Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual Natural Gas or Propane Fired Modulating, Condensing, Forced Draft, Hot Water Boiler 2,000,000 BTU/H Input Applicable for Serial Numbers: G-11-1861 and above. GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler USER MANUAL Installation, Operation, and Maintenance Benchmark 2.0LN Low NOx Boiler Revised 08/20/2012 PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E Benchmark 2.0LN 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.
GF-123 OMM-0046_0E Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual TABLE OF CONTENTS CHAPTER 1: SAFETY PRECAUTIONS ...................................................................................................... 9 1.1 WARNINGS & CAUTIONS ................................................................................................................. 9 1.2 EMERGENCY SHUTDOWN ...........................................................................................................
GF-123 OMM-0046_0E Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual 2.12 COMBUSTION AIR ........................................................................................................................ 30 2.12.1 Combustion Air From Outside the Building ......................................................................... 30 2.12.2 Combustion Air From Inside The Building .......................................................................... 30 2.12.3 Sealed Combustion ....
GF-123 OMM-0046_0E Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual 5.6 BOILER MANAGEMENT SYSTEM (BMS)....................................................................................... 69 5.6.1 BMS External Field Wiring .................................................................................................... 70 5.6.2 BMS Setup and Startup ........................................................................................................ 70 5.
GF-123 OMM-0046_0E Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual 9.4 DATA LOGGING ............................................................................................................................ 114 9.4.1 Fault Log ............................................................................................................................. 114 9.4.2 Operation Time Log ..........................................................................................................
GF-123 OMM-0046_0E Benchmark 2.0LN Boiler Installation, Operation & Maintenance Manual Foreword Foreword The AERCO Benchmark 2.0 Low NOx (LN) Boiler is a modulating unit. It represents 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 2.
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GF-123 OMM-0046_00E Benchmark 2.0LN Low NOx Boiler Installation, Operation and 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.
Chapter 1 Safety Precautions Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E WARNING FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES. CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO BEFORE PERFORMING MAINTENANCE. WARNING ELECTRICAL VOLTAGES UP TO 120 VAC MAY BE USED IN THIS EQUIPMENT.
GF-123 OMM-0046_00E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 1 Safety Precautions MANUAL GAS SHUTOFF VALVE VALVE OPEN VALVE CLOSED Figure 1-1: Manual Gas Shutoff Valve IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements: • Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
Chapter 1 Safety Precautions Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b.
GF-123 OMM-0046_00E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 1 Safety Precautions 2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.
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GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation CHAPTER 2. INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 2.0LN Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5. 2.2 RECEIVING THE UNIT Each Benchmark 2.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 2.4 SITE PREPARATION. Ensure that the site selected for installation of the Benchmark 2.0LN Boiler includes: • Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20A • Access to Natural Gas or Propane line at a Minimum supply gas pressure of 4" W.C. (2000 cfh for Natural Gas, 800 cfh for Propane).. 2.4.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation FOR MASSACHUSSETTS ONLY: For Massachusetts installations, the boiler must be installed by a plumber or gas fitter who is licensed within the Commonwealth of Massachusetts. In addition, the installation must comply with all requirements specified in Chapter 1 (Safety Precautions). 2.4.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 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.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation The procedure to install and connect the condensate drain is provided in paragraph 2.6.1. BOILER RETURN EXHAUST MANIFOLD 1/2” NPT CONDENSATE DRAIN CONNECTION HOUSEKEEPING PAD Figure 2-4: Condensate Drain Connection Location 2.6.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 4. If a floor drain is not available, a condensate pump can be used to remove the condensate to drain. The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated fittings and drain line must be removable for routine maintenance. Figure 2-5: Condensate Trap Installation: Older (left) and Newer (right) Style 2.7 GAS SUPPLY PIPING The AERCO Benchmark 2.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation 2.7.1 Gas Supply Specifications. The maximum static pressure to the unit must not exceed 14” W.C. The specifications for natural gas and propane are as follows: • Natural Gas: The gas supply pressure to the unit must be of sufficient capacity to provide 2000 cfh while maintaining the gas pressure at 4.0" W.C. for FM or 5.0" W.C. for IRI gas trains.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 2.7.4 IRI Gas Train Kit The IRI gas train is an optional gas train configuration which is required in some areas for code compliance or for insurance purposes. The IRI gas train is factory pre-piped and wired. See Appendix F, Drawing AP-A-843 for details. 2.8 AC ELECTRICAL POWER WIRING The AERCO Benchmark 2.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation For electrical power wiring diagrams, see the AERCO Benchmark 2.0LN Electrical Power Wiring Guide, (GF-2060LN). 120 VAC, 1 PHASE GND NEU L1 Figure 2-8: AC Terminal Block Configurations 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 2.0 Boiler is available in several different modes of operation.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Figure 2-9: Input/Output (I/O) Box Location 2.9.1 Constant Setpoint Mode The Constant Setpoint Mode is used when it is desired to have a fixed setpoint that does not deviate. No wiring connections, other than AC electrical power connections, are required for this mode. However, if desired, fault monitoring or enable/disable interlock wiring can be utilized (see paragraphs 2.9.9.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation 2.9.4 Remote Setpoint and Direct Drive Modes The Benchmark 2.0LN Boiler can accept several types of signal formats from an Energy Management System (EMS), Building Automation System (BAS) or other source, to control either the setpoint (Remote Setpoint Mode) or air/fuel valve position (Direct Drive Mode) of the Boiler.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Figure 2-10. I/O Box Terminal Locations and Functions 2.10 I/O BOX CONNECTIONS The types of input and output signals and devices to be connected to the I/O Box terminals shown in Figure 2-10 are described in the following paragraphs. NOTE Older I/O PCBs are wired the same as new ones, even if silk-screen designations differ.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation terminals labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and ungrounded. 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.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 2.10.5 SHIELD (5) The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit. Only shields must be connected to these terminals. IMPORTANT DO NOT USE the mA OUT output to remotely monitor Setpoint, Outlet Temp or Fire Rate Out. 2.10.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation 2.10.11.1 REMOTE INTERLOCK IN (10) The remote interlock circuit is provided to remotely start (enable) and stop (disable) the Boiler, if desired. The circuit is labeled REMOTE INTL’K IN and is located inside the I/O Box on the front panel. The circuit is 24 VAC and is factory pre-wired in the closed (jumpered) position. 2.10.11.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Selkirk Corporation, Heatfab Division ( www.heat-fab.com ),130 Industrial Blvd., Turners Falls, MA 01376 Phone: 1-800-772-0739 2.12 COMBUSTION AIR The AERCO Benchmark Venting and Combustion Air Guide, GF-2050 MUST be consulted before any flue or combustion supply air venting is designed or implemented. Combustion air supply is a direct requirement of ANSI 223.1, NFPA-54, CSA B149.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation recommends that a disposable air intake filter be installed, temporarily, above the boiler combustion air inlet. AERCO recommends that the temporary air filter be cut from a McMaster-Carr part no. 2122K315 Polyester Air Filter Roll Tackfield, ½” thick, 16” wide, or equivalent. Cover the Benchmark 2.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Diagram 2-1b: Schematic – System Pump Start using a Separate Contact Relay Figure 2-11: Identifying the Presence of BMK Pump Relay Option 69102 Page 32 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation CHAPTER 3. CONTROL PANEL OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 2.0LN 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.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 2 1 3 4 12 5 11 6 10 7 8 9 Figure 3-1: Control Panel Front View Page 3-34 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation Table 3-1 Operating Controls, Indicators and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY 1 LED Status Indicators FUNCTION Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring MANUAL Lights when the unit is being controlled using the front panel keypad.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Table 3-1 Operating Controls, Indicators and Displays (Continued) ITEM NO. 10 CONTROL, INDICATOR OR DISPLAY MENU Keypad Consists of 6 keys which provide the following functions for the Control Panel Menus: MENU Steps through the main menu categories shown in Figure 32. The Menu categories wrap around in the order shown.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation Once the valid level 1 password (159) is entered, the options listed in the Setup. Configuration and Tuning Menus can be viewed and changed, if desired. The Combustion Cal Menu is protected by the level 2 password which is used in Chapter 4 to perform combustion calibration prior to service use. 3.3.
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E OPERATING LEVEL 1 PWD SETUP CONFIGURATION TUNING LEVEL 2 PWD COMBUSTION CAL CALIBRATION (NOT USED IN THIS O & M) DIAGNOSTICS (NOT USED IN THIS O & M) Figure 3-2: Control Panel Menu Structure NOTE The following paragraphs provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation NOTE The Outdoor Temp display item shown with an asterisk in Table 3-2 will not be displayed unless the Outdoor Sensor function has been enabled in the Configuration Menu (Table 3-4).
Chapter 2 Installation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 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.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 2 Installation Table 3-4. Configuration Menu - Continued Menu Item Display Reset Ratio (If Mode = Outdoor Reset) Outdoor Sensor PR1 08/20/12 Default 1.
Chapter 3 Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E *CAUTION! DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V). 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. 3.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 3 Operation 3.9 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.
Chapter 3 Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E SSOV GAS INLET TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE Figure 3-3: SSOV Location 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. 5.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 3 Operation AIR IN TO BLOWER DIAL (DETAIL “A”) STEPPER MOTOR 100 DETAIL “A” Figure 3-4: Air/Fuel Valve In Purge Position Figure 3-5: Blower Proof Switch PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Chapter 3 Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E AIR IN TO BLOWER DIAL (DETAIL “A”) STEPPER MOTOR 25 DETAIL “A” Figure 3-6: Air/Fuel Valve In Ignition Position 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.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Chapter 3 Operation Installation, Operation and Maintenance Manual Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. Refer to Table 3-7 for the relationship between the energy input and Air/Fuel Valve position for a unit running on natural gas. Table 3-7.
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GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual CHAPTER 4. Chapter 4 Initial Start-Up INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 2.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 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.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up Install the 16” W.C. manometer(s) as described in the following steps: 1. Turn off the main gas supply upstream of the unit. 2. Remove the top panel and left or right side panel from the boiler to access the gas train components. 3. Perform the RSI regulator Safe Test as described in paragraph 4.3. If test shows a successful RSI ignition, proceed to the next step.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 1. Close the main gas supply shut-off valve upstream of the unit. 2. Refer to Figure 4.1 and CLOSE the following valves in the unit’s gas train: • RSI gas valve • RSI Bleed-off Valve • Manual shut-off valve to Air/Fuel Valve. 3. OPEN the main gas supply upstream of the unit. 4. Turn ON electrical power to the system. 5. Slowly OPEN the RSI Gas Valve. 6.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up 4.4 NATURAL GAS COMBUSTION CALIBRATION The Benchmark 2.0LN Boiler is combustion calibrated at the factory prior to shipping. However, recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 12. With the valve position at 100%, insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer reading to stabilize. 13. Compare the measured oxygen level to the oxygen range for the inlet air temperature shown in Table 4-1.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up 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 air/fuel valve positions of 80%, 60%, 45%, 30% and 16% as described in the following steps.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 31. The oxygen level at the 60% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Table 4-3: Combustion Oxygen Levels for a 60% Air/Fuel Valve Position Oxygen % ± 0.2 Carbon Monoxide NOx 5.7 % <50 ppm <30 ppm 32.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up 48. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level. 49.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E IMPORTANT The unit is shipped from the factory set up for either Natural Gas or Propane as specified by the Style No. on the Sales Order. Since the required gas pressures and oxygen (O2) levels for Propane differ from those required for Natural Gas, the Propane Combustion Calibration procedures are repeated in paragraph 4.5. 4.5 PROPANE COMBUSTION CALIBRATION The Benchmark 2.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up Table 4-7: Combustion Oxygen Levels for a 100% Valve Position Oxygen % NOx Carbon Monoxide ± 0.2 4.8 % <100 ppm <100 ppm 14. If necessary, adjust the iris air damper shown in Figure 4-4 until the oxygen level is within the range specified in Table 4-2. 15. Once the oxygen level is within the specified range at 100%, lower the valve position to 80%.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E NOTE The remaining steps basically repeat the procedures in steps 18 through 25 for valve positions of 60%, 45%, 30% and 16%. However, since oxygen levels vary, these steps are repeated in their entirety. When performing these steps, also ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown for each valve position. 26.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up 41. Once the oxygen level is within the specified range at 45%, press the ENTER key to store the selected blower output voltage for the 45% valve position. 42. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display. 43. Press the CHANGE key. SET Valve Position will begin to flash. 44.
Chapter 4 Initial Start-Up Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 4.6 UNIT REASSEMBLY Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation. 1. Set the ON/OFF switch in the OFF position. 2. Disconnect AC power from the unit. 3. Shut off the gas supply to the unit. 4. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound. 5.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 4 Initial Start-Up SEE DETAIL “A” FRONT VIEW ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH DETAIL “A” Figure 4-5: Over Temperature Limit Switch Locations PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E CHAPTER 5. Chapter 5 Mode of Operation MODE OF OPERATION 5.1 INTRODUCTION The 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 boiler is shipped from the factory tested and configured for the ordered mode of operation.
Chapter 5 Mode of Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data. 4. Once the design outdoor air temperature is chosen, go across the chart to the desired supply header temperature for the design temperature chosen in step 3. 5. Next, go up that column to the Reset Ratio row to find the corresponding reset ratio. 6.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 5 Mode of Operation 5.4 REMOTE SETPOINT MODES The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges: • 4-20 mA/1-5 Vdc • 0-20 mA/0-5 Vdc The factory default setting for the Remote Setpoint mode is 4 - 20 mA/1 - 5 Vdc.
Chapter 5 Mode of Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above. 5.4.2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled, no startup instructions are necessary.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 5 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.
Chapter 5 Mode of Operation Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Refer to paragraph 3.3 for instructions on changing menu options. 5.6.1 BMS External Field Wiring Wiring connections for BMS control using PWM signaling are made between connector JP2 on the BMS panel (boilers 1 through 8), and the B.M.S. (PWM) IN terminals in the I/O Box on the front of the boilers. Refer to the wiring diagram provided on the cover of the I/O Box.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Chapter 5 Mode of Operation to the BMS mode. For more information concerning the operation of the Combination Control Panel see the AERCO CCP-1 literature (BMS 168 applications) and TAG-0050 (ACS). 5.7.1 Combination Control System Field Wiring Wiring for this system is between the BMS Model 168 panel, the CCP and the B.M.S. (PWM) IN terminals in the I/O Box.
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GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual CHAPTER 6. Chapter 6 Safety Device Tests 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.
Chapter 6 Safety Device Tests Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E LOW GAS PRESSURE SWITCH SSOV HIGH GAS PRESSURE SWITCH GAS INLET 1/4” LEAK DETECTION VALVE (Shown Closed) TO AIR/FUEL VALVE 1/4” BALL VALVE (Shown Closed) 1/4” NPT PLUG (Install manometer here for LOW GAS PRESSURE TEST) 1/4” NPT PLUG (Install manometer here for HIGH GAS PRESSURE TEST) MANUAL SHUT-OFF VALVE (Shown Open) Figure 6-1: Low & High Gas Pressure Testing 7.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 6 Safety Device Tests 6.4 LOW WATER LEVEL FAULT TEST To simulate a low water level fault: 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.
Chapter 6 Safety Device Tests Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E SEE DETAIL “A” FRONT VIEW ADJUSTABLE TEMPERATURE LIMIT SWITCH RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH DETAIL “A” Figure 6-2: Temperature Limit Switch Setting 6. Once the adjustable over-temperature switch setting is approximately at, or just below, the actual outlet water temperature, the unit should shut down.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 6 Safety Device Tests 6.6.1 REMOTE INTERLOCK 1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals. 2. Start the unit in the Manual Mode and set the valve position between 25% and 30%. 3. If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the jumper.
Chapter 6 Safety Device Tests Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E (c) The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. 10. Since the manual gas shutoff valve is still closed, the unit will fail the ignition retry sequence. Therefore, it will shut down and display FLAME LOSS DURING IGNITION following the failed ignition retry cycle. 11. Open the valve previously closed in step 8. 12.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 6 Safety Device Tests 4. The unit should perform one IGNITION RETRY cycle and then shut down, since the blower is disabled. The unit will then display AIRFLOW FAULT DURING PURGE. 5. Re-enable the blower output drive voltage by performing the following steps: (a) Press the MENU key until CONFIGUR-ATION MENU is displayed.
Chapter 6 Safety Device Tests Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E SSOV ACTUATOR COVER ACTUATOR COVER SCREW Figure 6-4: SSOV Actuator Cover Location 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: 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.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 6 Safety Device Tests AIR/FUEL VALVE COVER (ROTATE CCW TO REMOVE) Figure 6-5: Air/Fuel Valve Cover Location STEPPER MOTOR DIAL TO BLOWER 170 IGNITION POSITION SWITCH 2 17 171 16 9 AIR IN PURGE POSITION SWITCH Figure 6-6: Air/Fuel Valve Purge and Ignition Switch Locations 6.
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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E CHAPTER 7. 7.1 Chapter 7 Maintenance MAINTENANCE 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. See Appendix I for a complete CSD-1 inspection check list.
Chapter 7 Maintenance Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 7.2 IGNITER-INJECTOR The igniter-injector (part no. 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.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual Chapter 7 Maintenance IMPORTANT Prior to removing the igniter-injector, note the position of the gas injector tube relative to the burner plate and blower. This is necessary to ensure that the igniter injector is reinstalled in the proper orientation when it is reconnected to the staged ignition assembly.
Chapter 7 Maintenance Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E BLOWER GAS INJECTOR TUBE IGNITORINJECTOR 0 12 BURNER PLATE Figure 7-3: Igniter-Injector Orientation 8. Reinstall the igniter-injector in the burner plate. Torque to 15 ft-lbs. Do not over tighten. 9. Connect the staged ignition assembly to the gas injector tube of the igniter-injector by securing the compression nut to the elbow of the staged ignition assembly. 10.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Chapter 7 Maintenance 7.4 COMBUSTION CALIBRATION & RSI REGULATOR ADJUSTMENT The Combustion Calibration settings and RSI Regulator adjustment must be checked at the intervals shown in Table 7-1 as part of the maintenance requirements. Refer to Chapter 4 for combustion calibration instructions. Refer to paragraph 7.4.1, below, for RSI regulator test and calibration instructions. 7.4.
Chapter 7 Maintenance Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E 7.4.1.2 RSI Regulator Calibration RSI regulator calibration is performed as follows: 1. Ensure that gas supply shut-off valve upstream of the unit is still turned OFF. 2. Turn OFF electrical power to the system. 3.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 7 Maintenance 18. Ensure power is restored and Boiler turned on in MANUAL Mode. 19. Open the Manual Shut-off Gas Valve (to the Air/Fuel Valve) and assure a smooth light off. Perform this test three times. 20. Leak test the RSI line after the first solenoid valve. 21. Refer to paragraph 4.4 in Chapter 4, Initial Start-up to perform the Combustion Calibration procedure. 22. Return the unit to service.
Chapter 7 Maintenance Part No. 81101 81048 81068 Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E Description Burner Gaskets (2) Flame Detector Gasket Blower Gasket To inspect or replace the burner assembly: 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 side and top panels from the unit. 3.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 7 Maintenance 8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench. 9. Disconnect the unit wiring harness connectors from the air/fuel valve and blower motor. 10. Disconnect the wire leads connected to the blower proof switch and blocked inlet switch (Figures 7-6). 11. Remove the 10-32 x 1/2" long grounding screw from the burner plate (Figures 7-4). 12.
Chapter 7 Maintenance Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E NOTE During reassembly, apply high-temperature, anti-seize lubricant to the threads of the igniter-injector and grounding screw. Also, ensure that the igniter-injector is properly positioned as indicated in Figure 7-3. Torque the igniter-injector to 15 ft-lbs. 19.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 7 Maintenance Figure 7-7: External Condensate Trap 7.8 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. 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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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Chapter 8 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 2.0LN Boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
Chapter 8 Troubleshooting GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION AIRFLOW FAULT DURING IGNITION Page 96 of 170 PROBABLE CAUSES CORRECTIVE ACTION 1. Blower stopped running due to thermal or current overload 1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices. 2. Blocked Blower inlet or inlet ductwork 2.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 8 Troubleshooting TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION AIRFLOW FAULT DURING PURGE PR1 08/20/12 PROBABLE CAUSES 1. Blower not running or running too slow CORRECTIVE ACTION 1. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage. If the relay is okay, check the blower. 2. Defective Air Flow Switch 2. Start the unit.
Chapter 8 Troubleshooting Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION AIRFLOW FAULT DURING RUN PROBABLE CAUSES 1. Blower stopped running due to thermal or current overload 1. Check combustion blower for signs of excessive heat or high current draw that may trip thermal or current overload devices. 2. Blocked Blower inlet or inlet ductwork 2.
GF-123 OMM-0046_0E FAULT INDICATION Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 8 Troubleshooting TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION DIRECT DRIVE SIGNAL FAULT 1. Direct drive signal is not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring. 2. Signal is not isolated (floating). 3.
Benchmark 2.0LN Low NOx Boiler Chapter 8 Troubleshooting Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION FLAME LOSS DURING IGN (continued) FLAME LOSS DURING RUN PROBABLE CAUSES 1. Unstable gas pressure. 2. Carbon or other debris on Burner. 3. Staged ignition solenoid valves don’t open. 4. Clogged staged ignition piece. 1. Worn Flame Detector or cracked ceramic. 2. Defective Regulator. 3.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 8 Troubleshooting TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION HIGH WATER TEMP SWITCH OPEN PROBABLE CAUSES 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.
Chapter 8 Troubleshooting FAULT INDICATION IGN SWTCH CLOSED DURING PURGE Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 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 Page 102 of 170 GF-123 OMM-0046_0E 1. Start the unit.
GF-123 OMM-0046_0E FAULT INDICATION INTERLOCK OPEN Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. Interlock jumper not installed or removed 1. Check for a jumper properly installed across the interlock terminals in the I/O box 2. Energy Management System does not have boiler enabled. 2.
FAULT INDICATION PRG SWTCH CLOSED DURING IGNITION (continued) PRG SWTCH OPEN DURING PURGE OUTDOOR TEMP SENSOR FAULT REMOTE SETPT SIGNAL FAULT Installation, Operation and Maintenance Manual OMM-0046_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 2. Defective or shorted switch. 2. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O. and COM terminals.
GF-123 OMM-0046_0E FAULT INDICATION RESIDUAL FLAME Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual TABLE 8-1. BOILER TROUBLESHOOTING (Continued) PROBABLE CAUSES CORRECTIVE ACTION 1. SSOV not fully closed. 2. Defective Flame Detector SSOV FAULT DURING PURGE Chapter 8 Troubleshooting 1. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.
Chapter 8 Troubleshooting Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES STEPPER MOTOR FAILURE 1. Air/Fuel Valve out of calibration. 2. Air/Fuel Valve unplugged. 3. Loose wiring connection to the stepper motor. Page 106 of 170 CORRECTIVE ACTION 1. Refer to GF-112 and perform Stepper Test (para. 6.3.
GF-123 OMM-0046_0E 8.2 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 8 Troubleshooting 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. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION Hard Light-Off 1. Staged Ignition Ball Valve closed. 2. Clogged/damaged Gas Injector (Figure 8-2). 3.
GF-123 Benchmark 2.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Chapter 8 Troubleshooting DAMPING ORIFICE SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT Figure 8-3: Damping Orifice Location PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E CHAPTER 9. Chapter 9 RS232 Comm. RS232 COMMUNICATION 9.1 INTRODUCTION The RS232 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.
Chapter 9 RS232 Comm. Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM- 0046_0E flow control), you can use the Serial Configuration panel (right image in Figure 9-1) by selecting “Serial” in the left navigation pane. 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.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Chapter 9 RS232 Comm. 6. You will have to provide an account name and password in the terminal window to complete the process. 9.
Chapter 9 RS232 Comm. Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM- 0046_0E 9. m0 m1 m2 m3 m4 m5 = = = = = = Default (Operating) Menu Setup Menu Configuration Menu Tuning Menu Calibration Menu Diagnostic Menu 10. To change a value or setting for a displayed menu option, proceed as follows: (a) Enter C, followed by the number to the right of the displayed option to be changed, and then press .
GF-123 Benchmark 2.0LN Low NOx Boiler Chapter 9 RS232 Comm. Installation, Operation and Maintenance Manual OMM-0046_0E means that no more than 30 minutes of data can be lost if the unit loses power. Table 9-2 shows a sample Operation Time Log for a boiler: The Operation Time Log can only be accessed through the RS232 interface using a laptop or other terminal device. Ten operation time records are displayed for each T command entry.
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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E APPENDIX A: Appendix A Menu Items MENU ITEM DESCRIPTIONS Table A-1: 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.
GF-123 Benchmark 2.0LN Low NOx Boiler Chapter 9 RS232 Comm. Installation, Operation and Maintenance Manual OMM-0046_0E Table A-1: 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 Permits selection of English, Spanish or French for displayed messages. Default is English.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Appendix A Menu Items Table A-1: Boiler Menu Item Descriptions-Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) 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.
GF-123 Benchmark 2.0LN Low NOx Boiler Chapter 9 RS232 Comm. Installation, Operation and Maintenance Manual OMM-0046_0E Table A-1: Boiler Menu Item Descriptions-Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH. Setting range is from 0 to 100.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Appendix A Menu Items Table A-1: Boiler Menu Item Descriptions-Continued MENU LEVEL & OPTION DESCRIPTION TUNING MENU 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%.
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GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Appendix D Reset Ratio Charts APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES Table B-1: Startup and Status Messages MESSAGE DESCRIPTION DEMAND DELAY XX sec Displayed if Demand Delay is active. DISABLED HH:MM pm, pm MM/DD/YY Displayed if ON/OFF switch is set to OFF. The display also shows the time (am or pm) and date that the unit was disabled.
GF-123 Benchmark 2.0LN Low NOx Boiler Appendix B Display Messages Installation, Operation and Maintenance Manual OMM-0046_0E Table B-2: Fault Messages FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT DURING PURGE The Blower Proof Switch opened during purge, or air inlet is blocked. AIRFLOW FAULT DURING IGN The Blower Proof Switch opened during ignition. AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run. DELAYED INTERLOCK OPEN The Delayed Interlock is open.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Appendix D Reset Ratio Charts Table B-2: Fault Messages (Continued) FAULT MESSAGE OUTDOOR TEMP SENSOR FAULT OUTLET TEMP SENSOR FAULT FAULT DESCRIPTION The temperature measured by the Outdoor Air Sensor is out of range.
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GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Appendix D Reset Ratio Charts APPENDIX C: SENSOR TEMPERATURE RESISTANCE TABLE C-1: Temperature Sensor Resistance Voltage Chart (Balco) PR1 08/20/12 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.
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GF-123 Benchmark 2.0LN Low NOx Boiler Appendix D Reset Ratio Charts Installation, Operation and Maintenance Manual OMM-0046_0E 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.
GF-123 Benchmark 2.0LN Low NOx Boiler Appendix D Reset Ratio Charts Installation, Operation and Maintenance Manual OMM-0046_0E 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.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E Appendix D Reset 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.
Appendix D Reset Ratio Charts GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E 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.
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Appendix E Default Settings Benchmark 2.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Appendix G Piping Drawings APPENDIX F: PART AND DIMENSIONAL DRAWINGS PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
210 240 Page 136 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 7.00 (17.8) 7-3/4 (19.7) 8" EXHAUST OUTLET 12-3/4 (32.4) 13-1/4 (33.7) 56 (142.2) 1-1/2" NPT DRAIN CONN. 23-1/2 (59.7) 7-1/2 (19.1) LIFTING LUGS 1-1/4 (3.2) 2-1/2 (6.4) CONDENSATE DRAIN PRESS./TEMP. GAUGE PRESS. RELIEF VA. 4" CONCRETE PAD -SET UNIT FLUSH AT REAR 15 (38.1) 4"-150# FLG'D COLD WATER INLET CONN. 2" NPT GAS INLET CONN. 3/4" NPT GAS VENT CONN.
GF-123 OMM-0046_0E PR1 08/20/12 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Page 138 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 PR1 08/20/12 *NOT TO SCALE* DRWN BY:SJD DATE:10/12/07 REV SD - A - 730 B Benchmark 2.0LN Low NOx Boiler 2) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS) INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 1.5 / 2.
GF-123 OMM-0046_0E PR1 08/20/12 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix G Piping Drawings Page 140 of 170 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
PR1 08/20/12 12 11 TORQUE TO 10 FT/LBS 12 26 19 11 14 27 25 17 31 32 33 APPLY HI-TEMP CONDUCTIVE ANTI-SIEZE PRIOR TO ASSY 30 TORQUE TO 170-180 IN/LBS 6 APPLY LOCTITE 242 24 7 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 INTERNATIONAL, INC. NORTHVALE, NJ 07647 DWN.BY SJD DATE8/4/09 SCALE SIZE CHKD. APPD. REV. DATE PL-A-159 BMK 2.0 LOW NOX BLOWER, BURNER & AIR/FUEL VALVE ACCESSORIES AERCO G REV.
Appendix G Piping Drawings Page 142 of 170 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E PR1 08/20/12 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix G Piping Drawings Page 144 of 170 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E PR1 08/20/12 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix G Piping Drawings Page 146 of 170 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E PR1 08/20/12 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix G Piping Drawings Page 148 of 170 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual APPENDIX G: PR1 08/20/12 Appendix G Piping Drawings PIPING DRAWINGS AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Page 150 of 170 1-1/2" NPT DRAIN CONN. SYSTEM PUMP * CONDENSATE DRAIN TRAP AIR SEPARATOR AUTOMATIC AIR VENT P&T RELIEF VALVE (TYP.) AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 HEATING SYSTEM RETURN DIRT TRAP PR1 08/20/12 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.
PR1 08/20/12 DRIP TRAP GAS SUPPLY * CONDENSATE DRAIN TRAP P&T AUTOMATIC AIR VENT AIR SEPARATOR 1-1/2" NPT DRAIN CONN. DIAPHRAGM TYPE EXPANSION TANK SYSTEM PUMP AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 ELECTRIC CONNECTIONS (SERVICE SWITCHES, CONDUIT BOXES) SHOULD LIKEWISE BE 6" AWAY FROM SIDE PANELS. Page 151 of 170 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE.
Page 152 of 170 * 2" MANUAL SHUTOFF VALVE DRIP TRAP GAS SUPPLY AUTOMATIC AIR VENT P&T AIR SEPARATOR * CONDENSATE DRAIN TRAP 1-1/2" NPT DRAIN CONN. SYSTEM PUMP P&T P&T RELIEF VALVE (TYP.) AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 PR1 08/20/12 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.
PR1 08/20/12 NOTES: DRIP TRAP GAS SUPPLY 1-1/2" NPT DRAIN CONN. P&T AUTOMATIC AIR VENT AIR SEPARATOR * CONDENSATE DRAIN TRAP SYSTEM PUMP P&T P&T AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913. ● Ph: 800-526-0288 Page 153 of 170 7) A GAS REGULATOR IS MANDATORY FOR THE STATE OF MASSACHUSETTS, REGARDLESS OF SUPPLY PRESSURE. SEE DIAGRAM 1 DOWNSTREAM OF THE 2" MANUAL SHUTOFF VALVE TO BRING THE GAS PRESSURE DOWN TO 2.0 PSIG. 6) WHEN AVAILABLE GAS PRESSURE IS GREATER THAN 2.
Appendix G Piping Drawings Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E (This page intentionally blank) Page 154 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual APPENDIX H: PR2: 08/20/12 Appendix H Wiring Schematics WIRING SCHEMATICS AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix H Wiring Schematics Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E (This page intentionally blank) Page 156 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 Benchmark 2.
Appendix H Wiring Schematics Benchmark 2.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Appendix G Wiring Schematics Installation, Operation and Maintenance Manual CONTROL BOX CONNECTORS 19-PIN CONNECTOR 4 3 135 138 192 140 1 16 15 14 13 12 11 10 9 WATER LEVEL PROBE 7 6 5 4 3 9 8 6 7 152 5 150 153 151 153 151 3 4 2 7 1 6 5 4 133 148 146 145 149 147 3 A STEPPING MOTOR 5K B 53 152 C SSOV 10K HIGH GAS PRESS. SW. LOW GAS PRESS. SW.
Appendix H Wiring Schematics Benchmark 2.
GF-123 Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0046_0E 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.
Appendix I Periodic Testing Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual GF-123 OMM-0046_0E (This page is intentionally blank) Page 162 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Appendix J Control Box APPENDIX J: BENCHMARK CONTROL PANEL FEATURES Figure J-1: Control Panel Exploded View PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E SHELL HARNESS CONNECTOR (19 PIN) P3 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) BOX SENSOR HARNESS CONNECTOR (7 PIN) P1 A/F VALVE HARNESS CONNECTOR (16 PIN) P2 GAS TRAIN HARNESS CONNECTOR (9 PIN) P5 INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) BOX P6 Benchmark 2.0LN Low NOx Boiler P4 Appendix J Control Box Figure J-2: Control Panel Rear Panel Page 164 of 170 AERCO International Inc.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Appendix J Control Box Installation, Operation and Maintenance Manual APPENDIX K: RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and optional spare parts listed in the following Tables.
Appendix K Spare Parts Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E (This page is intentionally blank) Page 166 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
GF-123 OMM-0046_0E Benchmark 2.0LN Low NOx Boiler Installation, Operation and Maintenance Manual Appendix J Control Box STANDARD WARRANTY: BENCHMARK GAS-FIRED HYDRONIC BOILER PRESSURE VESSEL/HEAT EXCHANGER: 10 YEARS FROM SHIPMENT The pressure vessel/heat exchanger shall carry a 10-year non-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.
Appendix K Spare Parts Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E (Continued) AERCO shall accept no responsibility if such item has been improperly installed, operated, or maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the item. The use of replacement parts not manufactured or sold by AERCO will void any warranty, express or limited.
GF-123 Benchmark 2.0LN Low NOx Boiler OMM-0046_0E Installation, Operation and Maintenance Manual (This page is intentionally blank) PR1 08/20/12 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
Appendix K Spare Parts Benchmark 2.0LN Low NOx Boiler GF-123 Installation, Operation and Maintenance Manual OMM-0046_0E © AERCO International, Inc., 2011 Page 170 of 170 AERCO International Inc.● 100 Oritani Dr. ● Blauvelt, NY 10913.
