Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual USER MANUAL Installation, Operation and Maintenance Natural Gas & Propane Modulating & Condensing Hot Water Boiler Models: BENCHMARK Series Gas-Fired Boilers • BMK 750 • BMK 1000 Applicable to Serial Numbers: • G-14-0752 and above Latest Update: 05/21/2014 OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual Technical Support (Mon-Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer 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 limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual TABLE OF CONTENTS FOREWORD ................................................................................................................. 7 CHAPTER 1. SAFETY PRECAUTIONS ..................................................................... 11 1.1 WARNINGS & CAUTIONS ................................................................................................................... 11 1.2 EMERGENCY SHUTDOWN ...........................
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual 2.12.2 Combustion Air from Inside the Building ................................................................................. 32 2.13 DUCTED COMBUSTION AIR ............................................................................................................. 33 2.14 BENCHMARK PUMP RELAY OPTION ................................................................................................ 33 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual 5.6.1 ACS External Field Wiring ........................................................................................................... 74 5.6.2 ACS Setup and Startup ................................................................................................................ 74 5.7 COMBINATION CONTROL SYSTEM (CCS)........................................................................................... 74 5.7.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual 9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................ 119 9.4 DATA LOGGING................................................................................................................................ 120 9.4.1 Fault Log.................................................................................................................................... 120 9.4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual FOREWORD The AERCO Benchmark (BMK) 750 and 1000 MBH Boilers are modulating and condensing units. They are a true industry advancement that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual Phrases, Abbreviations and Acronyms Phrase, Abbreviation or Acronym A (Amp) ACS ADDR AGND ALRM ASME AUX Meaning BMK BMS or BMS II Ampere AERCO Control System, AERCO’s boiler management systems Address Analog Ground Alarm American Society of Mechanical Engineers Auxiliary Building Automation System, often used interchangeably with EMS (see below) Symbol rate, or simply the number of distinct symbol changes (signaling events) transmitt
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual Phrases, Abbreviations and Acronyms - Continued Phrase, Abbreviation or Acronym INTLK (INTL’K) I/O I/O Box IP IRI ISO LED LN MA (mA) MAX (Max) MIN (Min) Modbus® NC (N.C.) NO (N.O.) NOx NPT O2 O.D. PMC Board PPM PTP PWM REF (Ref) RES.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual Phrases, Abbreviations and Acronyms – Continued Phrase, Abbreviation or Acronym Terminating Resistor VDC VFD W W.C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS CHAPTER 1. SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS WARNING ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS EQUIPMENT. THEREFORE THE COVER ON THE UNIT’S POWER BOX (LOCATED BEHIND THE FRONT PANEL DOOR) MUST BE INSTALLED AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING. WARNING A DOUBLE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL SUPPLY LINE OF THE UNIT.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS 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 systemoperating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream of the unit.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 4. INSPECTION.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION CHAPTER 2. INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install AERCO Benchmark Boiler Models BMK 750 and BMK 1000. 2.2 RECEIVING THE UNIT Each Benchmark Boiler System is shipped as a single crated unit. The shipping weights for the BMK 750 and BMK 1000 Models are approximately 1100 and 1200 pounds, respectively.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.4 SITE PREPARATION Ensure that the site selected for installation of the Benchmark Boiler includes: • • Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps. Access to one of the following with the unit operating at maximum capacity: o For Benchmark 750 & 1000, a NATURAL GAS line at a minimum pressure of 4” W.C. o For Benchmark 750, a PROPANE gas line at a minimum pressure of 7” W.C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION Figure 2-1b: BMK 750 & 1000 Anchor Bolt Locations WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS. CAUTION While packaged in the shipping container, the unit must be moved by pallet jack or forklift from the FRONT ONLY.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION lifting tab is provided at the top of the unit’s heat exchanger as shown. This tab is used to attach the lifting bar to the unit as follows: WARNING WHEN LIFTING OR MOVING THE BOILER: • DO NOT ATTEMPT TO MANIPULATE THE BOILER USING THE GAS TRAIN OR BLOWER • WHEN USING THE LIFTING TAB AND BAR, ENSURE THERE IS NO LOAD PLACED ON THE GAS TRAIN OR BLOWER Attachment of Lifting Bar 1.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient space for piping connections and future service/maintenance requirements must also be taken into consideration. All piping must include ample provisions for expansion.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION PRESSURE RELIEF VALVE 3” HOT BOILER WATER OUTLET P&T GAUGE COUPLING Figure2-4: Pressure Relief Valve Location 2.7 CONDENSATE DRAIN & PIPING The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION While observing the above guidelines, install the condensate trap as follows: Condensate Trap Installation 1. Connect the condensate trap inlet to the exhaust manifold drain connection using the appropriate piping components (nipples, reducers, elbows, etc.) for the boiler installation site. 2. At the condensate trap outlet, install a 3/4” NPT nipple. 3. Connect a length of 1” I.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.8 GAS SUPPLY PIPING The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS. CAUTION Many soaps used for gas pipe leak testing are corrosive to metals.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.8.2 Manual Gas Shutoff Valve A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown in Figure 2-7. Maximum allowable gas pressure to the boiler is 14” W.C. 2.8.3 External Gas Supply Regulator An external gas pressure regulator is required on the gas inlet piping under most conditions (see sections 2.8.3.1 and 2.8.3.2, below).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 1” MANUAL SHUTOFF VALVE GAS INLET DIRT TRAP GAS PRESSURE REGULATOR NOTE It is the responsibility of the customer to source and purchase the appropriate gas regulator as described above. However, AERCO offers for sale an appropriate regulator, which may be ordered at the time of unit purchase or separately. Contact AERCO for more information. Figure2-7: Manual Gas Shut-Off Valve and Gas Regulator Locations 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION WARNING THE AC POWER OUTLETS SHOWN IN ERROR! REFERENCE SOURCE NOT FOUND. 2-9 ARE LIMITED TO 600 WATTS (5 AMP) SERVICE. DO NOT OVER-LOAD THESE OUTLETS. ALSO, THE FUSIBLE LINK SHOWN IN FIGURE 2-9 DOES NOT REMOVE POWER FROM THE TERMINAL BLOCKS OR AC OUTLETS.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION Figure 2-10: Power Box Cover Label Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER. A double-pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet metal enclosures of the unit.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION C-MORE CONTROL BOX I/O BOARD ECU FOR O2 SENSOR TERMINAL STRIPS Figure2-11: Input/Output (I/O) Box Location The I/O board terminal strip connections are shown in Figure 2-12. All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided on the sides of the I/O board. NOTE Use Figure 2-12 to determine the functions of the I/O PCB connections.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION CAUTION DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. Figure2-12: I/O Box Terminal Strips 2.10.1 OUTDOOR AIR IN Terminals The OUTDOOR AIR IN terminal is used for connecting an outdoor temperature sensor (AERCO Part No. GM-123525), as required primarily for the Indoor/Outdoor reset mode of operation.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION When mounting the sensor, it must be located on the North side of the building where an average outside air temperature is expected. 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 COMBUSTION AIR Terminal The COMBUSTION AIR terminal is used to monitor the combustion air temperature sensor.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.10.8 ANALOG OUT Terminals The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor Setpoint, Outlet Temperature, Valve Position 4-20 mA, Valve Position 0-10v or be set to OFF.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION NOTE Both the Delayed Interlock and Remote Interlock must be in the closed position for the unit to fire. Remote Interlock In (OUT & IN) The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped). 2.10.12.2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION While there is a positive flue pressure during operation, the combined pressure drop of vent and combustion air systems must not exceed 140 equivalent feet or 1.9” W.C. Fittings as well as pipe lengths must be calculated as part of the equivalent length. For a natural draft installation the draft must not exceed - 0.25” W.C. These factors must be planned into the vent installation.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 2.13 DUCTED COMBUSTION AIR The AERCO Benchmark 750 & 1000 MBH Boilers are UL listed for 100%-ducted combustion. For ducted combustion air installations, the screen inlet air ductwork must then be attached directly to the unit’s air inlet. In a ducted combustion air application, the combustion air ducting pressure losses must be taken into account when calculating the total maximum allowable venting run.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION Figure2-14: Schematic – System Pump Start using a Separate Contact Relay Figure 2-15: Identifying the Presence of BMK Pump Relay Option 69102 2.15 SEQUENCING ISOLATION VALVE INSTALLATION All Benchmark units are shipped with a connection for an optional motorized external sequencing isolation valve (p/n 92084-TAB) included in the shipping container.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION 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 boilers. The implementation of BST, and the installation and use of this valve is optional. The boiler is pre-wired to accept the sequencing isolation valve.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION Installing Sequencing Isolation Valve – Continued 2. The boiler’s shell harness has one unused cable. One end of this cable is connected to the DELAYED INTERLOCK IN terminals in the I/O board (see Figure 2-14) while the other end contains a Molex connector with a jumper wire inserted in it (this jumper wire allows units that do not have a sequencing isolation valve to operate normally).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION CHAPTER 3. OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark Boiler using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 2 3 1 *4 12 5 11 6 7 10 8 9 Figure 3-1: Control Panel Front View *NOTE If there is a requirement to use the RS232 port (Item 4) on the CMore controller front panel, contact AERCO to purchase the RS232 Adaptor Cable (P/N 124675), which is designed for this purpose.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays ITEM FEATURE FUNCTION LED Status Indicators Four (4) Status LEDs indicate the current operating status as follows: COMM 1 MANUAL REMOTE DEMAND 2 OUTLET TEMPERATURE Display 3 VFD Display 4 RS-232 Port 5 FAULT Indicator 6 CLEAR Key 7 READY Indicator 8 ON/OFF Switch 9 LOW WATER LEVEL TEST/RESET Switches OMM-0082_0J GF-130 Lights when RS-232 c
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-1: Operating Controls, Indicators and Displays – Continued ITEM FEATURE FUNCTION MENU Keypad Six (6) keys provide the following functions for the Control Panel Menus: 10 MENU Steps through the main menu categories shown in Figure 3-2. The Menu categories wrap around in the order shown. BACK Allows you to go back to the previous menu level without changing any information.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 3.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual. These categories are shown in Figure 3-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION * Only if BST is enabled (see Chapter 10) Figure 3-2: Menu Structure NOTE The following sections provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for listings and descriptions of displayed startup, status and error messages. Page 42 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 3.4 OPERATING MENU The Operating Menu displays a number of key operating parameters for the unit as listed in Table 3-2. This menu is “Read-Only” and does not allow personnel to change or adjust any displayed items. Since this menu is “Read-Only”, it can be viewed at any time without entering a password. Pressing the ▲ arrow key to display the menu items in the order listed (Top-Down).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-3: Setup Menu Menu Item Display Password Language Time Date Unit of Temp Comm Address Baud Rate Upload Timer Unit Alpha Unit Serial # Unit Year C-More Year C-More Serial # C-More Alpha IP Address Software Available Choices or Limits Minimum Maximum 0 9999 English 12:00 am 11:59 pm 01/01/00 12/31/99 Fahrenheit or Celsius 0 127 2400, 4800, 9600, 19.2K 0 A Z 0000 9999 0 99 0 99 0 9999 A Z Ver 0.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-4: Configuration Menu Menu Item Display Internal Setpt Available Choices or Limits Minimum Maximum Lo Temp Limit Hi Temp Limit KC Boiler, KC Boiler LN, BMK Blr Std, BMK Blr Std Dual, BMK Blr LN, BMK Blr LN Dual KC Water Heater, KC Water Heater LN, Innovation WH Unit Type Default 130°F BMK Blr LN Unit Size (Only the unit sizes available for the Unit Type will be displayed) 750 MBH, 1000 MBH, 1500 MBH,
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-4: Configuration Menu - Continued Menu Item Display Max Valve Position Available Choices or Limits Minimum Maximum 40% 100% Default 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 Low Fire Timer 2 sec. Shutdown 600 sec. 2 sec.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 3.8 COMBUSTION CAL MENU The Combustion Cal (Calibration) Menu is protected by the level 2 password (6817) 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 prescribed Air/Fuel Valve positions (% open).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION The Items contained in group 1 (BST Monitor Items) are ALWAYS displayed within the menu, as these items are critical for proper system operation. Therefore, the BST Monitor Items Header itself is NOT displayed. The Items contained in groups 2-5 are NOT DISPLAYED unless that particular item group has been enabled from the C-More keypad.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Menu Item Display One Boiler Mode 1 Blr Threshold Setpoint Setback Setback Setpoint Setback Start Setback End Rate Threshold *BST OPERATE MENU* BST Next On VP BST Max Boilers BST On Delay BST On Timeout Valve Override Valve Off Delay BST Sequencing Select Lead Unit Select Lag Unit Lead/Lag Hours Available Choices or Limits Minimum Maximum On-Outlet Off On-Avg Temp Temp 10 35 Disable Enable BST Setpt Lo Limit BST S
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Available Choices or Limits Minimum Maximum 0 127 1 128 1 128 0 250 0 1000 1 9 Degrees Points 0 9999 sec Menu Item Display Comm Address BST Min Addr BST Max Addr SSD Address SSD Poll Control Err Threshold SSD Temp Format BST Upld Timer Default 0 1 8 247 0 5 Degrees 0 3.10 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.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE GAS INLET SSOV Figure 3-3: 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 energizes and turns on the blower. b) The Air/Fuel Valve rotates to the full-open purge position and closes purge position switch.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 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. BLOWER PROOF SWITCH BLOCKED INLET SWITCH Figure 3-5: Blower Proof Switch 5.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION 6. Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected. 7. After 2 seconds of continuous flame, Flame Proven will be displayed and the flame strength will be indicated. After 5 seconds, the current date and time will be displayed in place of the flame strength. 8.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION Table 3-9: Relationship Between Air/Fuel Valve Position and Energy Input For 750 MBH & 1000 MBH Units Running On PROPANE Air/Fuel Valve Position (% Open) 0% 10% 18% (Stop Level) 20% 30% 40% 50% 60% 70% 80% 90% 100% Page 54 of 192 05/21/2014 Energy Input (BTU/Hr) 750 MBH 0 0 50,000 71,000 128,000 373,000 508,000 565,000 621,000 660,000 723,000 750,000 1000 MBH 0 0 50,000 71,000 181,000 400,000 562,000 703,000 791
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP CHAPTER 4. INITIAL START-UP 4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP 4.2.1 Required Tools & Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit: • • • • • Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1PPM. 16 inch W.C. manometer or equivalent gauge and plastic tubing. 1/4 inch NPT-to-barbed fittings for use with gas supply manometer or gauge.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP Installing Gas Supply Manometer 1. Turn off the main gas supply upstream of the unit. 2. Remove the top panel and front panel from the boiler to access the gas train components. 3. To monitor the gas pressure on the downstream side of the SSOV during Combustion Calibration (section 4.3), remove the 1/4” NPT plug from the leak detection ball valve on the downstream side of the SSOV as shown in Figure 4-1. 4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP 4.3 NATURAL GAS COMBUSTION CALIBRATION Complete the instructions below if the unit will run on Natural Gas rather than PROPANE gas. NOTE When installed and operated in accordance with the requirements specified in this section, this Benchmark boiler delivers low NOx emissions of <20 ppm at all firing rates.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP NATURAL GAS Combustion Calibration – Continued BRASS HEAD CAP (Remove to access Gas Pressure Adjustment Screw) Figure 4-3: Gas Pressure Adjustment Screw Location 11. Using the ▲ arrow key, increase the valve open position to 100%. Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2.0” W.C. ± 0.4” W.C. Readjust the gas pressure if necessary. 12.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP NATURAL GAS Combustion Calibration – Continued NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve positions of 80%, 60%, 45%, 30% and 18% as described in the following steps.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP NATURAL GAS Combustion Calibration – Continued *NOTE Set the Valve Position at 18% but make adjustments to the Combustion Calibration value designated as 16%. NOTE If NOx readings exceed the target values shown (<20 ppm), increase the O2 level up to 1% higher than the listed calibration range shown in the table. Record the increased O2 value on the Combustion Calibration sheet.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP PROPANE Combustion Calibration 1. Open the water supply and return valves to the unit and ensure that the system pumps are running. 2. Open the natural gas supply valve to the unit. 3. Set the control panel ON/OFF switch to the OFF position 4. Turn on external ac power to the unit. The display will show loss of power and the time and date. 5. Set the unit to the manual mode by pressing the AUTO/MAN key.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP PROPANE Combustion Calibration – Continued 15. If the oxygen level is not within the required tolerance, the gas pressure on the downstream side of the SSOV must be adjusted using the gas pressure adjustment screw on the SSOV (Figure 4-3, above). Slowly rotate the gas pressure adjustment (approximately 1/4-turn increments). Allow the combustion analyzer to stabilize following each adjustment.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP PROPANE Combustion Calibration – Continued 27. Once the oxygen level is within the specified range at 80%, press the ENTER key to store the selected blower output voltage for the 80% valve position. Record all readings on the Combustion Calibration Sheets provided. 28. Repeat steps 20 through 27 for valve positions of 60%, 45%, 30% and 18%* (see *NOTE below).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP Reassembly After Combustion Calibration – Continued 5. Remove the combustion analyzer probe from the 1/4” vent hole in the exhaust manifold. Replace the 1/8” NPT plug in the manifold. 6. Replace all previously removed sheet metal enclosures on the unit. 4.6 OVER-TEMPERATURE LIMIT SWITCHES The unit contains three (3) types of over-temperature limit switches.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP Reset button for Manual Temperature Limit Switch Manual Temperature Limit Switch Digital OverTemperature Limit Controller Adjustable Temperature Limit Switch (auto-rest) PARTIAL FRONT VIEW WITH PANEL REMOVED Figure 4-4: Over Temperature Limit Switch Locations 4.6.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP Table 4-1: Digital Over-Temperature Limit Controller Features CONTROL OR DISPLAY MEANING LED Display TEMP status RST RESET Button SET FUNCTION Displays current water temperature or setpoint. Resets the unit after an alarm condition. UP Button Increases the displayed temperature. DOWN Button Decreases the displayed temperature. SET Button Used to access and store parameters in the unit.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION CHAPTER 5. MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following sections in this Chapter provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION 5.2.4 Indoor/Outdoor Startup Startup in the Indoor/Outdoor Reset Mode is accomplished as follows: NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data Indoor/Outdoor Startup 1. Refer to the Indoor/Outdoor reset ratio charts in Appendix D. 2. Choose the chart corresponding to the desired Building Reference Temperature. 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION Table 5-1: Constant Setpoint Mode Settings Menu Option Setting Boiler Mode Constant Setpoint Internal Setpt Select desired setpoint using ▲ and ▼ arrow keys (40°F to 240°F) Refer to section 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).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions and their factory defaults, refer to Appendices A and E. 5.4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION To enable the Direct Drive Mode, the following menu setting must be made in the Configuration Menu: Table 5-3: Direct Drive Mode Settings Menu Option Boiler Mode Setting Direct Drive Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to section 3.3 for instructions on changing menu options.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION operation, and Header Sensor installation details, see ACS Operations Guide, GF-131. For operation via an RS-485 Modbus network, refer to Modbus Communication Manual GF-114. To enable the ACS Mode, the following menu settings must be made in the Configuration Menu: Table 5-4: ACS Mode Settings Menu Option Setting Boiler Mode Direct Drive Remote Signal Network (RS-485) Refer to section 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION Table 5-5: Combination Mode Settings Menu Option Setting Boiler Mode Combination Remote Signal Network Internal Setpt 40°F to 190°F Refer to section 3.3 for instructions on changing menu options. While it is possible to change other temperature-related functions for combination mode, these functions are preset to their factory default values. These default settings work well in most applications.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING CHAPTER 6. SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustionrelated safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.2 LOW GAS PRESSURE FAULT TEST Refer to Figure 6-1A and ensure that the leak detection ball valve located at the High Gas Pressure switch is closed on both the Natural Gas and Propane gas trains. Low Gas Pressure Fault Test 1. Remove the 1/4“ plug from the leak detection ball valve at the Low Gas Pressure switch, shown in Figure 6-1A. 2. Install a 0 – 16“ W.C. manometer or a W.C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.3 HIGH GAS PRESSURE TEST The instructions below apply to both the Natural Gas and Propane gas trains. To simulate a high gas pressure fault, refer to Figure 6-1B and perform the following steps: High Gas Pressure Test 1. Remove the 1/4“ plug from the leak detection ball valve at the High Gas Pressure switch, shown in Figure 6-1B. 2. Install a 0 – 16” W.C. manometer (or W.C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault, proceed as follows: Low Water Level Fault Test 1. Set the ON/OFF switch to the OFF position 2. Close the water shut-off valves in the supply and return piping to the unit. 3. Slowly open the drain valve on the rear of the unit. If necessary the unit’s relief valve may be opened to aid in draining. 4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.5 WATER TEMPERATURE FAULT TEST A high water temperature fault is simulated by adjusting the automatic over-temperature switch. This switch is accessible from the front of the unit as shown in Figure 6-2. Water Temperature Fault Test 1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint. 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumpered (closed).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Flame Fault Tests 1. Set the ON/OFF switch to the OFF position. 2. Place the unit in the Manual Mode and set the valve position between 25% and 30%. 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.8 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3. 6.8.1 Blower Proof Switch Test Blower Proof Switch Test 1. Disable the blower output drive voltage as follows: a) Press the MENU key until CONFIGURATION MENU is displayed. b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, then press the CHANGE key.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING Blocked Inlet Switch Test – Continued WARNING THE BLOWER SUCTION IS VERY STRONG AND CAN PULL NEARBY OBJECTS INTO THE BLOWER’S FAN BLADES. DO ALLOW ANYTHING TO BE PULLED INTO THE BLOWER. DO NOT WEAR ANYTHING THAT COULD GET CAUGHT AND PULL YOU INTO THE BLOWER. 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING SECONDARY WATER INLET/RETURN AIR INLET (Combustion Air Duct removed) PRIMARY WATER INLET/RETURN EXHAUST MANIFOLD Figure 6-4: Boiler Rear View Showing Air Inlet Location 6.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains the proof of closure switch. The proof of closure switch circuit is checked as follows: SSOV Proof of Closure Switch 1. 2. 3. 4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING 6.10 PURGE SWITCH OPEN DURING PURGE The Purge Switch (and Ignition Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Purge Switch Open During Purge 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the valve position between 25% and 30%. 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 6 – SAFETY DEVICE TESTING Ignition Switch Open During Ignition – Continued Purge Position Switch Ignition Position Switch AIR IN TO BLOWER Figure 6-7: 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 88 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE CHAPTER 7. MAINTENANCE 7.1 MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 7-1. For a complete inspection check list see ASME CSD1 chart.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE 7.2 IGNITER-INJECTOR REPLACEMENT The igniter-injector (P/N 58023) is located on the burner plate at the top of the boiler. In addition to providing the ignition spark required to light the burner, the igniter-injector also contains a gas injector tube which connects to the staged ignition assembly.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Igniter-Injector Replacement – Continued 3. Disconnect the cable from the igniter-injector (Figure 7-1). 4. Refer to the partial exploded view in Figure 7-2. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly. Disconnect the staged ignition assembly from the igniter-injector. 5.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Igniter-Injector Replacement – Continued BLOWER BURNER PLATE INJECTER-IGNITOR 120° INJECTOR TUBE INJECTOR TUBE ANGLE Figure 7-3: Igniter-Injector Orientation (Looking Down from Above) 10. Reinstall the igniter-injector in the burner plate. Torque to 170 - 180 in-lbs. DO NOT over tighten. 11.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE 7.4 O2 SENSOR REPLACEMENT The Lean Oxygen Sensor (part no. 61026) is located on the burner plate at the top of the unit (see Figure 7-1 and Figure 7-2). The sensor and burner plate may be hot. Allow the unit to cool sufficiently before removing or replacing the O2 sensor. O2 Sensor Replacement 1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power from the unit. 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE To inspect or replace the burner assembly, proceed as follows: Burner Assembly Inspection 1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power from the unit and turn off the gas supply. 2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels. 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Burner Assembly Inspection – Continued REAR FRONT BLOWER BURNER PLATE 3/16”–16 HEX NUTS (8) BLOWER PROOF SWITCH BLOCKED INLET SWITCH IGNITOR-INJECTOR STAGED IGNITION ASSEMBLY 1/2" BOLTS & NUTS (4) (GAS TRAIN-to-A/F VALVE) AIR FILTER Figure 7-4: Burner Assembly Mounting Details – Overhead View BLOCKED INLET SWITCH BLOWER PROOF SWITCH AIR/FUEL VALVE BLOWER O2 SENSOR FLAME DETECTOR STAGED IGNITION SOLENOI
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Burner Assembly Inspection – Continued NOTE The burner assembly is heavy, weighing approximately 25 pounds. 16. Remove the burner assembly from burner flange by pulling straight up. 17. Remove and replace the burner gasket. NOTE During reassembly, apply a light coating of high-temperature, antiseize lubricant to the threads of the igniter-injector and grounding screw.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE Condensate Drain Trap Maintenance – Continued NOTE There are two slightly different types of condensate traps that may be used in your configuration; an older style with a separate inlet adapter, and a newer style with a built-in adapter (see Figure 7-6). Maintenance is the same, except that the newer style does not need an orifice gasket (Step 7).
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE 7.9 AIR FILTER CLEANING & REPLACEMENT The Benchmark boiler is equipped with an air filter (P/N 59139) which should be cleaned and reoiled every 12 months and replaced every 24 months. The air filter is located at the inlet of the air fuel valve at the top of the boiler as shown in Figure 7-7. To inspect/replace the air filter, proceed as follows: Air Filter Cleaning & Replacement 1.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE 7.10 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed. Shutting the Boiler Down for an Extended Period 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.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE CHAPTER 8. TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 750 MBH or 1000 MBH boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE Table 8-1 BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1. Blower stopped running due to thermal 1. Check combustion blower for signs of excessive heat or high or current overload. current drain that may trip thermal or current overload devices. 2. Blocked Blower inlet or inlet air filter. 2. Inspect the inlet to the combustion blower including the air filter 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 1. Blower not running or running too slow. 2. Defective Blocked Inlet switch. 3. Blockage in air filter or Blocked Inlet AIRFLOW FAULT DURING PURGE switch. 4. Blocked blower inlet or inlet ductwork. 5. No voltage to Blocked Inlet switch from C-More Control Box. 6.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION DELAYED INTERLOCK OPEN DIRECT DRIVE SIGNAL FAULT FLAME LOSS DURING IGN OMM-0082_0J GF-130 PROBABLE CAUSES 1. Delayed Interlock Jumper not properly installed or missing. 2. Device proving switch hooked to interlocks is not closed CORRECTIVE ACTION 1.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION FLAME LOSS DURING IGN (continued) PROBABLE CAUSES 6. Carbon or other debris on Burner. 7. Staged ignition solenoid valve doesn’t open. 8. Clogged staged ignition piece. FLAME LOSS DURING RUN 1. Worn Flame Detector or cracked 1. Remove and inspect the Flame Detector for signs of wear ceramic. 2. Defective Regulator. or cracked ceramic.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 1. Incorrect supply gas pressure. 2. Defective SSOV Actuator. HIGH GAS PRESSURE 3. Defective High Gas Pressure Switch. 1. Faulty Water temperature switch. 2. Incorrect PID settings. 3. Faulty shell temperature sensor. HIGH WATER TEMP SWITCH OPEN 4. Unit in Manual mode 5.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 1. Air/Fuel Valve not rotating 2. Defective or shorted switch IGN SWTCH CLOSED DURING PURGE 3. Switch wired incorrectly 4. Defective Power Supply Board or fuse 5. Defective IGST Board 1. Air/Fuel Valve not rotating to ignition position. IGN SWTCH OPEN DURING IGNITION 2. Defective ignition switch 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION INTERLOCK OPEN PROBABLE CAUSES 1. Interlock jumper not installed or 1. Check for a jumper properly installed across the interlock removed 2. Energy Management System does not have unit enabled. 2. If there are two external wires on these terminals check any 3. Device proving switch hooked to interlocks is not closed. 1.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PRG SWTCH CLOSED DURING IGNITION (continued) PROBABLE CAUSES 2. Defective or shorted switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board 1. Defective purge switch. CORRECTIVE ACTION 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION RECIRC PUMP FAILURE REMOTE SETPT SIGNAL FAULT PROBABLE CAUSES 1. Internal recirculation pump failed. 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.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 1. Actuator not allowing for full closure of gas valve 2. SSOV powered when it should not be SSOV SWITCH OPEN 3. Defective Switch or Actuator 4. Incorrectly wired switch. 1. Air/Fuel Valve out of calibration. 2. Air/Fuel Valve unplugged. 3. Loose wiring connection to the STEPPER MOTOR FAILURE stepper motor. 4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. Table 8-2 WATER HEATER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES 1. Staged Ignition Ball Valve closed. 2. Clogged/damaged Gas Injector on Igniter-Injector (Figure 8-2). Hard Light-Off 3.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE TO AIR/FUEL MANUAL SHUT-OFF VALVE HIGH PRESSURE GAS SWITCH LEAK DETECTION BALL VALVE SSOV GAS INLET Figure 8-1: Gas Train Component Locations COMPRESSION FITTING & ELBOW STAGED IGNITION SOLENOID FLAME DETECTOR & GASKET GAS INJECTOR TUBE BURNER PLATE INDEXING WASHERS (Quantity = 0-3 as required) O2 SENSOR & WASHERS INJECTOR-IGNITOR Figure 8-2: Staged Ignition Connection to Gas Injector Tube Pa
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE DAMPING ORIFICE BRASS HEX HEAD CAP (Remove to access Gas Pressure Adjustment screw) COVER SCREW SSOV ACTUATOR COVER Figure 8-3: SSOV Actuator With Gas Pressure Adjustment & Damping Orifice OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION CHAPTER 9. RS-232 COMMUNICATION 9.1 INTRODUCTION The RS-232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays. NOTE The information in this chapter does not apply when implementing BST.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION Now, to connect to the remote server, simply click the Open button at the bottom of the dialog box. A new terminal window will pop up and ask you to log in.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION 9.2 RS-232 COMMUNICATION SETUP Regardless of the terminal emulation utilized, the following guidelines must be adhered to when setting up the RS-232 communication link: • Baud Rate – The baud rates which can be used with the C-More Control Panel are: o 2400 o 4800 o 9600 (Default) o 19.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION Menu Processing Utilizing Rs-232 Communication – Continued 7. Shortcut keys are also available to go directly to a specific menu. These shortcut keys are: m0 m1 m2 m3 m4 m5 = = = = = = Default (Operating) Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu 8.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION NOTE The Operation Time (T) Log can store thousands of records. Therefore, to view the most recently logged record, enter “T” followed by 0 (zero) and press Enter (i.e. T0 ). To view earlier records in reverse chronological order, enter T and press Enter. To go back 200 or 1000 records, enter T200 or T1000, etc. and press Enter. 9.4.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual CHAPTER 9 – RS-232 COMMUNICATION 9.4.3 Sensor Log The sensor values can be logged at a different rate if needed by setting the Sensor Log Interval in the Diagnostics Menu. The log interval can vary from once every minute to once every day. Table 9-3 shows a sample Sensor Log every 5 minutes for a boiler running in Constant Setpoint mode.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.1 INTRODUCTION The C-More on-board Boiler Sequencing Technology system (BST) is an integrated 8 boiler control system designed into the C-More controller. The BST has its own sophisticated PID control system designed to simultaneously control the light off and modulation of up to 8 boilers while achieving maximum operational efficiency.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.2 AERCO BST QUICK START CHART Select the single option that suites your installation and then complete the instructions in the corresponding sub-sections of section 10.3 BST Implementation Instructions. Constant Setpoint (choose option 1 or 2) Option 1 – Direct Wired Header Complete section 10.3.1 OR Option 2 – Modbus Header Complete section 10.3.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3 BST IMPLEMENTATION INSTRUCTION 10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor Step 1: Direct Wired Header Sensor Wiring 1. On the MASTER Unit, Connect the Header Temperature Sensor (AERCO PN 61040) to the Feed Forward (FFWD) terminals on the P-1 Harness Via the terminal block labeled “Header Temp sensor” in the I/O Box.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor Step 1: MODbus Header Sensor Wiring 1. Using Shielded pair 18 - 22 AWG cable, connect the Temperature Transmitter (AERCO P/N 65169) terminal Pin B to the RS485+ terminal on the I/O Box of any of the Boiler units, and Pin A of the Temperature Transmitter to the RS485- terminal on the I/O Box of any of the Boiler units. 2.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Direct Wired Header Sensor Wiring 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 3 – Continued Step 3 - Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu 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. Go to the BST Setpoint Mode item and select Outdoor Reset. 6.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor NOTE: Both Header Sensor AND Outdoor Sensor must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1 - Modbus Header Sensor Wiring 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 4 – Continued • 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 and ungrounded. Temp Sensor PN 61043 Modbus Transmitter I/O Box Step 3 - Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu and set the BST Mode item to BST Slave (for now).
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 420ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 5 – Continued Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu 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. Go to the BST Setpoint Mode item and select Remote Setpoint. 6.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive NOTE: Both Header Sensor AND the ProtoNode SSD Device must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: Direct Wired Header Sensor Wiring 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive NOTE: Both Header Sensor AND 4-20ma Direct Drive must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: MODbus Header Sensor 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 7 – Continued Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu 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. Go to the BST Setpoint Mode item and select Remote Setpoint. 6.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY 10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive NOTE! Both Header Sensor AND ProtoNode SSD Device must be wired. See the C-More Controller User Manual, OMM-0032, GF-112 and ProtoNode User Manual, OMM-0080, GF-129 for more information. Step 1: MODbus Header Sensor 1.
Benchmark 750/1000 Boiler CHAPTER 10. BOILER SEQUENCING TECHNOLOGY Option 8 – Continued Step 3: Configure ALL C-More Units On ALL Boilers: 1. Go to the Configuration Menu and set the BST Menu item to Enabled. 2. Go to the BST Menu 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. Go to the BST Setpoint Mode item and select Remote Setpoint. 6.
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Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows Level 1 or Level 2 password to be entered. Entering the Level 1 Password (159) allows options in the Setup, Configuration and Tuning Menus to be modified.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU Internal Setpoint Allows internal setpoint to be set (40°F to 240°F). Default is 130°F. Unit Size Sets unit size from 600 MBH to 6000 MBH depending on the Unit Type.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.) between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler. Default is 0 sec.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS – Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Deadband High Deadband Low Deadband High and Deadband Low settings create an “Outlet Temperature” Zone in which no Valve Position corrections will be attempted.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS APPENDIX A: BOILER MENU ITEM DESCRIPTIONS – Continued TUNING MENU DESCRIPTION Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES APPENDIX B: STARTUP, STATUS & DISPLAY MESSAGES Table B-1: Startup and Status Messages MESSAGE DESCRIPTION DEMAND DELAY XX sec DISABLED HH:MM pm, pm MM/DD/YY FLAME PROVEN IGNITION TRIAL XX sec PURGING XX sec STANDBY WAIT WARMUP XX sec OMM-0082_0J GF-130 Displayed if Demand Delay is active. Displayed if ON/OFF switch is set to OFF.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages FAULT MESSAGE AIRFLOW FAULT DURING PURGE AIRFLOW FAULT DURING IGN AIRFLOW FAULT DURING RUN DELAYED INTERLOCK OPEN DIRECT DRIVE SIGNAL FAULT FFWD TEMP SENSOR FAULT FLAME LOSS DURING IGN FLAME LOSS DURING RUN HEAT DEMAND FAILURE HIGH EXHAUST TEMPERATURE GAS PRESSURE FAULT HIGH WATER TEMPERATURE HIGH WATER TEMP SWITCH OPEN IGN BOARD COMM FAULT IGN SWTCH CLOSED DURING
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES Table B-2: Fault Messages –Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES (This Page Is Intentionally Blank) Page 148 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART Temperature Sensor Resistance Voltage Chart (Balco) OMM-0082_0J GF-130 TEMP (°F) RES (OHMS) VOLTS* -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 779.0 797.5 816.3 835.4 854.8 874.6 894.7 915.1 935.9 956.9 978.3 1000.0 1022.0 1044.4 1067.0 1090.0 1113.3 1137.0 1160.9 1185.2 1209.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX C – SENSOR RESISTTANCE/VOLTAGE CHART (This Page Is Intentionally Blank) Page 150 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDOOR RATIO CHARTS APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1. Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F -20F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDOOR RATIO CHARTS Table D-3. Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 65 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDOOR RATIO CHARTS Table D-5. Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F -5F -10F -15F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX D – INDOOR/OUTDOOR RATIO CHARTS Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 90F 85F 80F 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F 5F 0F 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX E – BOILER DEFAULT SETTINGS APPENDIX E – BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Fahrenheit Comm Address 0 Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type BMK Boiler LN Unit Size 750 MBH or 1000 MBH Fuel Type Natural Gas Boiler Mode Constant Setpoint Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination) 4 –
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX E – BOILER DEFAULT SETTINGS BOILER DEFAULT SETTINGS – Continued MENU & OPTION FACTORY DEFAULT Configuration Menu (Cont.) Setpt Limit Band (If Setpt Limiting = Enabled) 5°F 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 156 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: AP-A-891 rev F OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: SD-A-871 rev B Page 158 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS Drawing Number: SD-A-872 rev B OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX F – DIMENSIONAL DRAWINGS (This Page Is Intentionally Blank) Page 160 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS APPENDIX G – PART LIST DRAWINGS Benchmark 750 - 1000 Parts List Item # Qty Part # EXHAUST MANIFOLD 1 1 43086 2 1 84033 3 1 9-22 GAS TRAIN ASSEMBLY 1 22140-1 4 1 22140-2 1 22140-3 5 1 99017 6 1 81155 7 1 61002-1 610029 1 12 10 1 92077 Description Item # MANIFOLD: EXHAUST SEAL: EXHAUST MANIFOLD PIPE PLUG: 1/4" NPT: STEEL STD FM GAS TRAIN ASSY DBB GAS TRAIN ASSY PROPANE GAS TRAIN ASSY SNUBBER: PRESSU
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS Benchmark 750 - 1000 Parts List Item # Qty Part # Description Item # SHEET METAL/PANEL ASSEMBLY Qty Part # Description 70 1 37110 PANEL: LEFT 71 1 37111 PANEL: RIGHT 72 1 37114 COVER ASSY OTHER ACCESSORIES / PARTS SEE TABLE 85 1 A SEE TABLE 86 1 A SEE TABLE 87 1 A 73 1 25068 ASSEMBLY: FRONT PANEL 88 1 92006-5 VALVE: BALL 1" NPT 74 1 25078 ASSEMBLY: FRONT PANEL 89
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS TOP VIEW ITEM 4 – FM GAS TRAIN 22140-1 ITEM 4 – DBB GAS TRAIN 22140-2 FRONT VIEW AERCO International, Inc. Blauvelt, NY 10913 OMM-0082_0J GF-130 Benchmark 750-1000 Part List 03/07/2014 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 3 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 Page 164 of 192 05/21/2014 Benchmark 750-1000 Part List 03/07/2014 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 4 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 OMM-0082_0J GF-130 Benchmark 750-1000 Part List 03/07/2014 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 5 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS AERCO International, Inc. Blauvelt, NY 10913 Page 166 of 192 05/21/2014 Benchmark 750-1000 Part List 03/07/2014 28321-1 rev D, 28253-1 rev F (reference PL-A-173) Sheet 6 of 6 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS Item Qty Part # Benchmark 750-1000 FM Gas Train – 22140-1 rev E Description Item Qty Part # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 1 1 2 2 1 3 1 1 2 1 1 2 2 1.25"NPT 125#: THREADED FLANGE ELBOW: 45: 1": B/I: 150# VALVE: SSOV 1" NPT ACTUATOR: SSOV W/ REGULATOR BUSHING: REDUCING 1/4" X 1/8" NPT BUSHING: CONTROL BOX PRESSURE SWITCH: 2.6" W.C. FALL N.O.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS Item Qty Part # 1 2 3 4 5 6 7 8 9 1 1 2 1 2 4 1 3 1 10 11 12 1 13 14 15 16 17 18 19 3 1 1 1 2 2 1 1 1 95026 93046 92036 69005 123536 12951-2 61002-1 99014 99015 Benchmark 750-1000 DBB Gas Train – 22140-2 rev D Description Item Qty Part # Description 1.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS BMK 750-1000 PROPANE Gas Train – p/n 22140-3 rev C Item Qty Part # Description Item Qty Part # Description 1 1 95026 1.25"NPT 125#: THREADED FLANGE 19 2 90104 2 1 92103 VALVE: SSOV 1/2" NPT 3 1 69005 4 1 5 NIPPLE: PIPE ½' NPT SCH 40 x 7.00 LG BLK STL 20 3 99014 NIPPLE: HEX 1/4" NPT X 3/8" NPT 21 3 124151 1/4" NPT SCH. 40 X 1-1/2" LG NIPPLE 22 1 124088 NIPPLE: 1/4" NPT: C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX G – PARTS LIST DRAWINGS Benchmark 750-1000 Burner BOM (ref p/n 24276 rev F) Description Item Qty Part # Description Item Qty Part # 1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 42140 81143 81064 24111 59104 24277 66020 88004 9 10 11 12 13 1 4 1 3 1 81048 54028 60011-1 53033 46026 Part # 24276-1 24276 PLATE: BURNER GASKET: BURNER GASKET: BLOWER BLOWER: AMETEK 8.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-870 rev B OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-868 rev B Page 172 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-869 rev B OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX H – PIPING DRAWINGS Drawing Number: SD-A-874 rev C Page 174 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68038 rev E Sheet 1 of 2 OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank Page 176 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS Drawing Number: 68038 rev E Sheet 2 of 2 OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX I – C-MORE WIRING DIAGRAMS This Page Is Intentionally Blank Page 178 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX J – RECOMMENDED PERIODIC TESTING APPENDIX J – RECOMMENDED PERIODIC TESTING WARNING Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX J – RECOMMENDED PERIODIC TESTING Frequency Accomplished By Low air flow Monthly Operator See section 6.8 High and low gas pressure interlocks Monthly Operator See sections 6.2 and 6.3 Air/Fuel Valve purge position switch Annually Service Technician See section 6.10 Air/Fuel Valve ignition position switch Annually Service Technician See section 6.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX K – C-MORE CONTROL PANEL VIEWS APPENDIX K – C-MORE CONTROL PANEL VIEWS CONNECTOR BOARD P/N 124366 LOW WATER CUTOFF BOARD P/N 124363 PMC BOARD P/N 124364 DISPLAY BOARD P/N 124365 GREEN LED P/N 124948 ENCLOSURE P/N 124951 ROCKER SWITCH P/N 124947 POWER SUPPLY BOARD P/N 124362 V.F.D.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual P3 EXT.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX L – RECOMMENDED SPARES APPENDIX L: RECOMMENDED SPARES NOTE Refer to the Parts List Illustrations in Appendix G for the locations of the recommended and optional spare parts listed in the following Tables.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX K – RECOMMENDED SPARES (This Page Is Intentionally Blank) Page 184 of 192 05/21/2014 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX M – ULTRA-LOW NOx CALIBRATION APPENDIX M – ULTRA-LOW NOx CALIBRATION M-1. ULTRA-LOW NOx COMBUSTION CALIBRATION The procedures provided in this Appendix are used to combustion calibrate the boiler to produce ultra-low NOx emissions of less than 9 ppm when running on natural gas. NOTE The instructions below do not apply to units running Propane gas.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX M – ULTRA-LOW NOx CALIBRATION Ultra-Low NOx Natural Gas Combustion Calibration – Continued BRASS HEAD CAP (Remove to access gas pressure adjustment screw) TYPICAL SSOV ACTUATOR WITH REGULATOR Figure M-1. Gas Pressure Adjustment Screw Location 11. Using the ▲ arrow key, increase the valve open position to 100%. Verify that the gas pressure on the downstream side of the SSOV settles within the range of 2.0 ± 0.4” W.C.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX M – ULTRA-LOW NOx CALIBRATION Ultra-Low NOx Natural Gas Combustion Calibration – Continued NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve positions of 80%, 60%, 45%, 30% and 18% as described in the following steps.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual APPENDIX M – ULTRA-LOW NOx CALIBRATION Ultra-Low NOx Natural Gas Combustion Calibration – Continued NOTE If NOx readings exceed the target values shown (<9 ppm), increase the O2 level up to 1% higher than the listed calibration range shown in the table. Record the increased O2 value on the Combustion Calibration sheet.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual LIMITED WARRANTY BENCHMARK 750 - 6000 GAS-FIRED BOILERS LIMITED WARRANTY: BENCHMARK 750 - 6000 GAS-FIRED BOILERS PRESSURE VESSEL/HEAT EXCHANGER: 10 YEAR NON-PRORATED FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10 year non-prorated, limited warranty from date of shipment against any condensate corrosion, thermal stress failure, mechanical defects or workmanship.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual WARRANTY In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item. In addition, the returned item must include a Returned Goods Authorization (RGA) label, attached to the shipping carton, which identifies the item's return address, register number and factory authorized RGA number.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual NOTES: OMM-0082_0J GF-130 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
Benchmark 750/1000 Boiler Installation, Operation & Maintenance Manual Change Log: Date Description Changed By 03/19/2014 Rev I: PIR 780: replaced mechanical latch with magnetic PIR 981: Expanded Table A in Appendix F Part List PIR 934-33: Modified step 13 in Combustion Calibration regarding defective O2 Sensor. PIR 934-37: Modified Blocked Inlet Switch Test instructions, section 6.8.2. PIR 960: Addition of two sub-sections in 2.10.12; addition of section 2.
