Aerco GF-123 Installation, Operation & Maintenance Instructions Manual Download

Page: 1 / 108

Printed in U.S.A.

REVISED 9/21/09

Instruction

No.

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

GF-123

Installation, Operation

& Maintenance Instructions

Benchmark

2.0 Low NOx

Natural Gas Fired

Boiler System

Condensing, Modulating

Forced Draft, Hot Water Boiler

2,000,000 BTU/H Input

Summary of Contents for GF-123

Page 1: ...on No AERCO INTERNATIONAL Inc Northvale New Jersey 07647 USA GF 123 Installation Operation Maintenance Instructions Benchmark 2 0 Low NOx Natural Gas Fired Boiler System Condensing Modulating Forced Draft Hot Water Boiler 2 000 000 BTU H Input ...

Page 2: ...ration and mainte nance 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 con...

Page 3: ...it s firing rate and return water temperature Output ranges from 99 000 BTU hr to 1 933 000 BTU hr depending on operating conditions When installed and operated in accordance with this Instruction Manual the Benchmark 2 0LN Boiler complies with the NOx emission standards outlined in South Coast Air Quality Management District SCAQMD Rule 1146 2 Whether used in singular or modular arrangements the ...

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Page 5: ...f Operation and Field Control Wiring 2 5 2 10 I O Box Connections 2 7 2 11 Auxiliary Relay Contacts 2 9 2 12 Flue Gas Vent Installation 2 9 2 13 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 4 3 4 Operating Menu 3 5 3 5 Setup Menu 3 5 Para Subject Page 3 6 Configu...

Page 6: ...ock Tests 6 3 6 7 Flame Fault Test 6 4 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 6 Chapter 7 MAINTENANCE REQUIREMENTS 7 1 Para Subject Page 7 1 Maintenance Schedule 7 1 7 2 Spark Ignitor 7 1 7 3 Flame Detector 7 2 7 4 Combustion Cal...

Page 7: ...sages 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 iii ...

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Page 9: ...uture reference 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 F...

Page 10: ... operating personnel Figure 1 1 Manual Gas Shutoff Valve 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 lo...

Page 11: ...nit should be made to ensure that there is no evidence of damage not indicated by the Tip N Tell indicator The freight carrier should be notified immediately if any damage is detected The following accessories come standard with each unit and are either packed separately within the unit s packing container or are factory installed on the boiler Pressure Temperature Gauge Spare Spark Igniter Spare ...

Page 12: ...ons Two lifting tabs are provided at the top of the heat exchanger as shown in Figure 2 2 USE THE TABS SHOWN IN FIGURE 2 2 TO LIFT AND MOVE THE UNIT Remove the top panel from the unit to provide access to the lifting tabs Remove the four 4 lag screws securing the unit to the shipping skid Lift the unit off the shipping skid and position it on the 4 inch to 6 inch housekeeping concrete pad required...

Page 13: ...E DRAIN CONNECTION HOUSE KEEPING PAD BOILER RETURN Figure 2 4 Condensate Drain Connection Location A separate condensate drain trap part no 24060 is shipped loose and must be installed on the floor behind the unit Connect the trap to the exhaust manifold as follows 1 First install a 1 2 NPT nipple in the condensate drain port shown in Figure 2 4 2 Next connect a 3 4 to 1 2 reducer to the 1 2 nippl...

Page 14: ...pported by the unit A suitable piping compound approved for use with natural gas should be used Any excess must be wiped off to prevent clogging of components To avoid unit damage when pressure testing gas piping isolate the unit from the gas supply piping At no time should the gas pressure applied to the unit exceed 2 psi Leak test all external piping thoroughly using a soap and water solution or...

Page 15: ... showing the required AC power connections is provided on the front cover of the Power Box Each Boiler must be connected to a dedicated electrical circuit NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER A means for disconnecting AC power from the unit such as a service switch must be installed near the unit for normal operation and maintenance All electrical connections sho...

Page 16: ...rmation on the available modes of operation 2 9 1 Constant Setpoint Mode The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate No wiring connections other than AC electrical power connections are required for this mode However if desired fault monitoring or enable disable interlock wiring can be utilized see paragraphs 2 10 9 1 and 2 10 10 Figure 2 9 ...

Page 17: ...e formats are 4 to 20 mA 1 to 5 VDC 0 to 20 mA 0 to 5 VDC PWM Pulse Width Modulated signal See para 2 10 4 Network RS485 Modbus See para 2 10 7 While it is possible to control a boiler or boilers using one of the previously described modes of operation it may not be the method best suited for the application Prior to selecting one of these modes of operation it is recommended that you consult with...

Page 18: ...Boiler s I O Box must be made using twisted shielded pair wire from 18 to 22 AWG such as Belden 9841 see Figure 2 10 Polarity must be maintained The shield must be connected only at the source end and must be left floating not connected at the Boiler s I O Box Regardless of whether voltage or current is used for the drive signal they are linearly mapped to a 40 F to 240 F setpoint or a 0 to 100 fi...

Page 19: ...y equipment such as pumps and louvers or can be used as a Boiler status indictor firing or not firing Its contacts are rated for 120 VAC 5 amps Refer to Figure 2 10 to locate the AUX RELAY terminals for wiring connections 2 12 FLUE GAS VENT INSTALLATION The minimum allowable vent diameter for a single Benchmark 2 0LN Boiler is 8 inches The AERCO Benchmark Venting and Combustion Air Guide GF 2050 m...

Page 20: ...ding When combustion air is provided from within the building it must be supplied through two permanent openings in an interior wall Each opening must have a free area of not less than one square inch per 1000 BTU H of total boiler input The free area must take into account any restrictions such as louvers 2 13 3 Sealed Combustion The AERCO Benchmark 2 0LN Boiler is UL listed for 100 sealed combus...

Page 21: ...fore attempting to start the unit WARNING ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460 208 AND 24 VOLTS AC IT MUST BE SERVICED ONLY BY 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 INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY Figur...

Page 22: ...ic 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 unit s 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 off the FAULT indicator and...

Page 23: ...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 24: ...l display the other available data items 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 Th...

Page 25: ...o enter date and time 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 function has been enabled ...

Page 26: ...anges 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 Boiler or 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...

Page 27: ...min 0 00 min Reset Defaults Yes No Are You Sure No 3 8 START SEQUENCE When the Control Box ON OFF switch is set to the ON position it checks all pre purge safety switches to ensure they are closed These switches include Safety Shut Off Valve Proof of Closure POC switch Low Water Level switch High Water Temperature switch High Gas Pressure switch Low Gas Pressure switch Blower Proof switch If all o...

Page 28: ...urge position switch The dial on the Air Fuel Valve Figure 3 4 will read 100 to indicate that it is full open 100 c The VFD sends a signal and turns on the Blower d The FIRE RATE bargraph will show 100 4 Next the Blower Proof Switch on the Air Fuel Valve Figure 3 5 closes The display will show Purging and indicate the elapsed time of the purge cycle in seconds The normal default time for the purge...

Page 29: ... be indicated After 5 seconds the current date and time will be displayed in place of the flame strength Figure 3 6 Air Fuel Valve In Ignition 3 9 START STOP LEVELS 8 With the unit firing properly it will be controlled by the temperature controller circuitry The boiler s FIRE RATE will be continuously displayed on the front panel bargraph The start and stop levels are the fire rate percentages tha...

Page 30: ...For Unit Running On Natural Gas Fire Rate Air Fuel Valve Position Open Energy Input BTU Hr Boiler Energy Input of Full Capacity 0 0 0 10 0 0 18 Stop Level 100 000 5 0 20 134 000 7 30 349 000 17 40 631 000 32 50 893 000 45 60 1 150 000 58 70 1 410 000 71 80 1 610 000 81 90 1 830 000 92 100 2 000 000 100 3 10 ...

Page 31: ...MPT TO DRY FIRE THE BOILER STARTING THE UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY DAMAGE THE UNIT AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY DAMAGE THIS SITUATION WILL VOID ANY WARRANTY CAUTION All applicable 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 c...

Page 32: ...pply regulators Factory Test Data sheets are shipped with each unit These sheets must be filled out and returned to AERCO for proper Warranty Validation 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 ensure that the system pumps are running 2 Open the ...

Page 33: ...mp Oxygen 0 2 Carbon Monoxide NOx 100 F 4 8 100 ppm 30 ppm 90 F 5 0 100 ppm 30 ppm 80 F 5 2 100 ppm 30 ppm 70 F 5 3 100 ppm 30 ppm 14 If necessary adjust the iris air damper shown in Figure 4 4 until the oxygen level is within the range specified in Table 4 1 15 Once the oxygen level is within the specified range at 100 lower the firing rate to 80 AIR INLET IRIS AIR DAMPER SEE VIEW A USE 1 2 WRENC...

Page 34: ...21 If the oxygen level is not within the specified range adjust the level using the up Λ and down V arrow keys on the VFD Using the up Λ arrow key will increase oxygen level and the down V arrow key will decrease the oxygen level 22 Once the oxygen level is within the specified range at 80 lower the firing rate to 60 and select VFD parameter 64 The oxygen level at the 60 firing rate should be as s...

Page 35: ...the combustion analyzer probe from 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 5 OVER TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over temperature limit switches These switches are mounted on a plate next to the VFD as shown in Figure 4 6 The switches can be accessed by o...

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Page 37: ...nces to begin 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 ave...

Page 38: ... 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 Setpoint can b...

Page 39: ...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 Management System EMS ...

Page 40: ...its 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 Communica tion Manual GF 114 To enable the BMS Mode the followin...

Page 41: ... water the CCP switches the combo units back to the domestic load 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 Contro...

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Page 43: ...ve the 1 8 plug from the ball valve at the low gas pressure switch shown in Figure 6 1 2 Install a 0 16 W C manometer or a W C gauge where the 1 8 plug was removed 3 Slowly open the ball valve at the low gas pressure switch 4 Start the unit in Manual Mode and adjust the firing rate to between 25 and 30 5 While the unit is firing slowly close the external manual gas shut off valve 6 The unit should...

Page 44: ... ON position The READY light should remain off and the unit should not start If the unit does start shut the unit off immediately and refer fault to qualified service personnel 7 Close the drain and pressure relief valve used in draining the unit 8 Open the water shut off valve in the return piping to the unit 9 Open the water supply shut off valve to the unit to refill 10 After the shell is full ...

Page 45: ... the interlock via the external device or disconnect one of the wires leading to the external device 4 The unit should shut down and display INTERLOCK OPEN 5 Once the interlock connection is reconnected the INTERLOCK OPEN message should automatically clear and the unit should restart 6 6 2 DELAYED INTERLOCK 1 Remove the cover from the I O Box and locate the DELAYED INTL K IN terminals 2 Start the ...

Page 46: ...memory stick in the VFD 5 Press the CLEAR button The unit should restart 6 Next check the Blocked Inlet Switch by closing the Iris Air Damper Figure 4 4 to position 8 7 The unit should shut down and again display AIRFLOW FAULT DURING RUN 8 Return the Iris Air Damper to its previous setting 9 Press the CLEAR button The unit should restart 6 9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6 ...

Page 47: ...PURGE 6 Replace the wire on the Purge Switch and depress the CLEAR button The unit should restart 6 11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch and the Purge Switch is located on the Air Fuel Valve To check the switch proceed as follows 1 Set the unit s ON OFF switch to the OFF position 2 Place the unit in Manual Mode and set the firing rate between 25 and 30 3 Remove the Air Fuel ...

Page 48: ... 6 6 1 7 2 1 6 9 Figure 6 6 Air Fuel Valve Purge and Ignition Switch Locations 6 12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code Section VI ...

Page 49: ... 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 5 The igniter is gapped at 1 8 inch If there is a substantial erosi...

Page 50: ... and remove it See Figure 7 2 4 Inspect the detector thoroughly If eroded the detector should be replaced Otherwise clean the detector with a fine emery cloth 5 Reinstall the flame detector and flame detector gasket if removed 6 Reconnect the flame detector lead wire 7 Reinstall the side and top panels on the unit 7 4 COMBUSTION CALIBRATION Combustion settings must be checked at the intervals show...

Page 51: ...move the igniter 5 Remove the two 2 10 32 screws securing the gas injector to the burner plate Separate the gas injector and gasket from the burner plate 6 Disconnect the gas train from the air fuel valve flange by removing the four 1 2 bolts and nuts Figure 7 3 7 Disconnect the inlet air flex hose from the air fuel valve by loosening the hose clamp 8 Remove the eight 8 3 8 16 nuts from the burner...

Page 52: ...se external gas supply valve 5 Open relief valve to vent water pressure 3 Loosen the four 4 thumbscrews securing the cover on the condensate trap Remove the cover 7 9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN 4 Remove the float from the condensate trap 5 Remove the orifice gasket from the trap After a prolonged shutdown one year or more the following procedures must be followed...

Page 53: ...lows 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 listed in ...

Page 54: ...f switch and inspect for signs of blockage clean or replace as necessary 4 Measure the Blower proof switch for continuity with the combustion blower running If there is an erratic resistance reading or the resistance reading is greater than zero ohms replace the switch 5 Measure the blocked air inlet switch for continuity with the combustion blower running If there is an erratic resistance reading...

Page 55: ...e 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 CORRECTIVE ACTION from 3 to 16 for AIRFLOW FAULT DURING IGNITION AIRFLOW FAULT DURING RUN 1 Blower stopped running due to thermal or current overload 2 Blocked Blower inlet or inlet ductwork 3 Blocked airflow switch 4 Defective airflow switch 5 Comb...

Page 56: ... 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 Stepper IGST Board 6 Defective SSOV 7 Closed manu...

Page 57: ...e 8 4 for VFD settings and faults 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 GAS PRESSURE 1 Incorrect supply gas pressure 2 Defective SSOV Supply Regula...

Page 58: ...x 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 Temperature Switch Ensure that the temperature switch is set higher than the unit s setpoint 6 Check the BMS for changes to PID default values correct as necessary 7 If system pump is controlled by Energy Management System o...

Page 59: ...place 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 che...

Page 60: ...tons Replace water level circuitry if it does not respond 3 Check continuity of probe end to the shell change probe if there is no continuity MODBUS COMM FAULT 1 Boiler not seeing information from modbus network 1 Check network connections If fault persists contact qualified Service Personnel PRG SWTCH CLOSED DURING IGNITION 1 A F Valve rotated open to purge and did not rotate to ignition position...

Page 61: ... wiring 2 Check resistance of sensor to determine if it is within specification 3 Ensure that the correct sensor is installed REMOTE SETPT SIGNAL FAULT 1 Remote setpoint signal not present Not yet installed Wrong polarity Signal defective at source Broken or loose wiring 2 Signal is not isolated floating if 4 to 20 mA 3 Control Box signal type selection switches not set for correct signal type vol...

Page 62: ...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 the switch or actuator 4 Ensure that the SSOV Proof of Closure switch is correctly wired STEPPER MOTOR FAILURE 1 Air Fuel Valve out of calibration 2 Air Fuel Valve unplugged 3 Loose wiring connection to the stepper motor 4 Defective Air F...

Page 63: ...ged or damaged 3 Close the 2 and the 1 4 Ball Valve downstream of the SSOV Fig 8 1 Start the unit and listen for a clicking sound that the Staged Ignition Solenoid makes during Ignition Trial If clicking sound is not heard after 2 or 3 attempts replace the Staged Ignition Solenoid Fluctuating Gas Pressure 1 Gas pressure going into unit is fluctuating 2 Damping Orifice not installed 1 Stabilize gas...

Page 64: ...LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE SWITCH SSOV STAGED IGNITION LINE BALL VALVE SNUBBER Figure 8 1 High Pressure Gas Switch Snubber Locations Figure 8 2 Staged Ignition Solenoid Location Figure 8 3 Damping Orifice Location Figure 8 4 VFD Terminal Locations 8 12 ...

Page 65: ... 143 39 102 2 1830 7 730 7 44 6 7595 3 267 40 104 1758 7 860 8 46 4 7234 3 387 41 105 8 1688 8 000 9 48 2 6891 3 514 42 107 6 1622 8 130 10 50 6566 3 643 43 109 4 1559 8 250 11 51 8 6260 3 772 44 111 2 1499 8 490 12 53 6 5969 3 900 45 113 1441 8 510 13 55 4 5692 4 040 46 114 8 1386 8 630 14 57 2 5432 4 170 47 116 6 1334 8 750 15 59 5184 4 310 48 118 4 1283 8 960 16 60 8 4972 4 440 49 120 2 1234 8 ...

Page 66: ...own in Table 8 4 reset the parameter to the value shown in the Table If a parameter value differs from the one shown in Table 8 4 reset the parameter to the value shown in Table 8 4 reset the parameter to the value shown in the Table If parameters 61 62 63 64 and 65 are skipped and do not appear perform the following procedure 1 Set Pr 28 to USA 2 Set Pr 1 to 0 0 3 Set Pr 2 to 100 0 4 Set Pr 10 to...

Page 67: ...TE Check parameters 55 56 57 58 for the last 4 Trips VFD Fault Possible Cause U U Low AC supply voltage OU High AC supply voltage O ht2 High ambient temperature CL1 Analog input loss 4 20 mA Air Fuel Valve position signal EEF Possible loss of parameters values C dAt Empty SmartStick has been read C Err Bad connection or faulty SmartStick C Acc Bad connection or faulty SmartStick 8 15 ...

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Page 69: ...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 Aux Temp For monitoring purposes only Outdoor Temp Displayed only if outdoor sensor is installed and enabled Fire Rate In Desired input fire rate This would normally be the same as the fire rate shown on the bar graph fire rate out when the boiler is operating Flame ...

Page 70: ... 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 CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set Default is 130 F Unit Type Allows selection of Boiler or Water Heater Unit Size Sets unit size from 0 5 to 3 0 MBTUs Default is 1 0 MBTU Boil...

Page 71: ...owable outlet temperature 40 to 240 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 run Default 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 Defa...

Page 72: ...han 100 If the error is equal to or greater than the proportional band setting the fire rate will be 100 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 00 Default is 0 10 Derivative Time This value 0 0 to 20 0 min responds to the rate of change of the setpoint err...

Page 73: ...LAY XX 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 ...

Page 74: ...switch on the 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 ...

Page 75: ... 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...

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Page 77: ...0 797 5 20 816 3 10 835 4 0 854 8 10 874 6 20 894 7 30 915 1 40 935 9 50 956 9 60 978 3 70 1000 0 80 1022 0 90 1044 4 100 1067 0 110 1090 0 120 1113 3 130 1137 0 140 1160 9 150 1185 2 160 1209 5 170 1234 7 180 1260 0 190 1285 6 200 1311 4 210 1337 7 220 1364 2 230 1391 0 240 1418 2 250 1445 7 TEMPERATURE SENSOR RESISTANCE CHART BALCO C 1 ...

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Page 79: ... 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 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 7...

Page 80: ...140 155 170 185 200 215 15 113 129 145 161 177 193 209 20 116 133 150 167 201 218 Table D 4 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...

Page 81: ...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 Table D 6 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 9...

Page 82: ... 118 122 126 130 134 138 65F 105 110 115 120 125 130 135 140 145 150 60F 108 114 120 126 132 138 144 150 156 162 55F 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...

Page 83: ...bination 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 Fire Rate Out CAUTION DO NOT Change Lo Fire Timer 2 sec...

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Page 85: ...DWN BY CHKD DATE SIZE REV C CONTROL PANEL DISPLAY 3 4 ELECTRICAL CONDUIT CONNECTION 5 36 23 OPTIONAL CONNECTION FOR 8 DIAMETER SEALED COMBUSTION AIR DUCTWORK LIFTING LUGS 7 00 7 3 4 12 3 4 25 1 2 23 1 2 2 1 2 1 1 4 7 1 2 18 THIS AREA TO BE ACCESSIBLE FOR MAINTENANCE 4 150 FLG D HOT WATER OUTLET CONN 2 NPT GAS INLET CONN 4 150 FLG D COLD WATER INLET CONN 1 1 2 NPT DRAIN CONN 8 EXHAUST OUTLET PRESS ...

Page 86: ...HVALE NJ 07647 BENCHMARK 1 5 2 0 LOW NOx GAS FIRED BOILER ANCHOR BOLT LOCATION SD A 730 B DRWN BY SJD DATE 10 12 07 NOT TO SCALE FRONT NOTES 1 ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME 2 ALL DIMENSIONS SHOWN ARE IN INCHES CENTIMETERS ...

Page 87: ...GAS PRESSURE SWITCH P N 61002 12 LOW GAS PRESSURE SWITCH P N 61002 1 1 8 NPT PLUG INSTALL MANOMETER HERE ENTIRE BMK2 0 LN FM GAS TRAIN P N 22064 1 2 SCH 40 PIPE 1 50 SAFETY SHUT OFF VALVE P N 124150 GAS PRESSURE SNUBBER P N 99017 TO A F VALVE ASSY FULL PORT BALL VALVE 1 50 NPT P N 92006 7 TEST COCK SAFETY SHUT OFF VALVE ACTUATOR W REGUALTOR P N 64048 ...

Page 88: ...R WITHOUT PROOF OF CLOSURE SWITCH P N 69038 1 5 SSOV VALVE BODY P N 124150 1 5 SAFETY SHUT OFF VALVE BODY P N 124150 1 8 NPT PLUG INSTALL MANOMETER HERE TEST COCK VENT TO ATMOSPHERE PER ANSI Z223 1 NFPA54 ENTIRE BMK2 0 LN IRI GAS TRAIN P N 22064 2 3 4 SCH 40 PIPE HIGH GAS PRESSURE SWITCH P N 61002 12 1 5 FULL PORT BALL VALVE P N 92006 7 LOW GAS PRESSURE SWITCH P N 61002 1 NORMALLY OPEN VENT VALVE ...

Page 89: ...APPENDIX F F 5 ...

Page 90: ...DESCRIPTION 10 80041 1 HEAT EXCHANGER UPPER INSULATION 11 80040 1 HEAT EXCHANGER LOWER INSULATION 12 28071 1 HEAT EXCHANGER 13 HOSES GASKETS INSULATION ITEM PART NO QTY DESCRIPTION 25 88003 1 O RING 2 339 A F VALVE 26 62005 1 CORD GRIP 27 28 29 GAS TRAIN ASSEMBLY ITEM PART NO QTY DESCRIPTION 4 22064 1 1 STD FM GAS TRAIN ASSY 22064 2 IRI GAS TRAIN ASSY DUAL FUEL FM GAS TRAIN DUAL FUEL IRI GAS TRAIN...

Page 91: ...FUEL PROPANE STICK 46 64059 1 120V POWER WIRING BOX 47 161450 1 BMK2 0LN GAS TRAIN WIRING HARNESS 48 122843 1 LOW WATER CUT OFF 49 123449 1 SHELL TEMP SENSOR 50 161521 1 THERMOWELL DUAL AQUASTAT BULB 51 61002 1 1 LOW GAS PRESSURE SWITCH 52 61002 12 1 HIGH GAS PRESSURE SWITCH NON DUAL FUEL DUAL FUEL HGPS NAT GAS DUAL FUEL HGPS PROPANE 53 65090 1 DRIVE REACTOR 54 55 OTHER ACCESORIES PARTS ITEM PART ...

Page 92: ...APPENDIX F F 8 ...

Page 93: ...PENDIX F F 9 SHEET 4 OF 7 NOT TO SCALE DATE 08 06 09 DRWN BY SJD B PL A 158 BENCHMARK 2 0 LOW NOx BOILER PARTS LIST NORTHVALE NJ 07647 INTERNATIONAL INC AERCO REV B DETAIL B 52 51 16 60 25 8 6 32 33 14 21 ...

Page 94: ...APPENDIX F F 10 ...

Page 95: ...APPENDIX F F 11 SHEET 6 OF 7 NOT TO SCALE DATE 08 06 09 DRWN BY SJD B PL A 158 NORTHVALE NJ 07647 INTERNATIONAL INC AERCO REV 75 74 73 71 72 BENCHMARK 2 0 LOW NOx BOILER PARTS LIST ...

Page 96: ...APPENDIX F F 12 ...

Page 97: ...STEM RETURN CHECK VALVE TYP HEATING SYSTEM SUPPLY SYSTEM PUMP AT MAXIMUM BTU HR INPUT MAINTAIN MINIMUM NATURAL GAS PRESSURE AT 4 0 W C FM GAS TRAIN 5 0 W C IRI GAS TRAIN MAX GAS PRESSURE 2 0 PSIG SEE NOTE 6 2 MANUAL SHUTOFF VALVE DIRT TRAP GAS SUPPLY FREELY BY GRAVITY TO A CONVENIENT FLOOR DRAIN RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PA...

Page 98: ...STEM RETURN CHECK VALVE TYP HEATING SYSTEM SUPPLY SYSTEM PUMP AT MAXIMUM BTU HR INPUT MAINTAIN MINIMUM NATURAL GAS PRESSURE AT 4 0 W C FM GAS TRAIN 5 0 W C IRI GAS TRAIN MAX GAS PRESSURE 2 0 PSIG SEE NOTE 6 2 MANUAL SHUTOFF VALVE DIRT TRAP GAS SUPPLY FREELY BY GRAVITY TO A CONVENIENT FLOOR DRAIN RELIEF VALVE SHOULD BE PIPED VERTICALLY TO A FITTINGS TO PREVENT INTERFERENCE WITH REMOVAL OF BOILER PA...

Page 99: ...SURE BALANCING VALVE ISOLATION VALVE UNION Y STRAINER LEGEND BENCHMARK 2 0 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 SIZE BYPASS SUPPLY WATER HEATING SYSTEM SUPPLY PRESSURE REDUCING FILL VALVE P T SYSTEM PUMP CHECK VALVE TYP AUTOMATIC AIR VENT AIR SEPARATOR GAS SUPPLY ...

Page 100: ...APPENDIX G G 4 ...

Page 101: ...9 XFORMER 24 VAC 205 204 202 201 FUSE FUSE 200 BLOWER 4 PIN 1 2 3 4 5 6 7 FROM 6 PIN CONNECTOR 362 365 364 361 1 2 3 4 363 TRANSMITTER 190 138 135 136 193 141 BLOWER PROOF SW 142 154 WATER LEVEL PROBE IGNITOR 351 321 FLAME ROD GND 352 137 191 194 155 154 TRANSFORMER IGNITION 141 192 140 195 19 PIN CONNECTOR 13 16 17 19 18 15 14 12 1110 9 8 7 6 5 4 3 2 1 16 15 134 133 162 166 168 172 170 3 STEPPING...

Page 102: ...15 7 6 7 5 3 4 6 1 2 OUT IN OUT IN IN OUT NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK N O C 4 3 5 1 2 NOT USED N C C N O N C AUX RELAY 12 13 14 11 SENSOR EXCIT 12 VDC BMS PWM IN ANALOG IN OXYGEN SENSOR IN FLOW SENSOR IN CO SENSOR IN AUX SENSOR IN SENSOR COMMON IN 1 OUTDOOR AIR SENSOR IN 9 8 7 5 3 4 2 6 10 OUT IN LONWORKS A B GND 4 1 2 1 2 2 1 3 3 ANALOG OUT 15 16 SHIELD B RS 485 IN A 1 2 4 3 ...

Page 103: ...07 209 XFORMER 24 VAC 205 204 202 201 FUSE FUSE 200 BLOWER 4 PIN 1 2 3 4 5 6 7 FROM 6 PIN CONNECTOR 362 365 364 361 1 2 3 4 363 TRANSMITTER 190 138 135 136 193 141 BLOWER PROOF SW 142 154 WATER LEVEL PROBE IGNITOR 351 321 FLAME ROD GND 352 137 191 194 155 154 TRANSFORMER IGNITION 141 192 140 195 19 PIN CONNECTOR 13 16 17 19 18 15 14 12 1110 9 8 7 6 5 4 3 2 1 16 15 134 133 162 166 168 172 170 3 STE...

Page 104: ...OUT NOT USED DELAYED INTLK EXHAUST TEMP REMOTE INTLK N O C 4 3 5 1 2 NOT USED N C C N O N C AUX RELAY 12 13 14 11 SENSOR EXCIT 12 VDC BMS PWM IN ANALOG IN OXYGEN SENSOR IN FLOW SENSOR IN CO SENSOR IN AUX SENSOR IN SENSOR COMMON IN 1 OUTDOOR AIR SENSOR IN 9 8 7 5 3 4 2 6 10 OUT IN LONWORKS A B GND 4 1 2 1 2 2 1 3 3 ANALOG OUT 15 16 SHIELD B RS 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...

Page 105: ...Igniter Weekly Operator See paragraph 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial paragraph 3 8 SSOV Leakage test Annually Service Technician Check for leakage in accordance with the SSOV manufacturer s Siemens recommendations Flame failure Weekly Operator Close manual gas shutoff valve and check safety shutdown See paragraph 6 9 Flame signal strength Weekly Operator ...

Page 106: ......

Page 107: ...APPENDIX J BENCHMARK CONTROL PANEL EXPLODED VIEW J 1 ...

Page 108: ...APPENDIX J J 2 P1 P2 P3 P4 P5 P6 BENCHMARK CONTROL PANEL REAR VIEW ...

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