Instruction No. GF-110LN AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions Benchmark™ Series Gas Fired Low NOx Boiler System Condensing, Modulating Forced Draft, Hot Water Boiler 2,000,000 BTU/H Input Applicable To Serial Numbers G-05-1393 and above Patent # : 2.155.12 Printed in U.S.A.
Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday) (800) 526-0288 The information contained in this installation, operation and maintenance manual is subject to change without notice from AERCO International, Inc. AERCO International, Inc. 159 Paris Avenue Northvale, NJ 07647-0128 www.aerco.com © AERCO International, Inc.
CONTENTS GF-110LN - AERCO BENCHMARK 2.0 GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWARD A Chapter 1 – SAFETY PRECAUTIONS Para. 1-1 1-2 Subject Safety Warnings Emergency Shutdown Page 1-1 1-1 1-1 Para. 1-3 Subject Prolonged Shutdown Chapter 2 – INSTALLATION PROCEDURES Para. 2.1 2.2 2.3 2.4 2.5 2.6 Subject Receiving the Unit Unpacking Installation Gas Supply Piping Electrical Supply Mode of Operation and Field Control Wiring Page 2-1 2-1 2-2 2-3 2-4 2-5 2-1 Para. 2.7 2.8 2.
CONTENTS Chapter 5 – MODE OF OPERATION Para. 5.1 5.2 5.3 5.4 5.5 Subject Introduction Indoor/Outdoor Reset Mode Constant Setpoint Mode Remote Setpoint Mode Direct Drive Modes Page 5-1 5-1 5-2 5-2 5-3 5-1 Para. 5.6 5.7 Subject Boiler Management System (BMS) Combination Control System (CCS) Page 5-4 5-5 Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1 Para. 6.1 6.2 6.3 6.4 6.5 6.6 6.
CONTENTS APPENDICES App A B C D Subject Boiler Menu Item Descriptions Startup, Status and Fault Messages Temperature Sensor Resistance Chart Indoor/Outdoor Reset Ratio Charts WARRANTIES Page A-1 B-1 C-1 App E F G H I D-1 J Subject Boiler Default Settings Dimensional and Part Drawings Piping Drawings Wiring Schematics Recommended Periodic Testing Checklist Benchmark Control Panel Views Page E-1 F-1 G-1 H-1 I-1 J-1 W-1 iii
FOREWORD Foreword The AERCO Benchmark 2.0 LN Boiler is a true industry advance 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. The Benchmark’s 20:1 turn down ratio and condensing capability, provides extremely high efficiencies and makes it ideally suited for modern low temperature, as well as, conventional heating systems.
SAFETY PRECAUTIONS CHAPTER 1 SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following general warnings and cautions must be given the same attention as specific precautions included in these instructions. In addition to all the requirements included in this Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.
SAFETY PRECAUTIONS 1.2 EMERGENCY SHUTDOWN If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit. IMPORTANT The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel. 1.
INSTALLATION Chapter 2 - INSTALLATION 2.1 RECEIVING THE UNIT 2.2 UNPACKING Each Benchmark is shipped as a single crated unit. The shipping weight is approximately 1850 pounds, and must be moved with the proper rigging equipment for safety and to avoid damages. The unit should be completely inspected for shipping damage and completeness at the time of receipt from the carrier and before the bill of lading is signed.
INSTALLATION 2.3 INSTALLATION The unit must be installed by qualified personnel (i.e. licensed plumber, gas fitter, etc.) in compliance with local and state regulations. The prescribed clearances for service are shown in Figure 2.1. The minimum clearance dimensions, required by AERCO, are listed below. Local building codes may require more clearance and take precedence Combination Mode units in the proper physical location. If these boilers are not properly located, it will be necessary to reprogram them.
INSTALLATION 2.3.3 CONDENSATE DRAIN & PIPING The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable drainage or collection. A 1/2” NPT drain connection is provided on the exhaust manifold (see Fig 2.4). A separate condensate drain trap (part no. 24060) is shipped loose and must be installed on the floor behind the unit. Connect the trap to the exhaust manifold as follows: 1.
INSTALLATION should be supported from floor, ceiling or walls only and must not be secured to the unit. A suitable piping compound, approved for use with natural gas or propane, should be used. Any excess must be wiped off to prevent clogging of components. To avoid damage to the unit, when pressure testing gas piping, isolate the unit from the gas supply piping. At no time should there be more than 2 psi to the unit.
INSTALLATION Each of the above power configurations contain a Power Box with a terminal block which matches the configuration ordered. The three different terminal block configurations are shown in Figure 2.7. A wiring diagram showing the required AC power connections is provided on the front panel of each Power Box. Each Benchmark Boiler must be connected to a dedicated electrical circuit. No other devices should be on the same electrical circuit as the Benchmark Boiler.
INSTALLATION 2.6.2 INDOOR/OUTDOOR RESET MODE This mode of operation increases supply water temperature as outdoor temperatures decrease. An outside air temperature sensor (AERCO PN 122790) is required. The sensor MUST BE wired to the I/O Box wiring terminals (see Fig. 2.9). For more information concerning the outside air sensor installation, refer to paragraph 2.7.1 Figure 2.9 I/O Box Terminal Strip 2.6.
INSTALLATION While it is possible to control a boiler or boilers using one of the previously described modes of operation, it may not be the method best suited for the application. Prior to selecting one of these modes of operation, it is recommended that you consult with your local AERCO representative or the factory for the mode of operation that will work best with your application. For more information on wiring the 4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5 VDC, see paragraph 2.7.3. 2.6.
INSTALLATION Whether using voltage or current for the drive signal, they are linearly mapped to a 40o to 240oF setpoint or a 0% to 100% firing rate. No scaling for these signals is provided 2.7.4 B.M.S. (PWM) IN NOTE Only BMS Model 168 can utilize Pulse Width Modulation (PWM), not the BMS II (Model 5R5-384). These terminals are used to connect the AERCO Boiler Management System (BMS) Model 168 to the unit. The BMS Model 168 utilizes a 12 millisecond, ON/ OFF duty cycle.
INSTALLATION firing). Its contacts are rated for 120 VAC @ 5 amps. Refer to Figure 2.9 to locate the AUX RELAY terminals for wiring connections. 2.9 FLUE GAS VENT INSTALLATION The AERCO Venting and Combustion Air Guide, GF-2050, must be consulted before any flue gas vent or inlet air venting is designed or installed. U/L listed, positive pressure, watertight vent materials as specified in AERCO’s GF-2050, must be used for safety and code compliance.
CONTROL PANEL OPERATING PROCEDURES Chapter 3 - CONTROL PANEL OPERATING PROCEDURES 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 will void the equipment warranty.
CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays ITEM NO. 1 CONTROL, INDICATOR OR DISPLAY LED Status Indicators 3 VFD Display 4 RS-232 Port 5 FAULT Indicator 6 CLEAR Key 7 READY Indicator Lights when RS-232 communication is occurring Lights when the unit is being controlled using the front panel keypad. Lights when the unit is being controlled by an external signal from an Energy Management System Lights when there is a demand for heat.
CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays - Continued ITEM NO. 10 11 CONTROL, INDICATOR OR DISPLAY Menu Keypad FUNCTION Consists of 6 keys which provide the following functions for the Control Panel Menus: 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.
CONTROL PANEL OPERATING PROCEDURES 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 four major menu categories as shown in Figure 3-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by a password to prevent unauthorized use.
CONTROL PANEL OPERATING PROCEDURES 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 other displayed items. Since this menu is “ReadOnly”, it can be viewed at any time without entering a password. Press the ▲ arrow key to display the menu items in the order listed (TopDown). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up). 3.
CONTROL PANEL OPERATING PROCEDURES 3.6. CONFIGURATION MENU The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the Constant Setpoint mode. The remaining options in this menu require the valid password to be entered, prior to changing existing entries.
CONTROL PANEL OPERATING PROCEDURES 3.7. TUNING MENU The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel. Table 3-5. Tuning Menu Menu Item Display Prop Band Integral Gain Derivative Time Reset Defaults? Available Choices or Limits Minimum Maximum 1°F 120°F 0.00 2.00 0.0 min 2.0 min Yes No Are You Sure? Default 70°F 1.00 0.0 min No 3.8.
CONTROL PANEL OPERATING PROCEDURES (a) Blower relay energizes and turns on blower. (b) Air/Fuel Valve rotates to full-open purge position and closes purge position switch. The dial on the Air/Fuel Valve (Figure 3-4) will read 100 to indicate that it is full-open (100%). (c) The FIRE RATE bargraph will show 100%. Figure 3-5. Blower Proof Switch 5.
CONTROL PANEL OPERATING PROCEDURES 8. With the unit firing properly, it will be controlled by the temperature controller circuitry. The FIRE RATE will be continuously displayed on the front panel bargraph. Once the demand for heat has been satisfied, the Control Box will turn off the gas valve. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will be displayed. BURNER BLOWER 3.9.
INITIAL START-UP Chapter 4 - INITIAL START- UP 4.1 INITIAL START- UP REQUIREMENTS The initial start-up of the Benchmark Boiler is comprised of the following steps: • • • • • installation completed combustion calibration proper setting of controls and limits mode of operation settings (see Chapter 5) safety device testing (see Chapter 6) Installation should be fully completed before performing initial start-up; and the start-up must be complete prior to putting the unit into service.
INITIAL START-UP 4.2.4 INSTALLING THE DIFFERENTIAL REGULATOR ADJUSTMENT TOOL FOR NATURAL GAS UNIT. 1. Remove the cap from the differential pressure regulator (see Figure 4.3). 2. Place the gasket from the regulator cap onto the regulator adjustment tool. 3. Prior to installing the tool on the regulator, pull up the screwdriver blade of the tool. Then thread the tool into the regulator and hand tighten. 4. Engage the tool’s screwdriver blade into the regulator’s adjustment screw slot. Figure 4.
INITIAL START-UP It is important to perform the following procedure as outlined. This will keep readjustments to a minimum and provide for optimum performance. 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 ON/OFF switch in the OFF position. Turn on AC power to the unit. The display will show LOSS OF POWER and the time and date. 4. Set the unit to the Manual Mode by pressing the AUTO/MAN key.
INITIAL START-UP 11. If the required oxygen level from Table 1 is achieved, proceed to step 18. If the oxygen level is lower than the required value and cannot be sufficiently raised using the differential regulator, proceed to step 12. 12. Close the 1/4” ball valve in the staged ignition assembly downstream of the SSOV. 13. If the oxygen level rises, it is an indication that the staged ignition solenoid is stuck, or is adding gas and preventing the proper oxygen level from being achieved.
INITIAL START-UP Table 3 - Combustion Oxygen Levels for 100% Firing Rate Temp (ºF) 130 120 110 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 O2 4.3 4.5 4.7 4.8 5.0 5.1 5.1 5.2 5.3 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.
MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION The Benchmark 2.0 Low NOx Boiler is capable of being operated in any one of six different modes. The following paragraphs in this Chapter provide descriptions of each of these operating modes. Each unit is shipped from the factory tested and configured for the ordered mode of operation. All temperature related parameters are at their factory default values which work well in most applications.
MODE OF OPERATION 7. Press the CHANGE key. The display will begin to flash. 8. Use the ▲ and ▼ arrow keys to select the desired Building Reference Temperature. 9. Press ENTER to save any changes. 10. Next, scroll through the Configuration Menu until the display shows Reset Ratio. 11. Press the CHANGE key. The display will begin to flash. 12. Use the ▲ and ▼ arrow keys to select the Reset Ratio determined in step 5. 13. Press ENTER to save the change. Refer to paragraph 3.
MODE OF OPERATION If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information. 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.
MODE OF OPERATION If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information. 5.5.1 Direct Drive Field Wiring The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box.
MODE OF OPERATION 5.7 COMBINATION CONTROL SYSTEM (CCS) NOTE Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R5-384). A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. An AERCO Boiler Management System (BMS) Model 168 and a Combination Control Panel (CCP) are necessary to configure this system.
SAFETY DEVICE TESTING Chapter 6 - SAFETY DEVICE TESTING PROCEDURES 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating as designed. The AERCO control system comprehensively monitors all combustion related safety devices before, during and after the start sequence. The following tests have been chosen to ensure that the system will either not start or will shut-down as intended. outside the boiler.
SAFETY DEVICE TESTING 6.4 LOW WATER LEVEL FAULT TEST 1. Place the ON/OFF switch in the OFF position. RESET BUTTON FOR MANUAL RESET TEMPERATURE LIMIT SWITCH 2. Close 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 it is necessary to vent the unit to aid in draining, the unit’s relief valve may be opened. 4. Drain the unit until the LOW WATER LEVEL fault message is displayed and the FAULT LED flashes. 5.
SAFETY DEVICE TESTING 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 manual mode and fire at 25% to 30% firing rate. 3. If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the jumper. If the interlock is being controlled by an external device, either open the interlock via the external device or disconnect one of the wires leading to the external device. 4.
SAFETY DEVICE TESTING 9. Replace the wire previously disconnected and depress the CLEAR button. The unit should restart. SSOV ACTUATOR COVER Figure 6.4 Blower Proof Switch Location and Wiring SSOV ACTUATOR COVER SCREW 6.9 SSOV PROOF OF CLOSURE SWITCH 1. Set the unit’s ON/OFF switch to the OFF position. Place the unit in manual mode and set the fire rate between 25% and 30%. 2. Remove the Safety Shut-Off Valve (SSOV) cover (see Fig. 6.5).
SAFETY DEVICE TESTING 6.11 IGNITION SWITCH OPEN DURING IGNITION 1. Set the unit’s ON/OFF switch to the off position. Place the unit in manual mode and set the fire rate between 25% and 30%. 2. Remove the air/fuel valve cover (Fig. 6.8) by rotating the cover counterclockwise to unlock it then pulling it towards you. 3. Disconnect one of the two wires from the ignition position switch (Fig. 6.7) and start the unit. 4. The unit should begin to start then shut down and display IGN SWITCH OPEN DURING IGNITION.
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 carried out in the time periods specified in Table 7-1.
MAINTENANCE Table 7-1. - Maintenance Schedule PARAGRAPH 7.2 7.3 7.4 7.5 7.6 7.7 ITEM Spark Igniter (GP-122435-S) Flame Detector (66006) Combustion Adj. 6 Mos. 12 Mos. 24 Mos. Labor Time *Inspect Inspect Replace 15 mins. *Inspect Inspect Replace 15 mins. *Check Check 1 hr. See CSD-1 Chart in Appendix I 20 mins. Testing of Safety Devices Burner Condensate Drain Trap Inspect Inspect Inspect & Clean 2 hrs. 1 hr. * Only performed after initial 6 month period after initial startup. 7.
MAINTENANCE 7.5 SAFETY DEVICE TESTING Systematic and thorough tests of the operating and safety devices should be performed to ensure that they are operating as designed. Certain code requirements, such as ASME CSD1, require that these tests be performed on a scheduled basis. Test schedules must conform to local jurisdictions. The results of the tests should be recorded in a logbook. See Chapter 6Safety Device Testing Procedures. 7.6 BURNER The burner assembly is located at the top of the unit.
MAINTENANCE 7.7 CONDENSATE DRAIN TRAP The boiler contains a condensate drain trap connected to the drain line of the exhaust manifold (see Figures 2.4 & 2.5). The trap should be inspected and, if necessary, cleaned to ensure proper operation. Proceed as follows: 1. Disconnect the external condensate trap by loosening the hose clamps between the trap and the condensate drain connection on the exhaust manifold of the boiler (Figure 2.5). 2.
TROUBLESHOOTING 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 Series Boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are comprised of three columns labeled: Fault Indication, Probable Cause and Corrective Action.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT DURING IGNITION 1. Blower stopped running due to thermal or current overload 2. Blocked Blower inlet or inlet ductwork 1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. 2. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage. 3.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION DELAYED INTERLOCK OPEN 1. Delayed Interlock Jumper not installed or removed. 2. Device proving switch hooked to interlocks is not closed 1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box. 2. If there are 2 external wires on these terminals, check to see if an end switch for a device such as a pump, louver, etc. is tied these interlocks.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) PROBABLE CAUSES 7. Defective Differential Pressure Regulator 8. Carbon or other debris on Burner FLAME LOSS DURING RUN 1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary. 2. Defective Differential Regulator. 2.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION continued PROBABLE CAUSES 2. continued 3. Defective High Gas Pressure Switch 4. Gas pressure snubber not installed. HIGH WATER TEMP SWITCH OPEN 1. Faulty Water temperature switch. 2. Incorrect PID settings. 3. Faulty shell temperature sensor. 4. Unit in Manual mode 5. Unit setpoint is greater than Over Temperature Switch setpoint. 6. Boiler Management System PID or other settings not correctly setup. 7.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION IGN SWTCH CLOSED DURING PURGE PROBABLE CAUSES 1. Air/Fuel Valve not rotating 2. Defective or shorted switch 3. Switch wired incorrectly 4. Defective Power Supply Board or fuse 5. Defective IGST Board IGN SWTCH OPEN DURING IGNITION 1. Air/Fuel Valve not rotating to ignition position. 2. Defective ignition switch 3. Defective Power Supply Board or fuse 4. Defective IGST Board INTERLOCK OPEN 8-6 1.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION continued LINE VOLTAGE OUT OF PHASE LOW GAS PRESSURE PROBABLE CAUSES 3. Device proving switch hooked to interlocks is not closed. 1. Line and Neutral switched in AC Power Box. 2. Incorrect power supply transformer wiring. 1. Incorrect supply gas pressure. 2. Defective Low Pressure Gas Switch LOW WATER LEVEL 1. Insufficient water level in system 2. Defective water level circuitry. 3. Defective water level probe.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION continued PROBABLE CAUSES 2. Defective or shorted switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board PRG SWTCH OPEN DURING PURGE 1. Defective purge switch. 2. No voltage present at switch. 3. Switch wired incorrectly. 4. Defective Power Supply Board or fuse 5. Defective IGST Board OUTDOOR TEMP SENSOR FAULT 1. Loose or broken wiring. 2. Defective Sensor. 6. Incorrect Sensor.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION continued RESIDUAL FLAME SSOV FAULT DURING PURGE SSOV FAULT DURING RUN SSOV RELAY FAILURE SSOV SWITCH OPEN PROBABLE CAUSES 3. Control Box signal type selection switches not set for correct signal type (voltage or current). 1. SSOV not fully closed. 2. Defective Flame Detector. See SSOV SWITCH OPEN Close gas shut-off valve downstream of SSOV.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION continued 8.2 PROBABLE CAUSES 4. Defective Air/Fuel Valve stepper motor. 5. Defective Power Supply Board or fuse. 6. Defective IGST Board CORRECTIVE ACTION 4. Replace stepper motor. 5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board. 6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.
TROUBLESHOOTING HIGH GAS PRESSURE SWITCH GAS PRESSURE SNUBBER Figure 8.1 High Pressure Gas Switch & Gas Pressure Snubber Locations Figure 8.2 Staged Ignition Solenoid Location 8-11 Figure 8.
APPENDIX A BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is operating 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. When in the Remote Setpoint Mode, this value is the setpoint equivalent to the remote analog signal supplied to the unit.
APPENDIX A BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered. Once the valid password (159) is entered, options in the Setup, Configuration and Tuning Menus can be modified. Language English only. Time Displays time from 12:00am to 11:59pm. Date Displays dates from 01/01/00 to 12/31/99 Unit of Temp Permits selection of temperature displays in degrees Fahrenheit (°F) or degrees Celsius (°C). Default is °F.
APPENDIX A BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Reset Ratio Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode. Reset Ratio is adjustable from 0.1 to 9.9. Default is 1.2. Outdoor Sensor Allows outdoor sensor function to be enabled or disabled. Default is Disabled. System Start Tmp If outdoor sensor is enabled in the Configuration Menu, this menu item allows the system start temperature to be set from 30°F to 100°F. Default is 60°F.
APPENDIX A BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION Setpt Limiting Allows Setpoint Limiting to be enabled or disabled. Default is disabled. Setpt Limit Band If Setpoint Limiting is enabled, this menu item allows the Setpt Limit Band to be set from 0°F to 10°F. Default is 5°F. TUNING MENU A-4 Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature.
APPENDIX B STARTUP, STATUS AND FAULT MESSAGES STARTUP AND STATUS MESSAGES MESSAGE DISABLED HH:MM pm MM/DD/YY STANDBY DEMAND DELAY XX sec PURGING XX sec IGNITION TRIAL XX sec FLAME PROVEN WARMUP XX sec WAIT DESCRIPTION Displayed if ON/OFF switch is set to OFF. The display also shows the time and date that the unit was disabled. Displayed when ON/OFF switch is in the ON position, but there is no demand for heat. The time and date are also displayed. Displayed if Demand Delay is active.
APPENDIX B FAULT MESSAGES FAULT MESSAGE HIGH WATER TEMP SWITCH OPEN LOW WATER LEVEL LOW GAS PRESSURE HIGH GAS PRESSURE INTERLOCK OPEN DELAYED INTERLOCK OPEN AIRFLOW FAULT DURING PURGE PRG SWTCH OPEN DURING PURGE IGN SWTCH OPEN DURING IGNITION IGN SWTCH CLOSED DURING PURGE PRG SWTCH CLOSED DURING IGNITION AIRFLOW FAULT DURING IGN AIRFLOW FAULT DURING RUN SSOV SWITCH OPEN SSOV FAULT DURING PURGE SSOV FAULT DURING IGN SSOV FAULT DURING RUN SSOV RELAY FAILURE FLAME LOSS DURING IGN FLAME LOSS DURING RUN HIGH EX
APPENDIX B FAULT MESSAGES - Continued FAULT MESSAGE RESIDUAL FLAME HEAT DEMAND FAILURE IGN BOARD COMM FAULT DIRECT DRIVE SIGNAL FAULT REMOTE SETPT SIGNAL FAULT OUTDOOR TEMP SENSOR FAULT OUTLET TEMP SENSOR FAULT FFWD TEMP SENSOR FAULT HIGH WATER TEMPERATURE LINE VOLTAGE OUT OF PHASE STEPPER MOTOR FAILURE NETWORK COMM FAULT FAULT DESCRIPTION The Flame signal was seen for more than 60 seconds during standby. The Heat Demand Relays on the Ignition board failed to activate when commanded.
APPENDIX C Temperature Sensor Resistance Chart (Balco) C-1
APPENDIX D INDOOR/OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX D Header Temperature for a Building Reference Temperature of 65F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX D Header Temperature for a Building Reference Temperature of 75F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX D Header Temperature for a Building Reference Temperature of 90F RESET RATIO Air Temp 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
APPENDIX E BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password 0 Language English Unit of Temp Comm Address Baud Rate Fahrenheit 0 9600 Configuration Menu Internal Setpt 130°F Unit Type Boiler Unit Size 1.0 MBTU Boiler Mode Constant Setpoint Remote Signal (If Mode = Remote 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.
APPENDIX F F-1
APPENDIX F F-2
APPENDIX F F-3
APPENDIX F F-4
APPENDIX F F-5
APPENDIX F F-6
FULL PORT BALL VALVE 2" NPT P/N: 123540 2"-SCH.40 PIPE TO AIR-FUEL VALVE ASS'Y BOILER BOUNDARY 2" NPT DIFFERENTIAL GAS PRESSURE REGULATOR P/N 123541 LOW GAS PRESS. SWITCH P/N: 61002-11 2" SAFETY SHUT-OFF VALVE ACTUATOR w/ REGULATOR P/N 64048 NORTHVALE, NJ 07647 INTERNATIONAL, INC. 1/8" NPT PLUG (INSTALL MANOMETER HERE) DWN.BY CZ DATE 021406 SCALE NTS SIZE CHKD. APPD. AP-A-800 BENCHMARK2.0 LOW NOx FM GAS TRAIN (1.75 MIL.
APPENDIX F F-8
APPENDIX F F-9
APPENDIX F F-10
APPENDIX F F-11
APPENDIX F F-12
DRIP TRAP GAS SUPPLY SYSTEM PUMP 1-1/2" NPT DRAIN CONN. DIAPHRAGM TYPE EXPANSION TANK CHECK VALVE (TYP.) * CONDENSATE DRAIN TRAP AIR SEPARATOR AUTOMATIC AIR VENT P&T HEATING SYSTEM RETURN 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 5) THIS IS A TYPICAL INSTALLATION DRAWING. LOCAL CODES AND AUTHORITIES SHOULD BE CONSULTED. 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.
G-2 DRIP TRAP GAS SUPPLY SYSTEM PUMP AUTOMATIC AIR VENT P&T AIR SEPARATOR * CONDENSATE DRAIN TRAP 1-1/2" NPT DRAIN CONN. DIAPHRAGM TYPE EXPANSION TANK CHECK VALVE (TYP.) DIRT TRAP RELIEF VALVE (TYP.) P&T 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.0 PSIG, A LOCK-UP STYLE REGULATOR MUST BE INSTALLED DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.
APPENDIX G G-3
APPENDIX G G-4
APPENDIX G G-5
APPENDIX H H-1
APPENDIX H H-2
154 155 136 154 138 AUTO RESET 192 209 135 170 169 168 DATE REVISIONS THESE DRAWINGS AND/OR SPECIFICATIONS ARE THE PROPERTY OF AERCO INTERNATIONAL, INC. THEY ARE ISSUED IN STRICT CONFIDENCE AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION OF THE OWNER.
APPENDIX H H-4
APPENDIX H H-5
APPENDIX H H-6
APPENDIX I RECOMMENDED PERIODIC TESTING CHECK LIST WARNING NOTE: 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. The owner or user of an automatic boiler system should set up a formal system of periodic preventive maintenance and testing. Tests should be conducted on a regular basis and the results recorded in a log-book.
APPENDIX J 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.
P1 P2 P3 P4 P5 P6 APPENDIX J BENCHMARK CONTROL PANEL REAR VIEW J-2
Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International, Inc. PRESSURE VESSEL/HEAT EXCHANGER: 10 YEARS FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10-year prorated, limited warranty from shipment against any failure due to condensate corrosion, thermal stress, mechanical defects or workmanship. Operation of the boiler using contaminated air will void the warranty.
Standard Warranty: Benchmark Gas-Fired Hydronic Boiler International, Inc. CONDITIONS OF WARRANTY Should an AERCO gas-fired Hydronic boiler fail for any of the above reasons within the specified time period from the date of original shipment(s), AERCO shall, at its option, modify, repair or exchange the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation.
