Instruction No. GF-120 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions Benchmark 1.5LN Series Gas Fired Low NOx Boiler System Condensing, Modulating Forced Draft, Hot Water Boiler 1,500,000 BTU/H Input Printed in U.S.A.
Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday): 1-800-526-0288 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-120 - AERCO BENCHMARK 1.5LN GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWARD A Chapter 1 – SAFETY PRECAUTIONS Para. 1-1 1-2 Subject Warnings & Cautions Emergency Shutdown Page 1-1 1-2 1-1 Para. 1-3 Subject Prolonged Shutdown Chapter 2 – INSTALLATION Para. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 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 1.5LN 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 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. In addition to all the requirements included in this AERCO 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 1.3 PROLONGED 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. After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the safety device test procedures in Chapter 6 of this manual be performed, to verify all systemoperating parameters.
INSTALLATION CHAPTER 2 INSTALLATION 2.1 INTRODUCTION • Pressure/Temperature Gauge This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 1.5 Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5. • Spare Spark Igniter 2.
INSTALLATION Figure 2-1 Benchmark 1.5 Boiler Clearances WARNING KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS. BLOWER CAUTION While packaged in the shipping container, the boiler must be moved by pallet jack or forklift from the FRONT ONLY. 2.4.2 Setting the Unit The unit must be installed on a 4 inch to 6 inch housekeeping pad to ensure proper condensate drainage.
INSTALLATION If installing a Combination Control Panel (CCP) system, it is important to identify the Combination Mode Boilers in advance and place them in the proper physical location. Refer to Chapter 5 for information on Combination Mode Boilers. 2.5 SUPPLY AND RETURN PIPING The Benchmark 1.5 Boiler utilizes 3” 150# flanges for the water system supply and return piping connections. The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-3.
INSTALLATION A suitable piping compound, approved for use with natural gas, should be used. Any excess must be wiped off to prevent clogging of components. To avoid unit damage when pressure testing gas piping, isolate the unit from the gas supply piping. At no time should the gas pressure applied to the unit exceed 2 psi. Leak test all external piping thoroughly using a soap and water solution or suitable equivalent. The gas piping used must meet all applicable codes. 2.7.1 Gas Supply Specifications.
INSTALLATION 2.7.3 IRI Gas Train Kit 2.8.1 Electrical Power Requirements 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-830 for details. The AERCO Benchmark 1.5 Boiler accepts 120 VAC, single-phase, 60 Hz @ 20 A. The Power Box contains a terminal block as shown in Figure 2-8.
INSTALLATION To access the I/O Box terminal strips shown in Figure 2-10, loosen the four cover screws and remove the cover. All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided. Refer to the wiring diagram provided on the cover of the I/O Box (Figure 2-10) when making all wiring connections.
INSTALLATION 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 2.9.9.1 and 2.9.10). 2.9.2 Indoor/Outdoor Reset Mode This mode of operation increases supply water temperature as outdoor temperatures decrease.
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. 2.10.
INSTALLATION 2.10.9.1 REMOTE INTERLOCK IN 2.12 FLUE GAS VENT INSTALLATION 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. The minimum allowable vent diameter for a single Benchmark 1.5 Boiler is 6 inches. 2.10.9.
INSTALLATION The AERCO Benchmark 1.5 Boiler is UL listed for 100% sealed combustion. It can also be installed using room air, provided there is an adequate supply. (See paragraph 2.13.3 for more information concerning sealed combustion air). If the sealed combustion air option is not being used, an inlet screen will be attached at the air inlet on the top of the unit The more common methods of supplying combustion air are outlined below.
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 1.5 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 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.
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 32. 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 displayed items. Since this menu is “Read-Only”, it can be viewed at any time without entering a password. Pressing the ▲ arrow key to display the menu items in the order listed (Top-Down). Pressing the ▼ arrow key will display the menu items in reverse order (Bottom-Up). 3.
CONTROL PANEL OPERATING PROCEDURES 3.6 CONFIGURATION MENU NOTE 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 Table 3-4. Configuration Menu - Continued Available Choices or Limits Minimum Maximum Default Shutdown or Constant Setpt Shutdown *mA Output (See CAUTION) Setpoint, Outlet Temp, Fire Rate Out, Off *Fire Rate Out Low Fire Timer 2 sec. Menu Item Display Failsafe Mode 120 sec. Setpt Limiting Enabled or Disabled Setpt Limit Band 0°F 10°F 2 sec. Disabled 5°F *CAUTION: DO NOT CHANGE mA Output Menu Item from its Default setting. 3.
CONTROL PANEL OPERATING PROCEDURES DIAL (DETAIL “A”) STEPPER MOTOR 3. With all required safety device switches closed, a purge cycle will be initiated and the following events will occur: (a) The Blower relay energizes and turns on blower. 100 Figure 3-3. SSOV Locations DETAIL “A” Figure 3-4. Air/Fuel Valve In Purge Position (b) The Air/Fuel Valve rotates to the fullopen purge position and closes purge position switch.
CONTROL PANEL OPERATING PROCEDURES 8. With the unit firing properly, it will be controlled by the temperature controller circuitry. The boiler’s FIRE RATE will be continuously displayed on the front panel bargraph. 3.9 START/STOP LEVELS Once the demand for heat has been satisfied, the Control Box will turn off the dual SSOV gas valves. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will be displayed.
CONTROL PANEL OPERATING PROCEDURES Table 3-6. Relationship Between Air/Fuel Valve Position and Energy Input For Unit Running On Natural Gas 3-10 Fire Rate, Air/Fuel Valve Position (% Open) Energy Input (BTU/Hr) Boiler Energy Input (% of Full Capacity) 0% 0 0 10% 0 0 16 % (Stop Level) 75,000 5.
INITIAL START-UP CHAPTER 4 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 1.5 Boiler consists of the following: • • • • • Complete installation Perform combustion calibration Set proper controls and limits Set up mode of operation (see Chapter 5) Test safety devices (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 5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch W.C. manometer. 4.3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark 1.5LN 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.
INITIAL START-UP AIR/FUEL VALVE AIR INLET A A IRIS AIR DAMPER FRONT Figure 4-3 Regulator Adjustment Screw Location 11. Raise the firing rate to 100% and verify that the gas pressure downstream of the SSOV remains at 3” W.C. Readjust pressure if necessary. 12. With the firing rate at 100%, insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer to settle. 13.
INITIAL START-UP 22. Once the oxygen level is within the specified range at 80%, lower the firing rate to 60% and select VFD parameter 64. The oxygen level at the 60% firing rate should be as shown below. Combustion Oxygen Level at 60% Firing Rate Oxygen % ± 0.2 6.3 % Figure 4-5 VFD Controls and Displays 17. Press the M (Menu) programming key on the VFD. 18. Using the up (▲) arrow key, select VFD parameter 65.
INITIAL START-UP Combustion Oxygen Level at 16% Firing Rate Oxygen % ± 0.2 8.0 % Carbon Monoxide <50 ppm NOx <30 ppm 29. Adjust the oxygen level as necessary to obtain the required reading at the 16% firing rate. 30. This completes the Natural Gas combustion calibration procedures. 4.4 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.
MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION The Benchmark 1.5 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 Benchmark 1.5 Boiler 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 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 Benchmark 1.5LN control system comprehensively monitors all combustion-related safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed. 4. Place the unit in Manual Mode and adjust the firing rate between 25 and 30%. 5.
SAFETY DEVICE TESTING 6.3 HIGH GAS PRESSURE TEST shut the unit off immediately and refer fault to qualified service personnel. To simulate a high gas pressure fault, refer to Figure 6-1 and proceed as follows: 7. Close the drain and pressure relief valve used in draining the unit. 1. Remove the 1/8“ plug from the leak detection ball valve shown in Figure 6-1. 8. Open the water shut-off valve in the return piping to the unit. 2. Install a 0 – 16” W.C. manometer (or W.C.
SAFETY DEVICE TESTING 6.6 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-9) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumpered (closed).
SAFETY DEVICE TESTING 6. Press the CLEAR button to reset the fault 7. The unit should start. 6.7 FLAME FAULT TESTS Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: 1. Set the ON/OFF switch to the OFF position. 2. Place the unit in the Manual Mode and set the firing rate between 25% and 30%. 3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV) and the Air/Fuel Valve (see Figure 6-3).
SAFETY DEVICE TESTING 8. Set the ON/OFF switch to ON to start the unit. 6.11 IGNITION SWITCH OPEN DURING IGNITION 9. Remove the wire again when the unit reaches the purge cycle and PURGING is displayed. The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: 10. The unit should shut down and display SSOV FAULT DURING PURGE. 11. Replace the wire on the SSOV and press the CLEAR button. The unit should restart. 1.
2 17 16 9 SAFETY DEVICE TESTING Figure 6-6 Air/Fuel Valve Purge and Ignition Switch Locations 6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.
MAINTENANCE CHAPTER 7 MAINTENANCE 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. See Appendix I for a complete CSD-1 inspection check list. 5. The igniter is gapped at 1/8-inch. If there is a substantial erosion of the spark gap or ground electrode, the igniter should be replaced.
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 Calibration 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 Traps Inspect *Inspect Inspect & Clean 2 hrs. 1 hr. * Only performed after initial 6 month period after initial startup.
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 CSD-1, 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 log book. See Chapter 6-Safety Device Testing Procedures. 8.
MAINTENANCE 7.7 CONDENSATE DRAIN TRAP The Benchmark 1.5 Boiler contains a condensate trap as shown in Figure 2-5. The trap is located external to the unit and attached to the drain pipe from the exhaust manifold. This traps should be inspected and, if necessary, cleaned to ensure proper operation. To inspect and clean the trap, proceed as follows: 7.
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 1.5 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. The numbered items in the Probable Cause and Corrective Action columns correspond to each other.
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 AIRFLOW FAULT DURING PURGE 1. Blower not running or running too slow 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. Start the unit. If the blower runs, check the airflow switch for continuity. Replace the switch if there is no continuity. 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) FLAME LOSS DURING RUN PROBABLE CAUSES 7. Carbon or other debris on Burner. 8. Staged ignition ball valve closed. 7. Remove the burner and inspect for any carbon or debris. Clean and reinstall. 8. Open ball valve downstream of SSOV (see Figure 8-1). 1. Worn Flame Detector or cracked ceramic. 1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary. 2.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION continued 3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity. 4. See Figure 8-1. Ensure that the gas pressure snubber is installed at the high gas pressure switch. 1.
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 8-7 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 PRG SWTCH OPEN DURING PURGE PROBABLE CAUSES 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. 3. Incorrect Sensor. REMOTE SETPT SIGNAL FAULT RESIDUAL FLAME CORRECTIVE ACTION 1.
TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION (continued) SSOV FAULT DURING PURGE SSOV FAULT DURING RUN SSOV RELAY FAILURE SSOV SWITCH OPEN PROBABLE CAUSES 2. Defective Flame Detector 3. 1. SSOV switch closed for 15 seconds during run. 1. Replace or adjust microswitch in SSOV actuator. If fault persists, replace actuator. 1. SSOV relay failed on board. 1. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board. 1.
TROUBLESHOOTING 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 8-2. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT Hard Light-Off Fluctuating Gas Pressure Air/Fuel Valve “hunting” at 80% Firing Rate 8-11 PROBABLE CAUSES 1. Staged Ignition Ball Valve closed. 2. Clogged/damaged Gas Injector (Figure 8-2). 3.
TROUBLESHOOTING Figure 8-2 Staged Ignition Solenoid Location Figure 8-1 High Pressure Gas Switch & Snubber Locations Figure 8-3 Damping Orifice Location 8-12
TROUBLESHOOTING Table 8-3 BMK 1.5 LN (3.3 KΩ) Temperature Sensor and Temperature Transmitter Outputs TEMP ºC TEMP ºF UA33 Resistance Ohm Volts outputs UA33 TEMP ºC TEMP ºF UA33 Resistance Ohm Volts outputs UA33 -40 -30 -20 -10 -5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 -40 -22 -4 14 23 32 33.8 35.6 37.4 39.2 41 42.8 44.6 46.4 48.2 50 51.8 53.6 55.4 57.2 59 60.8 62.6 64.4 66.2 68 69.8 71.6 73.4 75.2 77 78.8 80.
APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu. When in the Remote Setpoint Mode, this value is the setpoint equivalent to the remote analog signal supplied to the unit.
APPENDIX A 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 Permits selection of English, Spanish or French for displayed messages. Default is English. Time Displays time from 12:00 am to 11:59 pm.
APPENDIX A 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, this menu item allows the system start temperature to be set from 30 to 100°F. Default is 60°F.
APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION 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. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%. If the error is equal to or greater than the proportional band setting, the fire rate will be 100%.
APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. 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.
APPENDIX B TABLE B-2.
APPENDIX B TABLE B-2. 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) TEMPERATURE SENSOR AERCO PART NO. 123449 R = RESISTANCE (OHMS) T = TEMPERATURE (°F) R=.00161T^2+1.961T+854.841 TEMP (°F) RES. (OHMS) -40 779.0 -30 797.5 -20 816.3 -10 835.4 0 854.8 10 874.6 20 894.7 30 915.1 40 935.9 50 956.9 60 978.3 70 1000.0 80 1022.0 90 1044.4 100 1067.0 110 1090.0 120 1113.3 130 1137.0 140 1160.9 150 1185.2 160 1209.5 170 1234.7 180 1260.0 190 1285.6 200 1311.4 210 1337.7 220 1364.2 230 1391.0 240 1418.2 250 1445.
APPENDIX D APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1. 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 Table D-3. 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 Table D-5. 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 Table D-7. 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 1.5 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
F-2 NOTES: 1) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF 2) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS) THE FRAME FRONT INTERNATIONAL, INC. NORTHVALE, NJ 07647 *NOT TO SCALE* DRWN BY:SJD DATE:10/12/07 REV SD - A - 730 A BENCHMARK 1.
APPENDIX F F-3
F-4 79" 18" 1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING 2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS: LEFT & RIGHT SIDES: 24" FRONT: 24" REAR: 42" * CEILING HIEGHT: 101" INSTALLATION CLEARANCES: 44.5" SIDE VIEW 101" 24" FRONT 24" INTERNATIONAL, INC. NORTHVALE, NJ 07647 *NOT TO SCALE* DRWN BY:SJD DATE:10/12/07 REV SD - A - 731 A BENCHMARK 1.
ENTIRE BMK1.5 LN FM GAS TRAIN P/N: 22039-1 LOW GAS PRESS SWITCH P/N: 61002-1 1/8" NPT PLUG (INSTALL MANOMETER HERE) HIGH GAS PRESS SWITCH P/N: 61002-12 1.5" - SCH.40 PIPE 1.5" SAFETY SHUT-OFF VALVE P/N: 124150 SAFETY SHUT-OFF VALVE ACTUATOR W/REGULATOR P/N 64048 NORTHVALE, NJ 07647 INTERNATIONAL, INC. *NOT TO SCALE* DRWN BY:SJD DATE:12/18/07 AP - A - 829 B REV BENCHMARK 1.5 LOW NOx FM GAS TRAIN AERCO TEST COCK TO AIR-FUEL VALVE ASSY FULL PORT BALL VALVE 1.
F-6 1.5" DOUBLE BODY SSOV CONNECTING FLANGE P/N: 124178 SAFETY SHUT OFF VALVE ACTUATOR WITHOUT PROOF OF CLOSURE SWITCH P/N: 69038 NORMALLY OPEN VENT VALVE P/N: 122774 3/4" SCH.40 PIPE 1.5" SCH.40 PIPE ENTIRE BMK 1.5 LN IRI GAS TRAIN P/N: 22039-2 1.5" DOUBLE BODY SSOV P/N: 124137 SAFETY SHUT-OFF VALVE ACTUATOR W/ REGULATOR P/N: 64048 HIGH GAS PRESSURE SWITCH P/N: 61002-12 *NOT TO SCALE* DRWN BY:SJD DATE:10/11/07 AP - A - 830 B REV BENCHMARK 1.
8 APPLY HI TEMP CONDUCTIVE ANTI-SIEZE PRIOR TO ASSY 2 4 3 1 7 5 22 6 14 11 17 17 20 21 15 16 10 19 18 9 1 2 4 3 5 6 7 8 9 10 11 24 13 14 15 16 17 18 19 20 21 22 23 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 6 6 4 1 42048 81063 46015 81063 81064 24111 59072 122435-s 24113 66006 42049 24010-2 81057 88004 81047 81048 54016 122377 54015 54027 122544 54028 88003 ITEM NO. QTY PART NUMBER 13 DESCRIPTION 23 *DRAWING NOT TO SCALE* DRWN.
APPENDIX F HOSES,GASKETS, & INSULATION ITEM PART NO. QTY DESCRIPTION 22 88003 1 O-RING #2-339 (A/F VALVE) 23 59041 1 HOSE ASSEMBLY, 4" 24 88004 1 O-RING #2-244 BUNA - N (BLOWER) 25 62005 1 CORD GRIP 26 EXHAUST MANIFOLD ITEM PART NO. QTY DESCRIPTION 43045 84020 EXHAUST MANIFOLD EXHAUST MANIFOLD SEAL 1 2 3 1 1 GAS TRAIN ASSEMBLY ITEM PART NO.
APPENDIX F OTHER DUAL FUEL COMPONENTS CONTROLS ITEM PART NO. QTY DESCRIPTION ITEM PART NO. QTY DESCRIPTION 27 123966 1 OVER TEMP SWITCH AUTO (1)(4) 56 72031 1 "PROPANE" LABEL 28 123552 1 OVER TEMP SWITCH MANUAL (1)(4) 57 72032 1 "NAT.
APPENDIX F 7 45 51 23 35 5 20 4 18 DETAIL A 17 A 15 19 10 11 12 AERCO 1 INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 1.
16 APPENDIX F 25 46 44 B 47 24 21 14 22 6 30 29 54 8 48 AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 1.
APPENDIX F 42 28 27 35 32 C 75 31 37 41 34 DETAIL C 48 74 47 61 AERCO NORTHVALE, NJ 07647 BENCHMARK 1.5 LOW NOx BOILER PARTS LIST 59 FUEL SELECTOR SWITCH (DUAL FUEL ONLY) INTERNATIONAL, INC.
APPENDIX F 66 67 68 64 65 AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 1.
APPENDIX F 71 73 69 72 70 AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 1.
APPENDIX G G-1
G-2 NOTES: 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.) 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 2.0 PSIG.
APPENDIX G G-3
APPENDIX G G-4
APPENDIX G G-5
H-1 BLOCKED AIR INLET SW. BLOWER PROOF SW. 142 FLAME ROD WATER LEVEL PROBE 351 321 IGNITOR GND 352 IGNITION POSITION SWITCH PURGE POSITION SWITCH WHT YEL BLK BLU GRN RED 142 205 LOW GAS PRESS. SW. HIGH GAS PRESS. SW.
H-2 J1 1 231 1 2 232 2 3 233 3 4 5 6 237 7 7 236 6 235 5 234 4 8 238 8 240 241 242 243 244 245 246 1 247 3 4 251 5 252 6 253 7 254 8 INPUT/OUTPUT BOX 2 250 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 239 9 10 11 12 24-PIN CONNECTOR J3 226 LS3 LS4 J2 1 2 4 220 LS2 3 221 LS1 5 219 6 8 7 216 7 6 8 215 5 9 213 3 212 2 211 1 SHEET 68014 2 OF 2 DWG. NO.: A REV INTERNATIONAL INC. 159 PARIS AVE, NORTHVALE, N.J.
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 BENCHMARK CONTROL PANEL EXPLODED VIEW J-1
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: 7 YEARS FROM SHIPMENT The pressure vessel/heat exchanger shall carry a (7) seven year non-prorated 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. 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. In order to process a warranty claim a formal purchase order number is required prior to shipment of any warranty item.
