Aerco Benchmark 2.0, Installation, Operation & Maintenance Instructions Manual

Page 1: ...thvale New Jersey 07647 USA GF 123 Installation Operation Maintenance Instructions Benchmark 2 0 Low NOx Gas Fired Boiler System Natural Gas or Propane Fired Condensing Modulating Forced Draft Hot Water Boiler 2 000 000 BTU H Input Applicable for Serial Numbers G 10 0927 and above ...

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: ...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 on natural gas 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 arran...

Page 4: ......

Page 5: ...l Wiring 2 6 2 10 I O Box Connections 2 8 2 11 Auxiliary Relay Contacts 2 10 2 12 Flue Gas Vent Installation 2 10 2 13 Combustion Air 2 10 Chapter 3 CONTROL PANEL 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 Configuration Menu 3 6 3 7 Tuning Menu 3 8 3 8 ...

Page 6: ...Tests 6 3 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 5 6 10 Purge Switch Open During Purge 6 5 6 11 Ignition Switch Open During Ignition 6 6 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 Ignitor Injector 7 2 7 3 Flame Detector 7 3 7 4 Combustion Cali...

Page 7: ...ES App Subject Page A Boiler Menu Item Descriptions A 1 B Startup Status and Fault Messages B 1 C Temperature Sensor Resistance Chart C 1 D Indoor Outdoor Reset Ratio Charts D 1 E Boiler Default Settings E 1 App Subject Page F Dimensional and Part Drawings F 1 G Piping Drawings G 1 H Wiring Schematics H 1 I Recommended Periodic Testing Checklist I 1 J Benchmark Control Panel Views J 1 K Recommende...

Page 8: ......

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: ...ter must be installed upstream of the Fill Makeup Valve The vent termination must be located a minimum of 4 feet above grade level If side wall venting is used the installation must conform to the following requirements extracted from 248 CMR 5 08 2 a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residentia...

Page 11: ...ented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizon...

Page 12: ......

Page 13: ...ediately if any damage is detected IMPORTANT After unpacking take off the unit top panel and remove the strap and packing material at the top of the heat exchanger The packing material is located in the area of the ignitor injector and staged ignition solenoid on the burner assembly The following accessories come standard with each unit and are either packed separately within the unit s packing co...

Page 14: ... housekeeping pad to ensure proper condensate drainage If anchoring the unit refer to the dimensional drawings in Appendix F for anchor locations 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 securin...

Page 15: ...OUSE KEEPING PAD BOILER RETURN Figure 2 4 Condensate Drain Connection Location A condensate drain trap part no 24060 is shipped loose and must be installed at the rear of the unit The trap inlet and outlet contain tapped 3 4 NPT ports The actual installation details for the condensate trap will depend on the available clearances housekeeping pad height dimensions and other prevailing condi tions a...

Page 16: ...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 suitable equivalent The gas pi...

Page 17: ...7 NOTE All electrical conduit and hardware must be installed so that it does not interfere with the removal of any unit covers inhibit service maintenance or prevent access between the unit and walls or another unit UPPER RIGHT CORNER OF FRONT PANEL TERMINAL BLOCK Figure 2 7 AC Input Terminal Block Location 2 8 1 Electrical Power Requirements The AERCO Benchmark 2 0LN Boiler accepts 120 VAC single...

Page 18: ...ure 2 9 behind the removable front door To access the I O Box terminal strips shown in Figure 2 9 loosen the four cover screws and remove the cover All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided Figure 2 9 Input Output I O Box Location 2 9 2 Indoor Outdoor Reset Mode Refer to the wiring diagram provided on the cover of the I ...

Page 19: ...ling connections are made from the BMS to the RS485 COMM terminals on the I O Box terminal strip Polarity must be maintained and the shield must be connected only at the AERCO BMS The boiler end of the shield must be left floating For additional instructions refer to Chapter 5 paragraph 5 6 in this manual Also refer to GF 108M BMS Model 168 and GF 124 BMS II Model 5R5 384 BMS Operations Guides 2 9...

Page 20: ...ed The sensor must be shielded from direct sunlight as well as impingement by the elements If a shield is used it must allow for free air circulation 2 10 2 AIR SENSOR IN The AIR SENSOR IN is connected to the AUX SENSOR IN and SENSOR COMMON terminals on the I O board The AIR SENSOR measures the temperature of the air input to the Air Fuel Valve This temperature reading is one of the components use...

Page 21: ...called the Remote Interlock and Delayed Interlock Figure 2 10 The wiring terminals for these interlocks are located inside the I O Box on the unit front panel The I O Box cover contains a wiring diagram which shows the terminal strip locations for these interlocks REMOTE INTL K IN and DELAYED INTL K IN Both interlocks described below are factory wired in the closed position NOTE Both the Remote In...

Page 22: ...this supplier are as follows Selkirk Corporation Heatfab Division 130 Industrial Blvd Turners Falls MA 01376 Phone 1 800 772 0739 www heat fab com 2 13 COMBUSTION AIR The AERCO Benchmark Venting and Combustion Air Guide GF 2050 MUST be consulted before any flue or combustion supply air venting is designed or implemented Combustion air supply is a direct requirement of ANSI 223 1 NFPA 54 and local ...

Page 23: ...LN Boiler is used to provide heat temporarily during ongoing building construction accumulated drywall dust sawdust and similar particles can accumulate in the unit s combustion air intake filter and block combustion air flow In these situations AERCO recommends that a disposable air intake filter be installed temporarily above the boiler combustion air inlet AERCO recommends that the temporary ai...

Page 24: ......

Page 25: ...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 3 2 CONTRO...

Page 26: ...playing 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 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 ...

Page 27: ... 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 to flash Pre...

Page 28: ...ive that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures 1 The Control Panel will normally be in the Operating Menu and the VFD will display the current unit status Pressing the or arrow key will 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 men...

Page 29: ...nter the unit password 159 which is required to change the menu options To prevent unauthorized use the password will time out after 1 hour Therefore the correct password must be reentered when required In addition to permitting password entries the Setup Menu is also used to enter date and time units of temperature measurements and entries required for external communication and control of the un...

Page 30: ...ries This menu contains a number of other configuration settings which may or may not be displayed depending on the current operating mode setting NOTE The Configuration Menu settings shown in Table 3 4 are Factory Set in accordance with the requirements specified for each individual order Therefore under normal operating conditions no changes will be required Table 3 4 Configuration Menu Availabl...

Page 31: ...it 60 F Setpt Hi Limit Setpt Lo Limit 220 F 200 F Temp Hi Limit 40 F 240 F 210 F Max Valve Position 40 100 100 Pump Delay Timer 0 min 30 min 0 min Aux Start On Dly 0 sec 120 sec 0 sec Failsafe Mode Shutdown or Constant Setpt Shutdown Analog Output See CAUTION at end of Table 3 4 Off Setpoint Outlet Temp Valve Position 4 20 mA Valve Position 0 10V Valve Position 0 10V Low Fire Timer 2 sec 600 sec 2...

Page 32: ...n Reset Defaults Yes No Are You Sure No Table 3 6 Combustion Cal Menu Available Choices or Limits Menu Item Display Minimum Maximum Default CAL Voltage 16 25 8 20 1 80v CAL Voltage 30 25 8 20 3 20v CAL Voltage 45 25 8 20 3 70v CAL Voltage 60 25 8 20 3 80 CAL Voltage 80 25 8 20 4 60 CAL Voltage 100 25 8 20 6 00 SET Valve Position 0 100 0 Blower Output Monitor Blower Output Voltage 00 3 9 START SEQU...

Page 33: ...is full open 100 c The VALVE POSITION 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 cycle is 7 seconds 5 Upon completion of the purge cycle the Control Box initiates an ignition cycle and the following events occur a The Air...

Page 34: ...7 seconds will be allowed for ignition to be detected The igniter relay will be turned off one second after flame is detected Note that the energy input of the boiler is not linearly related to the Air Fuel Valve position Refer to Table 3 7 on the following page for the relationship between the energy input and valve open position for a unit running on natural gas 7 After 2 seconds of continuous f...

Page 35: ...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 36: ... the factory prior to shipping However recalibration as part of initial start up is necessary due to changes in the local altitude gas BTU content gas supply piping and supply regulators Factory Test Data sheets are shipped with each unit These sheets must be filled out and returned to AERCO for proper Warranty Validation It is important to perform the following procedure as outlined This will kee...

Page 37: ...own Table 4 1 Combustion Oxygen Levels for a 100 Valve Position Inlet Air Temp 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 lo...

Page 38: ...erforming these steps also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown for each valve position 26 Press the arrow key until SET Valve Position appears on the C MORE display 27 Press the CHANGE key SET Valve Position will begin to flash 28 Press the arrow key until the SET Valve Position reads 60 and press the ENTER key 29 Press the down arrow k...

Page 39: ...display Pressing the arrow key increases the oxygen level and pressing the arrow key decreases the oxygen level 49 Once the oxygen level is within the specified range at 30 press the ENTER key to store the selected blower output voltage for 30 valve position 50 Press the arrow key until SET Valve Position appears on the C MORE display 51 Press the CHANGE key SET Valve Position will begin to flash ...

Page 40: ... arrow key 7 Ensure that the leak detection ball valve Figure 4 1 down stream of the SSOV is open 8 Set the ON OFF switch to the ON position 9 Change the valve position to 29 using the arrow key The unit should begin its start sequence and fire 10 Next verify that the gas pressure downstream of the SSOV is 2 3 W C for both FM and IRI gas trains If gas pressure adjustment is required remove the bra...

Page 41: ...en performing these steps also ensure that the carbon monoxide CO and nitrogen oxide NOx readings do not exceed the values shown for each valve position 26 Press the arrow key until SET Valve Position appears on the C MORE display 27 Press the CHANGE key SET Valve Position will begin to flash 28 Press the arrow key until the SET Valve Position reads 60 and press the ENTER key 29 Press the down arr...

Page 42: ...cted blower output voltage for 30 valve position 50 Press the arrow key until SET Valve Position appears on the C MORE display 51 Press the CHANGE key SET Valve Position will begin to flash 52 Press the arrow key until the SET Valve Position reads 20 then press the ENTER key 53 Press the arrow key until CAL Voltage 16 is displayed 54 Press the CHANGE key CAL Voltage 20 will begin to flash 55 The o...

Page 43: ...and is permanently fixed at 210 F This switch will shut down and lock out the boiler if the water temperature exceeds 210 F Following an over temperature condition it must be manually reset by pressing the RESET button before the boiler can be restarted The automatic reset over temperature switch is adjustable and allows the boiler to restart once the temperature drops below its temperature settin...

Page 44: ......

Page 45: ...reasing 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 outside air ...

Page 46: ...ngs 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 Setpoi...

Page 47: ...e 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 air fuel valve position open can be changed by a remote signal which is typically sent from an Energy Management S...

Page 48: ...ate multiple units in the most efficient manner possible For this mode of operation a BMS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant s supply water header 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 operation and Header Sensor installation d...

Page 49: ...ot 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 Cont...

Page 50: ......

Page 51: ...ORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK 6 2 LOW GAS PRESSURE FAULT TEST Refer to Figure 6 1 and ensure that the leak detection ball valve located at the high gas pressure switch is closed 1 Remove the 1 8 plug from the ball valve at the low gas pressure switch shown in the lower portion of Figure 6 1 2 Install a 0 16 W C manometer or a W C gauge where the 1...

Page 52: ...al Mode and raise the valve position above 30 6 Set the ON OFF switch to the 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 w...

Page 53: ...that a device such as a pump gas booster or louver is operational 6 6 1 REMOTE INTERLOCK 1 Remove the cover from the I O Box and locate the REMOTE INTL K IN terminals 2 Start the unit in the Manual Mode and set the 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 ei...

Page 54: ...and display WAIT RETRY PAUSE c The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY 10 Since the manual gas shutoff valve is still closed the unit will shut down and display FLAME LOSS DURING IGNITION following the IGNITION RETRY cycle 11 Open the valve previously closed in step 8 12 Press the CLEAR button The unit should restart and fire Figure 6 3 Manual Gas Sh...

Page 55: ...uit is checked as follows 1 Set the unit s ON OFF switch to the OFF position 2 Place the unit in Manual Mode and set the valve position between 25 and 30 3 Refer to Figure 6 1 and locate the SSOV 4 Remove the cover from the SSOV by loosening the screw shown in Figure 6 4 Lift off the cover to access the terminal wiring connections 5 Disconnect wire 148 from the SSOV to open the proof of closure sw...

Page 56: ...nd 30 3 Remove the Air Fuel Valve cover Figure 6 5 by rotating the cover counterclockwise to unlock and lift up to remove Figure 6 6 Air Fuel Valve Purge and Ignition Switch Locations 4 Remove one of the two wires 169 or 170 from the Ignition Switch Figure 6 6 5 Initiate a unit start sequence 6 The unit should begin it s start sequence and then shut down and display IGN SWITCH OPEN DURING IGNITION...

Page 57: ...58025 06 is required when performing the waterside fireside inspections Appendix K contains recommended spare parts lists for maintenance of the boiler WARNING TO AVOID PERSONAL INJURY PRIOR TO SERVICING ENSURE THAT THE FOLLOWING GUIDE LINES ARE STRICTLY OBSERVED DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE SWITCH AND AC SUPPLY CIRCUIT BREAKER SHUT OFF THE GAS SUPPLY AT THE MANUAL SHUT OFF ...

Page 58: ...nch disconnect the compression nut securing the gas injector tube of the ignitor injector to the elbow of the staged ignition assembly Disconnect the staged ignition assembly from the ignitor injector STAGED IGNITION ASSEMBLY FLAME DETECTOR IGNITOR INJECTOR BURNER PLATE COMPRESSION FITTING ELBOW FLAME DETECTOR GASKET INDEXING WASHERS QTY 0 3 AS REQ D Figure 7 2 Ignitor Injector Flame Detector Moun...

Page 59: ...or 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 Thoroughly inspect the detector If eroded the detector should be replaced Otherwise clean the detector with a fine emery cloth 7 Reinstall the flame detector and flame detector gasket 8 Reconnect the flame detector lead wire 9 Reinstall the side and top panel...

Page 60: ...uring the gas injector tube of the ignitor injector to the elbow of the staged ignition assembly see Figure 7 2 Disconnect the staged ignition assembly from the ignitor injector IMPORTANT Prior to removing the ignitor injector note the position of the gas injector tube relative to the burner plate and blower This is necessary to ensure that the ignitor injector is reinstalled in the proper orienta...

Page 61: ... the burner assembly removed in step 17 reinstall all the components in the reverse order that they were removed During reassembly replace the gaskets for the blower and flame detector with new parts 20 Make sure to align the ignitor injector and flame detector tapped holes in the burner plate with the heat exchanger top head 21 Check to ensure that the grounding screw is reinstalled 7 7 CONDENSAT...

Page 62: ...aken out of service for an extended period of time one year or more the following instructions must be followed 1 Set ON OFF switch on the front panel to the OFF position to shut down the boiler s operating controls 2 Disconnect AC power from the unit 3 Close the water supply and return valves to isolate boiler 4 Close external gas supply valve 5 Open relief valve to vent water pressure 7 9 PLACIN...

Page 63: ...an be useful in isolating faults Refer to Chapter 9 of this manual for detailed RS232 communication set up and procedures When a fault occurs in the Benchmark Boiler proceed as follows to isolate and correct the fault 1 Observe the fault messages displayed in the Control Box display 2 Refer to the Fault Indication column in Troubleshooting Table 8 1 which follows and locate the Fault that best des...

Page 64: ...ssary 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 Remove the blocked air inlet switch and inspect for signs of blockage clean or replace as necessary 6 Measure the blocked air inlet switch for continuity with the combustion blower running If the...

Page 65: ...of the switch to ground If 24VAC is not present refer to qualified service personnel 6 See CORRECTIVE ACTION from 3 to 12 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 Combustion oscillations 6 PROBABLE CAUSES from 3 to 16 for AIRFL...

Page 66: ... 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 67: ... ceramic Replace if necessary 2 Check combustion calibration Adjust as necessary 3 Remove the burner and inspect for any carbon or debris Clean and reinstall 4 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 ...

Page 68: ... its actual water temperature 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...

Page 69: ...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 the Air Fuel Valve calibration If calibration is okay the problem may be in the Air Fue...

Page 70: ...pond 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 2 Defective or shorted switch 3 Switch wired incorre...

Page 71: ... 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 voltage or current 1 Check I ...

Page 72: ...tinuously Close the gas supply and remove power from the unit Refer fault to qualified service personnel 3 Remove the electrical cover from the SSOV and check switch continuity If the switch does not show continuity with the gas valve 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 o...

Page 73: ...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 pressure going into unit If necessar...

Page 74: ...SURE 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 SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT DAMPING ORIFICE Figure 8 3 Damping Orifice Location 8 12 ...

Page 75: ...tters and press Enter 4 Welcome to Aerco will appear in the laptop or dumb terminal display with a listing of the following available entry choices M Display next Menu D Display menu items N Display next menu items Cxx Change item xx F Fault log display S Sensor log display T Time line display L Log off NOTE The Level 1 password 159 must be entered to change options in the Setup Configuration and ...

Page 76: ...tc and press Enter 9 4 2 Operation Time Log The Operation Time Log consists of a string of ASCII records stored in non volatile memory within the C More Control Panel Events such as power up ignition and turn off are time stamped Data logged while the unit is running are run length encoded Data is logged or the run length incremented every 30 seconds For a new run record to be logged the fire rate...

Page 77: ...5 02 12 30pm Run Manual 40 100 0 1 15 02 11 55am Ignition 0 0 0 1 15 02 11 55am Power up 0 0 0 1 15 02 11 50am Table 9 3 Sample Sensor Log Display Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 51pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 46pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 0 0 1 15 02 5 41pm 130 179 OPEN OPEN OPEN OPEN OP...

Page 78: ......

Page 79: ...t Mode this is the derived value from the charts in Appendix D Air Temp Air Temp is the air temperature at the input to the Air Fuel Valve This reading is one of the parameters used to control the Blower Motor speed Outdoor Temp Displayed only if outdoor sensor is installed and enabled Valve Position In Desired input valve position This would normally be the same as the fire valve position shown o...

Page 80: ...K 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 KC Boiler KC Boiler LN BMK Boiler BMK Boiler LN BMK Boiler Dual KC Water Heater KC Water Heater LN Water Heater 2010 Unit Size Sets unit size from 0 5 to 6 0 MBTUs Defa...

Page 81: ...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 Valve Positon Sets the maximum allowable valve position 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 Start On Dly Specifies the amount of time to wai...

Page 82: ...n reaches the Start Level value There will not be a one minute delay when firing at the 29 Valve Position level Setting range is 0 to 25 Default is 10 Deadband High Deadband Low Deadband High and Deadband Low settings create an Outlet Temperature Zone In which no Valve Position corrections will be attempted The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoin...

Page 83: ...ual 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 error This is the time that t...

Page 84: ......

Page 85: ...ds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds PURGING XX sec Displayed during the purge cycle during startup The duration of the purge cycle counts up in seconds STANDBY Displayed when ON OFF switch is ...

Page 86: ...vate when commanded HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switch is closed HIGH GAS PRESSURE The High Gas Pressure Limit Switch is open HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting HIGH WATER TEMP SWITCH OPEN The High Water Temperature Limit Switch is open IGN BOARD COMM FAULT A communication fault has occurred betwee...

Page 87: ...RING PURGE The Purge Position Limit Switch on the Air Fuel Valve opened during purge REMOTE SETPT SIGNAL FAULT The Remote Setpoint signal is not present or is out of range RESIDUAL FLAME The Flame signal was seen for more than 60 seconds during standby SSOV SWITCH OPEN The SSOV switch opened during standby SSOV FAULT DURING PURGE The SSOV switch opened during purge SSOV FAULT DURING IGN The SSOV s...

Page 88: ......

Page 89: ...250 779 0 797 5 816 3 835 4 854 8 874 6 894 7 915 1 935 9 956 9 978 3 1000 0 1022 0 1044 4 1067 0 1090 0 1113 3 1137 0 1160 9 1185 2 1209 5 1234 7 1260 0 1285 6 1311 4 1337 7 1364 2 1391 0 1418 2 1445 7 1 93 1 96 1 99 2 02 2 05 2 07 2 10 2 12 2 15 2 17 2 20 2 23 2 25 2 27 2 30 2 32 2 34 2 36 2 39 2 41 2 43 2 45 2 47 2 50 2 52 2 54 2 56 2 58 Voltage at AUX Common terminals in the I O Box ...

Page 90: ......

Page 91: ... 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 92: ...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 93: ...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 94: ... 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 95: ...e Setpoint 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 Valve Position 100 Pump Delay Timer 0 min Aux Start On Dly 0 sec Failsafe Mode Shutdown Analog Output Valve Position 0...

Page 96: ...TINGS Continued MENU OPTION FACTORY DEFAULT Configuration Menu Continued Network Timeout 30 seconds Hi DB Setpt En 30 Demand Offset 10 Deadband High 2 Deadband Low 2 Tuning Menu Prop Band 70 F Integral Gain 1 00 Derivative Time 0 0 min ...

Page 97: ...Y 3 4 ELECTRICAL CONDUIT CONNECTION 5 36 23 12 1 4 28 OPTIONAL CONNECTION FOR 8 DIAMETER SEALED COMBUSTION AIR DUCTWORK LIFTING LUGS 79 56 71 7 00 13 1 4 15 7 3 4 12 3 4 23 1 2 2 1 2 1 1 4 7 1 2 18 00 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 TEMP GAUGE PRESS RELIEF...

Page 98: ...VALE 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 F 2 ...

Page 99: ...H 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 P N 64048 F 3 ...

Page 100: ... OF CLOSURE SWITCH P N 69038 3 4 SCH 40 PIPE ENTIRE BMK2 0 LN IRI GAS TRAIN P N 22064 2 1 8 NPT PLUG INSTALL MANOMETER HERE TEST COCK 1 5 IRI SSOV DOUBLE BODY P N 124137 LOW GAS PRESSURES SWITCH P N 61002 1 GAS PRESSURE SNUBBER P N 99017 HIGH GAS PRESSURE SWITCH P N 61002 12 VENT TO ATMOSPHERE PER ANSI Z223 1 NFPA54 NORMALLY OPEN VENT VALVE P N GP 122774 1 5 FULL PORT BALL VALVE P N 92006 7 1 5 DO...

Page 101: ...APPENDIX F F 5 ...

Page 102: ...APPENDIX F F 6 ...

Page 103: ...2 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 NO QTY DESCRIPTION 56 69087 1 PRESS TEMP GAUGE 57 SEE SD A 613 1 PRESSURE RELIEF VALVE 58 92006 7 1 EXT MANUAL SHUT OFF VALVE 59 91030 1 1 DRAIN HOSE 60 LG 60 92006 7 1 1 1 2 NPT BALL VALVE 61 24060 1 COND TRAP ASSEMBLY 62 OTHER DUAL FUEL COMPO...

Page 104: ...APPENDIX F F 8 ...

Page 105: ...APPENDIX F F 9 ...

Page 106: ...APPENDIX F F 10 ...

Page 107: ...APPENDIX F F 11 ...

Page 108: ...APPENDIX F F 12 ...

Page 109: ...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 110: ...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 111: ...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 112: ...APPENDIX G G 4 ...

Page 113: ...APPENDIX H H 1 ...

Page 114: ...APPENDIX H H 2 ...

Page 115: ...APPENDIX H H 3 ...

Page 116: ... N O C 4 3 5 1 2 NOT USED N C C N O N C RELAY AUX 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 IN 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 6 5 4 3 2 1 12 11 10 9 13 14 15 231 234 232 233 238 236 235 237 239 ...

Page 117: ...rk Igniter Weekly Operator See paragraph 7 2 Air Fuel Valve position Weekly Operator Check position indicator dial paragraph 3 9 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 7 Flame signal strength Weekly Operat...

Page 118: ......

Page 119: ...APPENDIX J BENCHMARK CONTROL PANEL EXPLODED VIEW J 1 ...

Page 120: ...APPENDIX J J 2 P1 P2 P3 P4 P5 P6 BENCHMARK CONTROL PANEL REAR VIEW ...

Page 121: ...048 SSOV Actuator Without Proof of Closure Switch Used on Upstream SSOV of IRI gas train models 69038 Temperature Switch Manual Reset SEE NOTE 1 123552 Table K 2 Spare Parts Recommended for Maintenance DESCRIPTION PART NUMBER Annual Maintenance Kit 58025 01 24 month Waterside Fireside Inspection Kit 58025 06 Table K 3 Optional Spare Parts DESCRIPTION PART NUMBER C More Control Box 181197 1 Burner ...

Page 122: ......