menu items shown in Table 3 6 These menu items are used to vary the speed of the unit s blower motor based on air temperature and air density at prescri...

Page 46: ...k in order to readily identify them within the item list The Items contained in group 1 BST Monitor Items are always displayed within the menu as these items are critical for proper system operation T...

Page 47: ...120 sec 30 sec 24 Remote Intlk Use Heating Boiler Shutdown System Shutdown System Shutdown 25 One Boiler Mode Off On Outlet Temp On Avg Temp Off 26 1 Blr Threshold 10 35 25 27 Setpoint Setback Disabl...

Page 48: ...90 6 C 47 BST Prop Band 1 F 17 2 C 120 F 48 9 C 100 F 37 8 C 48 BST Intgral Gain 0 00 2 00 0 50 49 BST Deriv Time 0 00 Min 2 00 Min 0 10 Min 50 BST Deadband Hi 0 25 1 51 BST Deadband Lo 0 25 1 52 Dead...

Page 49: ...Level switch High Water Temperature switch High Gas Pressure switch Low Gas Pressure switch NOTE The Blocked Inlet and downstream Blower Proof switches are not checked prior to starting the pre purge...

Page 50: ...for SSOV location Figure 3 3 BMK 750 1000 SSOV Location 3 With all required safety device switches closed a purge cycle will be initiated and the following events will occur a The Blower relay energi...

Page 51: ...and indicate the elapsed time of the purge cycle in seconds Figure 3 5 Blower Proof Switch 5 Upon completion of the purge cycle the Control Box initiates an ignition cycle and the following events oc...

Page 52: ...k is present 3 seconds into the IGNITION TRIAL the C More will abort the Ignition Cycle and shut down the Heating Boiler Refer to Chapter 8 Troubleshooting for guidance if this occurs Figure 3 6 Air F...

Page 53: ...on Table 3 8a BMK 750 Air Fuel Valve Position and Energy Input Relationship Air Fuel Valve Position Open Energy Input BTU Hr Heating Boiler Energy Input of Full Capacity 0 0 0 10 0 0 18 Stop Level 50...

Page 54: ...1000 Boiler User Manual INTERNATIONAL CHAPTER 3 OPERATION Page 54 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page left intent...

Page 55: ...gh thermal efficiency with low flue gas emissions Initial unit start up must be performed ONLY by AERCO factory trained start up and service personnel After performing the start up procedures in this...

Page 56: ...equivalent gauge and plastic tubing 1 4 inch NPT to barbed fittings for use with gas supply manometer or gauge Small and large flat blade screwdrivers Tube of silicone adhesive 4 2 2 Installing Gas S...

Page 57: ...all valve on the downstream side of the SSOV 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 oth...

Page 58: ...e control panel ON OFF switch to the OFF position 4 Turn on external AC power to the unit The display will show the time and date of the last time the unit was shut down or lost power 5 Set the unit t...

Page 59: ...l while counterclockwise rotation increases the oxygen level 16 Once the oxygen level is within the specified range at 100 record the O2 NOx and CO readings on the Combustion Calibration Data Sheets p...

Page 60: ...lower output voltage for the 80 valve position Record all readings on the Combustion Calibration Sheets provided 29 Repeat steps 20 through 27 for valve positions of 60 45 30 and 18 The oxygen O2 nitr...

Page 61: ..._0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 61 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Figure 4 3 Gas Pressure Adjustment Screw Location Figure 4 4 TAC Valve Adjust Idle Screw...

Page 62: ...te as shown in Figure 4 5 They can be accessed by opening the front panel door of the unit The Manual Reset button is not adjustable and is permanently fixed at 210 F 98 9 C This button will shut down...

Page 63: ...unit Perform the following steps to check or adjust the Over Temperature Alarm switch settings Switch Check or Adjustment 1 Set the ON OFF switch to the ON position 2 Press the SET button on the Over...

Page 64: ...is not displayed modify the setting using the and arrow keys The value can be changed from 10 to 10 5 5 C to 5 5 C offset Press SET to enter the value and exit to the text parameter 11 To exit the pr...

Page 65: ...o is an adjustable number from 0 1 to 9 9 Once adjusted the supply header temperature will increase by that number for each degree that the outside air temperature decreases For instance if a reset ra...

Page 66: ...fer to section 3 3 for detailed instructions on menu changing 7 Press the CHANGE key The display will begin to flash 8 Use the and arrow keys to select the desired Building Reference Temperature 9 Pre...

Page 67: ...1 5 VDC With this setting a 4 to 20 mA 1 to 5 VDC signal sent by an EMS or BAS is used to change the unit s setpoint The 4 mA 1V signal is equal to a 40 F 4 4 C setpoint while a 20 mA 5V signal is eq...

Page 68: ...ion is factory preset and the setpoint is being externally controlled no startup instructions are necessary In this mode the REMOTE LED will light when the external signal is present To operate the un...

Page 69: ...signal leads from the source to the unit s I O Box For either a 4 20mA 0 5V or a 0 20mA 0 5V setting the connections are made at the ANALOG IN terminals in the I O Box For a Network setting the conne...

Page 70: ...0 Boiler User Manual INTERNATIONAL CHAPTER 5 MODE OF OPERATION Page 70 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page left in...

Page 71: ...start sequence The following 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 replaceme...

Page 72: ...witch 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 external manual gas shut off valve 7 The unit should shu...

Page 73: ...monitor the gas pressure on the manometer installed in step 2 and record the gas pressure reading 7 Slowly increase the gas pressure using the adjustment screw on the SSOV 8 The FAULT indicator shoul...

Page 74: ...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 CLEAR button to reset...

Page 75: ...Blauvelt NY 10913 Page 75 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Figure 6 2 Temperature Limit Switch Location See Detail A below Front view with Panel removed Digital Over Temperature Limit Contr...

Page 76: ...valve position between 25 and 30 3 If there is a jumper across the REMOTE INTL K IN terminals remove one side of the jumper If the interlock is being controlled by an external device either open the...

Page 77: ...he main burner ignition cycle and display FLAME LOSS DURING IGN 6 Open the valve previously closed in step 3 and press the CLEAR button 7 Restart the unit and allow it to prove flame 8 Once flame is p...

Page 78: ...E TESTING Page 78 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I Figure 6 3 Bare Heating Boiler Partial View SSOV AIR FILTER BLOCKED IN...

Page 79: ...nce the blower is disabled The unit will then display AIRFLOW FAULT DURING PURGE 5 Re enable the blower output drive voltage by performing the following steps a Press the MENU key until CONFIGURATION...

Page 80: ...ition phase the Control Panel will show IGNITION TRIAL At that point attach the alligator clip see Figure 6 4 to any bare metal surface or ground The C More display should now show FLAME PROVEN and be...

Page 81: ...to Figure 6 1 and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 6 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from th...

Page 82: ...hould begin its start sequence then shut down and display PRG SWITCH OPEN DURING PURGE 7 Replace the wire on the Purge switch and depress the CLEAR button The unit should restart 6 11 IGNITION SWITCH...

Page 83: ...al Inc 100 Oritani Dr Blauvelt NY 10913 Page 83 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Figure 6 7 Air Fuel Valve Cover Location Figure 6 8 Air Fuel Valve Purge and Ignition Switch Locations AIR FU...

Page 84: ...E TESTING Page 84 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief...

Page 85: ...025 01 Therefore only Kit P N 58025 08 is required when performing the waterside fireside inspections Refer to Appendix K for recommended spare parts WARNING To avoid personal injury prior to servicin...

Page 86: ...d components Figure 7 1 Benchmark 750 1000 Burner Assembly Removed from Unit The igniter injector may be hot therefore care should be exercised to avoid burns It is easier to remove the igniter inject...

Page 87: ...the burner plate using a 1 open end wrench 6 Check the igniter injector for evidence of erosion or carbon build up If there is evidence of substantial erosion or carbon build up the igniter injector s...

Page 88: ...2 20 3 Nm DO NOT over tighten 9 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 10 Re...

Page 89: ...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 90: ...e flame detector to the plate The flame detector is secured to the burner plate with one 1 10 32 screw and one 1 8 32 screw 5 Remove the flame detector and gasket from the burner plate 6 Disconnect th...

Page 91: ...inued Figure 7 4 Burner Assembly Mounting Details Overhead View Figure 7 5 Burner Assembly Exploded View AIR FUEL VALVE BLOCKED INLET SWITCH BURNER GASKET FLAME DETECTOR O2 SENSOR STAGED IGNITION SOLE...

Page 92: ...igniter injector to 170 180 in lbs 19 2 20 3 Nm 18 Beginning with the burner assembly removed in step 16 reinstall all the components in the reverse order that they were removed When reinstalling the...

Page 93: ...and Cleaning 1 Disconnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap see Figure 7 6 2 Loosen the four 4 thumbscrews se...

Page 94: ...oud from the four 4 pins in the side panels 3 Refer to Figure 7 7 and locate the air filter attached to the air fuel valve inlet 4 Using a flat tip screwdriver or 5 16 nut driver loosen the clamp secu...

Page 95: ...er to Figure 7 8 for an illustration of the LWCO probe assembly and its typical installation Figure 7 8 LWCO Probe Location BMK750 Shown 7 9 1 Low Water Cutoff LWCO Capacitor Electrical Short Test Thi...

Page 96: ...9 Removing Shell Harness Cable from P5 Conn on C More Rear Panel 3 Using an ohmmeter connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on left in Figure 7 10 4 Conne...

Page 97: ...he unit to the ON position 2 Press the TEST switch on the C More controller and confirm that the blinking LOW WATER LEVEL message appears on the C More display within 4 seconds 3 Press the RESET key f...

Page 98: ...spark monitor P N 61034 evaluates the strength of the current between the ignition transformer and igniter injector Wire 140 connected to the ignition transformer see Figure 7 11 passes through the mo...

Page 99: ...lows to isolate and correct the fault Fault Correction 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 8 1 which follo...

Page 100: ...oiler User Manual INTERNATIONAL CHAPTER 8 TROUBLESHOOTING GUIDE Page 100 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page left...

Page 101: ...clean or replace as necessary 4 Remove the Blocked Inlet switch and inspect for signs of blockage clean or replace as necessary 5 Check the continuity of the Blower Proof switch with the combustion bl...

Page 102: ...ncluding any ductwork leading up to the combustion blower for signs of blockage 5 During the start sequence verify that 24 VAC is present between each side of the switch and ground If 24 VAC is not pr...

Page 103: ...e voltage or current 1 Check I O Box to ensure signal is hooked up Hook up if not installed If installed check polarity Measure signal level Check wiring continuity between source and unit 2 Check sig...

Page 104: ...tion calibration 4 Debris on burner 5 Blocked condensate drain 1 Remove and inspect the Flame Detector for signs of wear or cracked ceramic Replace if necessary 2 Check gas pressure readings using a g...

Page 105: ...MANUAL mode 5 Unit setpoint is greater than Over Temperature switch setpoint 6 System flow rate changes are occurring faster than units can respond 1 Test the temperature switch to insure it trips at...

Page 106: ...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 replace Po...

Page 107: ...y LOW GAS PRESSURE 1 Incorrect supply gas pressure 2 Defective Low Gas Pressure switch 1 Measure gas pressure upstream of the SSOV Actuator s with the unit firing For FM gas trains ensure it is betwee...

Page 108: ...RING PURGE 1 Defective Purge switch 2 No voltage present at switch 3 Switch wired incorrectly 4 Defective Power Supply Board or fuse 5 Defective IGST Board 1 If the air fuel valve does rotate check Pu...

Page 109: ...f signal being sent Check control signal type set in Configuration menu RESIDUAL FLAME 1 Defective Flame Detector 2 SSOV not fully closed 1 Replace Flame Detector 2 Check open close indicator window o...

Page 110: ...ault 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 closed either adjust or replace th...

Page 111: ...solenoid from the Gas injector Tube of the Igniter Injector Figure 8 2 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...

Page 112: ...8 2 Staged Ignition Connection to Gas Injector Tube Figure 8 3 SSOV Actuator With Gas Pressure Adjustment Damping Orifice COMPRESSION FITTING ELBOW GAS INJECTOR TUBE SSOV ACTUATOR COVER COVER SCREW BR...

Page 113: ...lve Position Fire Rate Operating all Heating Boilers below the defined Fire Rate Next on VP for Next Turn on Valve Position insures that they are firing at their most efficient Fire Rate One C More un...

Page 114: ...ice is already installed you must physically disconnect it from the Modbus network in I O board b Make sure that the Modbus load and bias resistors are properly configured for the system to operate wi...

Page 115: ...int choose option 1 or 2 Option 1 Direct Wired Header Complete section 9 3 1 OR Option 2 Modbus Header Complete section 9 3 2 Outdoor Reset choose option 3 or 4 Option 3 Direct Wired Header AND Direct...

Page 116: ...elded pair 18 22 AWG cable is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield...

Page 117: ...the Box The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST Heating Boiler in the plant s supply water header There is no polarity to be observed The ground...

Page 118: ...e is recommended for header sensor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and un...

Page 119: ...er Sequencing Menu item and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5...

Page 120: ...of the LAST Heating Boiler in the plant s supply water header There is no polarity to be observed The ground for the shield is at the power supply ground The sensor end of the shield must be left free...

Page 121: ...R only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and select Outdoor Reset 6 Go to the Head Tem...

Page 122: ...he I O Box NOTES The header sensor must be installed between 2 and 10 feet 0 61 and 3 1m downstream of the LAST Heating Boiler in the plant s supply water header Shielded pair 18 22 AWG cable is recom...

Page 123: ...nabled 2 Go to the Boiler Sequencing Menu item and set the BST Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu it...

Page 124: ...nsor wiring There is no polarity to be observed The ground for the shield is at the SHLD terminal in the I O the Box The sensor end of the shield must be left free and ungrounded Step 2 Remote Setpoin...

Page 125: ...to pins 2 and 3 of the Temperature Transmitter 3 Install a jumper wire between pins 1 and 2 of the Temperature Transmitter NOTES Polarity must be observed for the RS485 connections The ground for the...

Page 126: ...de item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the Failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and sele...

Page 127: ...f any of the units 2 Using Shielded pair 18 22 AWG cable connect the Modbus Header Temperature Sensor P N 24410 to pins 2 and 3 of the Temperature Transmitter 3 Install a jumper wire between pins 1 an...

Page 128: ...T Mode item to BST Slave for now On MASTER only 3 Go to the BST Setpoint item and enter the failsafe Setpoint 4 Go to the BST Setup Menu item and set to Enabled 5 Go to the BST Setpoint Mode item and...

Page 129: ...mperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed 4 Outdoor Temp Outdoor temperature is displayed in F or C only if outdoor temp...

Page 130: ...it of Temp Permits selection of temperature displays in degrees Fahrenheit F or degrees Celsius C 6 Comm Address For RS 485 communications 0 to 127 RS232 should have its own programmable password 7 Ba...

Page 131: ...Direct Drive or Combination Used to set the type of external signal which will be used when operating in the Remote Setpoint Direct Drive or Combination Mode 7 Outdoor Sensor Allows outdoor sensor fu...

Page 132: ...be Enabled or Disabled 21 Setpt Limit Band The Setpoint Limit Band can be set from 0 F to 10 F 0 C to 5 5 C 22 Network Timeout Specifies the timeout value in seconds before a Modbus fault is declared...

Page 133: ...remains anywhere within the Deadband ZONE When the unit is in the DEADBAND MODE the F or C LED will flash on and off When the Outlet Temperature drifts out of the Deadband ZONE the DEADBAND MODE will...

Page 134: ...te will be 100 2 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 1...

Page 135: ...C drive voltage provided to the blower at each of the Air Fuel Valve positions show in the left hand column This drive voltage adjusts the rotational speed of the blower to maximize combustion efficie...

Page 136: ...iler User Manual INTERNATIONAL APPENDIX A BOILER MENU DESCRIPTIONS Page 136 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This Page Is...

Page 137: ...that the unit 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 sho...

Page 138: ...ignition or lost within 5 seconds after ignition FLAME LOSS DURING RUN The Flame signal was lost during run HEAT DEMAND FAILURE The Heat Demand Relays on the Ignition board failed to activate when co...

Page 139: ...shorted OUTLET TEMPERATURE display Opn indicates sensor is open circuited PRG SWTCH CLOSED DURING IGNITION The Purge Position Limit switch on the Air Fuel Valve closed during ignition PRG SWTCH OPEN...

Page 140: ...r User Manual INTERNATIONAL APPENDIX B STARTUP STATUS DISPLAY MESSAGES Page 140 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This Pag...

Page 141: ...40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 40 34 4 28 9 23 3 17 2 12 2 6 7 1 1 4 4 10 15 5 21 1 26 7 32 2 37 8 43 3 48 9 54 4 60 65 6 71 1 76 7 82 2 87 8 93 3 98...

Page 142: ...r User Manual INTERNATIONAL APPENDIX C SENSOR RESISTANCE VOLTAGE CHART Page 142 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This Pag...

Page 143: ...isually inspection condition and check for obstructions Spark Igniter Injector Weekly Operator See section 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial section 3 10 SSOV L...

Page 144: ...er User Manual INTERNATIONAL APPENDIX D RECOMMENDED PERIODIC TESTING Page 144 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This Page...

Page 145: ...70 5 20 6 83 94 105 116 127 138 149 160 171 182 10 23 3 86 98 110 122 134 146 158 170 182 194 15 26 1 89 102 115 128 141 154 167 180 193 206 20 28 9 92 106 120 134 148 162 176 190 204 218 Table E 2 He...

Page 146: ...17 8 104 117 130 143 156 169 182 195 208 5 20 6 107 121 135 149 163 177 191 205 219 10 23 3 110 125 140 155 170 185 200 215 15 26 1 113 129 145 161 177 193 209 20 28 9 116 133 150 167 201 218 Table E...

Page 147: ...2 2 114 127 140 153 166 179 192 205 218 5 15 0 117 131 145 159 173 187 201 215 0 17 8 120 135 150 165 180 195 210 5 20 6 123 139 155 171 187 203 219 10 23 3 126 143 160 177 194 211 15 26 1 129 147 165...

Page 148: ...106 108 110 112 114 75 23 9 99 102 105 108 111 114 117 120 123 126 70 21 1 102 106 110 114 118 122 126 130 134 138 65 18 3 105 110 115 120 125 130 135 140 145 150 60 15 6 108 114 120 126 132 138 144 1...

Page 149: ...ONAL APPENDIX F DIMENSIONAL AND CLEARANCE DRAWINGS OMM 0119_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 149 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Appendix F DIMENSIONAL AND C...

Page 150: ...r User Manual INTERNATIONAL APPENDIX F DIMENSIONAL AND CLEARANCE DRAWINGS Page 150 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I Drawi...

Page 151: ...IGNITION ASSY 47 2 124512 FUSE 4 AMP 14 1 81143 BURNER GASKET 48 1 123449 SENSOR TEMPERATURE 15 1 59171 REFLECTOR SIGHT GLASS 49 1 58132 THERMOWELL 16 1 59104 OBSERVATION PORT 50 1 33137 ELECTRICAL P...

Page 152: ...78 FRONT PANEL ASSEMBLY 89 1 122843 LOW WATER CUTOFF 75 1 74042 LABEL DOME 90 1 123863 VALVE BALL 1 8 NPT 76 2 59179 HANDLE CONCEALED PULL 91 1 92094 VALVE 3 4 BOILER DRAIN MNPT x GHT 77 4 59133 LATCH...

Page 153: ...ERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 153 of 170 GF 130 I Ph 800 526 0288 11 03 2016 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 11 2016 Whole Boil...

Page 154: ...RAWINGS Page 154 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List...

Page 155: ...MM 0119_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 155 of 170 GF 130 I Ph 800 526 0288 11 03 2016 AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List 03 11 201...

Page 156: ...RAWINGS Page 156 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I AERCO International Inc Blauvelt NY 10913 Benchmark 750 1000 Part List...

Page 157: ...006 5 VALVE BALL 1 NPT 3 2 92036 VALVE SSOV 1 NPT 18 1 69038 ACTUATOR SSOV W O P O C SWITCH 4 1 69005 ACTUATOR SSOV W REGULATOR 19 1 61002 12 HIGH GAS PRESSURE SWITCH 4 7 W C 6 4 12951 2 BUSHING CONTR...

Page 158: ...81064 GASKET BLOWER 15 1 24298 A F VALVE ASSY BMK 1000 4 1 24111 BLOWER AMETEK 8 9 24298 1 A F VALVE ASSY BMK 750 5 1 59104 OBSERVATION PORT 17 1 61002 5 BLOCKED INLET SWITCH 8 0 W C 6 1 24277 STAGED...

Page 159: ...nual INTERNATIONAL APPENDIX H WIRING DIAGRAMS OMM 0119_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 159 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Appendix H WIRING DIAGRAMS Drawin...

Page 160: ...000 Boiler User Manual INTERNATIONAL APPENDIX H WIRING DIAGRAMS Page 160 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page inten...

Page 161: ...Boiler User Manual INTERNATIONAL APPENDIX H WIRING DIAGRAMS OMM 0119_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 161 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Drawing Number 6809...

Page 162: ...000 Boiler User Manual INTERNATIONAL APPENDIX H WIRING DIAGRAMS Page 162 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page inten...

Page 163: ...TIONAL APPENDIX I PIPING DRAWINGS OMM 0119_0A AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 163 of 170 GF 130 I Ph 800 526 0288 11 03 2016 Appendix I PIPING DRAWINGS Diagram 1 Single B...

Page 164: ...t 4 This is a typical installation drawing Local codes and authorities should be consulted 5 Locate water inlet and outlet fittings i e unions elbows etc a minimum of 0 2 m from heating boiler fitting...

Page 165: ...1 Benchmark Series Control Panel Exploded View ENCLOSURE P N 124951 POWER SUPPLY BOARD P N 124362 IGNITION STEPPER BOARD P N 124361 FISH PAPER INSULATOR P N 124960 V F D DISPLAY MODULE P N 124527 FRO...

Page 166: ...Y 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I Figure J 2 Benchmark Control Panel Rear View SENSOR HARNESS CONNECTOR 7 PIN A F VALVE HARNESS CONNECTOR 16 PIN EXT SENSOR COMM HARNESS CONNECTOR...

Page 167: ...1 Recommended Emergency Spare Parts DESCRIPTION PART NUMBER 120 VAC Blower 58061 SSOV Actuator Regulator Combo Used on ALL gas train models Downstream SSOV of gas train models 64048 SSOV Actuator With...

Page 168: ...Boiler User Manual INTERNATIONAL APPENDIX K RECOMMENDED SPARES Page 168 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I This page left i...

Page 169: ...Benchmark 750 and 1000 units that connect to a 220 VAC power source include a pre installed 220 VAC to 120 VAC transformer This transformer P N 24468 is installed inside the unit as shown in Figure L...

Page 170: ...hmark 750 1000 Boiler User Manual INTERNATIONAL Page 170 of 170 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0119_0A 11 03 2016 Ph 800 526 0288 GF 130 I AERCO International Inc 2016 NO...

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