Aerco BMK 750P, BMK 750, BMK 1500DF, BMK 1000P, BMK 1500P User Manual

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

GF-206

Natural Gas:

APPLIES TO MODELS:

Applies to Serial Numbers:

G-17-2400 and above.

USER MANUAL

SEE ALSO: Benchmark

750, 1000, 1500, 2000, 2500, and 3000 MBH Boilers

Propane:

BMK 2000P

(2 of 2)

OPERATION, SERVICE and MAINTENANCE GUIDE

Natural Gas, Propane Gas, or Dual Fuel Fired Modulating, Condensing Boilers

Installation and Startup Guide,

Dual-Fuel (NG/P):

• BMK 750

• BMK 1000

• BMK 1500

• BMK 2000

• BMK 2500

• BMK 3000

• BMK 750P

• BMK 1000P

• BMK 1500P

•

• BMK 1500DF

• BMK 2000DF

• BMK 2500DF

• BMK 3000DF

• BMK 2500P

• BMK 3000P

Latest Update: 11/29/2017

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

CONTENTS

TABLE OF CONTENTS

FOREWORD ...................................................................................................... 5

SECTION 1: SAFETY PRECAUTIONS ................................................................... 9

1.1 WARNINGS & CAUTIONS ..................................................................................................................... 9

1.2 EMERGENC Y SHUT D OWN ................................................................................................................. 10

1.3 PROLONGED SHUTDOWN ................................................................................................................. 10

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ............................................................... 11

SECTION 2: OPERATION ................................................................................. 13

2.1 INTRODUCTION ................................................................................................................................... 13

2.2 C-MORE CONTROLLER DESCRIPTION ............................................................................................ 14

2.3 C-MORE CONTROLLER MENUS ........................................................................................................ 17

2.3.1 Menu Navigation and Processing Procedure .................................................................................................. 17

2.4 OPERATING MENU ............................................................................................................................. 19

2.5 SETUP MENU ....................................................................................................................................... 20

2.6 CONFIGURATION MENU .................................................................................................................... 21

2.7 TUNING MENU ..................................................................................................................................... 23

2.8 COMBUSTION CAL MENU .................................................................................................................. 23

2.8.1 BMK 750/1000 COMBUSTION CAL Menu ....................................................................................................... 23

2.8.2 BMK 1500/2000 COMBUSTION CAL Menus ................................................................................................... 24

2.8.3 BMK 2500/3000 COMBUSTION CAL Menus ................................................................................................... 25

2.9 BST (BOILER SEQUENCING TECHNOLOGY) MENU ....................................................................... 26

2.10 CALIBRATION MENU......................................................................................................................... 29

SECTION 3: MODES OF OPERATION ............................................................... 31

3.1 INTRODUCTION ................................................................................................................................... 31

3.2 INDOOR/OUTDOOR RESET MODE ................................................................................................... 31

3.2.1 Reset Ratio ...................................................................................................................................................... 31

3.2.2 Building Reference Temperature .................................................................................................................... 31

3.2.3 Outdoor Air Temperature Sensor Installation ................................................................................................ 31

3.2.4 Indoor/Outdoor Startup ................................................................................................................................. 32

3.3 CONSTANT SETPOINT MODE ........................................................................................................... 32

3.3.1 Setting the Setpoint ........................................................................................................................................ 33

3.4 REMOTE SETPOINT MODES ............................................................................................................. 33

3.4.1 Remote Setpoint Field Wiring ......................................................................................................................... 34

3.4.2 Remote Setpoint Startup ................................................................................................................................ 34

3.5 DIRECT DRIVE MODES....................................................................................................................... 34

3.5.1 Direct Drive Field Wiring ................................................................................................................................. 35

3.5.2 Direct Drive Startup ........................................................................................................................................ 35

3.6 AERCO CONTROL SYSTEM (ACS) .................................................................................................... 36

3.6.1 ACS External Field Wiring................................................................................................................................ 36

3.6.2 ACS Setup and Startup .................................................................................................................................... 36

3.7 COMBINATION CONTROL SYSTEM (CCS) ....................................................................................... 37

3.7.1 Combination Control System Field Wiring ...................................................................................................... 38

3.7.2 Combination Control System Setup and Startup ............................................................................................ 38

SECTION 4: MAINTENANCE ............................................................................ 39

4.1 MAINTENANCE SCHEDULE ............................................................................................................... 39

4.2 IGNITER-INJECTOR ............................................................................................................................ 40

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CONTENTS

4.3 FLAME DETECTOR ............................................................................................................................. 45

4.4 O2 SENSOR .......................................................................................................................................... 45

4.5 SAFETY DEVICE TESTING ................................................................................................................. 46

4.6 BURNER INSPECTION ........................................................................................................................ 46

4.6.1 BMK 750/1000 BURNER INSPECTION ............................................................................................................. 47

4.6.2 BMK 1500 – 3000 BURNER INSPECTION ......................................................................................................... 49

4.7 CONDENSATE DRAIN TRAP .............................................................................................................. 53

4.8 AIR FILTER CLEANING AND REPLACEMENT .................................................................................. 54

4.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST ............................................................... 55

4.9.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test ........................................................................... 56

4.9.2 Low Water Cutoff (LWCO) - Standard C-More Test ........................................................................................ 57

4.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD ................................................................... 57

4.11 PLACING THE BO IL E R BACK IN SER VI C E AF TER A PRO LO N G ED SHUTDOWN ....................... 57

4.12 SPARK MONITOR (AC CURRENT TRANSDUCER) ......................................................................... 58

SECTION 5: TROUBLESHOOTING GUIDE ......................................................... 59

5.1 INTRODUCTION ................................................................................................................................... 59

5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES .................................................... 71

APPENDIX A: BOILER MENU ITEM DESCRIPTIONS ............................................. 73

TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS ......................................................................... 73

TABLE A-2: SETUP MENU ITEM DESCRIPTIONS ................................................................................... 75

TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS ................................................................ 76

TABLE A-4: TUNING MENU ITEM DESCRIPTIONS ................................................................................. 79

TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS ............................................. 80

TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS ....................................................................... 81

APPENDIX B: STARTUP, STATUS, & FAULT MESSAGES ...................................... 85

TABLE B-1: STARTUP AND STATUS MESSAGES .................................................................................. 85

TABLE B-2: FAULT MESSAGES ............................................................................................................... 86

APPENDIX C: SENSOR RESISTANCE/VOLTAGE CHART ........................................ 89

APPENDIX D: RECOMMENDED PERIODIC TESTING ............................................ 91

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS .................................. 93

APPENDIX F: BENCHMARK 750/1000 PART LIST ............................................... 97

APPENDIX G: BENCHMARK 1500/2000 PART LIST ........................................... 107

APPENDIX H: BENCHMARK 2500/3000 PART LIST ........................................... 123

APPENDIX I: WIRING DIAGRAMS ................................................................... 145

APPENDIX J: C-MORE CONTROLLER VIEWS .................................................... 161

APPENDIX K: RECOMMENDED SPARES ........................................................... 163

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CONTENTS

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FORWARD

FOREWORD

The AERCO Benchmark (BMK) 750, 1000, 1500, 2000, 2500, and 3000 natural gas and propane fueled boilers are modulating and condensing units. They represent 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. These BMK models provide extremely high efficiency operation and are ideally suited f or modern low temperature, as well as, conventional heating systems.

The Benchmark models operate within the following input and output ranges:

IMPORTANT!

Unless otherwise specified, all measurements apply to both natural gas and propane models.

Benchmark Boiler Intake and Output Ranges

INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.)

MODEL

MINIMUM MAXIMUM MINIMUM MAXIMUM

BMK 750 50,000 (14.6 kW) 750,000 (220 kW) 47,750 (14 kW) 716,250 (210 kW)

BMK 1000 50,000 (14.6 kW) 1,000,000 (293 kW) 48,300 (14.15 kW) 968,000 (284 kW)

BMK 1500 75,000 (22 kW) 1,500,000 (440 kW) 64,500 (18.9 kW) 1,395,000 (409 kW)

BMK 2000 100,000 (29.3 kW) 2,000,000 (586 kW) 86,000 (25.2 kW) 1,860,000 (545 kW)

BMK 2500 167,000 (48.9 kW) 2,500,000 (732 kW) 144,000 (42.2 kW) 2,395,000 (702 kW)

BMK 3000 200,000 (58.6 kW) 3,000,000 (879 kW) 174,000 (51.0 kW) 2,874,000 (842 kW)

The output of the boiler is a function of the unit’s firing rate (valve position) and return water temperature.

When installed and operated in accordance with this Instruction Manual, these boilers comply with the NO

(SCAQMD), Rule 1146.2. In addition, the BMK 750 & 1000 comply with the Bay Area Air Quality Management District regulation 9, Rule 7.

Whether used in singular or modular arrangements, the BMK boilers offer the maximum venting flexibility with minimum installation space requirements. These boilers are Categ ory II and IV, positive pressure appliances. Single and/or multiple breeched units are capable of operation in the following vent configurations:

• Room Combustion Air:

• Ducted Combustion Air:

emission standards outlined in: South Coast Air Quality Management District

o Vertical Discharge o Horizontal Discharge

These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems. The Benchmark's advanced electronics are available in several selectable modes of operation

offering the most efficient operating methods and energy management system integration.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

A (Amp)

Ampere

(see below)

British Thermal Unit. A unit of energy approximately equal to the BTU/HR

BTUs p er Hour

CCP

Combination Control Panel

CCS

Combination Control System

system developed by AERCO and currently used in all

Double Block and Bleed, a gas trains containing 2 Safety Shutoff

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

ACS AERCO Control System, AERCO’s boiler management systems ADDR Address AGND Anal og Ground ALRM Alarm ANSI American National Standards Institute, ASME American Society of Mechanical Engineers AUX Auxiliary

BAS

Building Automation System, often used interchangeably with EMS

Symbol rate, or simply the number of distinct symbol changes

Baud Rate

(signaling events) transmitted per second. It is not equal to bits per

second, unless each symbol is 1 bit long. BMK (Benchmark) AERCO’s Benchmark series boilers BMS or BMS II AERCO Boiler Management Systems

BLDG (Bldg) Building BST AERCO on-board Boiler Sequencing Technology

BTU

C-More Controller CFH Cubic Feet per Hour (1 CFH = 0.028 m

heat required to raise 1 pound (0.45 kg) of water 1°F (0.55 °C)

(1 BTU/hr = 0.29 W)

A control

Benchmark, Innovation and KC1000 Series product lines.

/hr)

CO Carbon Monoxide COMM (Comm) Communication Cal. Calibration CNTL Control CPU Central Processing Unit

DBB

Valves (SSOVs) and a solenoid operated vent valve. DIP Dual In-Line Package, a type of switch

ECU Electronic Control Unit (O2 sensor) EMS Energy Management System; often used interchangeably with BAS FM Factor y Mutual. Used to define boiler gas trains. GF-xxxx Gas Fired (an AERCO document numbering system) GND Ground

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

HDR

Header

MBH

1000 BTUs per Hour

duplex data transmission protocol developed by AEG

POC

Proof of Clos ure

PPM

Parts per Million

PSI

Pounds per Square Inch (1 PSI = 6.89 kPa)

PTP

Point-to-Point (usually over RS232 networks)

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

Hex Hexadecimal Number (0 – 9, A – F) HP Horse Power HX Heat Exchanger Hz Hertz (Cycles Per Second) I.D. Inside Diameter IGN Ignition IGST Board Ignition/Stepper Board, contained in the C-More Controller INTLK (INTL’K) Interlock I/O Input/Output

I/O Box

Input/Output (I/O) Box currently used on Benchmark, Innovation and

KC1000 Series products IP Internet Protocol ISO International Organization for Standardization Lbs. Pounds (1 lb = 0.45 kg) LED Light Emitting Diode LN Low Nitrogen Oxide MA (mA) Milliampere (1 thousandth of an ampere) MAX (Max) Maximum

MIN (Min) Minimum Modbus®

A serial, half-

Modicon NC (N.C.) Normally Closed NO (N.O.) Normally Open NOx Nitrogen Oxide NPT National Pipe Thread O2 Oxygen O.D. Outside Diameter OMM & O&M Oper ation and Maintenance Manual onAER

AERCO’s on-line remote monitoring system PCB Printed Circuit Board PMC Board Primary Micro-Controller (PMC) board, contained in the C-More P/N Part Number

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

P&T

Pressure and Temperature

(or EIA-232)

duplex (FDX) transmission of data based

on the RS232 Standard

duplex (FDX) transmission of data based

(or EIA-485)

on the RS485 Standard

data in the

FORWARD

AERCO Technical Terminology Meanings

TERMINOLOGY MEANING

ProtoNode Hardware interface between BAS and a boiler or water heater PVC Poly Vinyl Chloride, a common synthetic plastic PWM Pulse Width Modulation REF (Ref) Reference RES. Resistive RS232

RS422 (or EIA-422)

RS485

A standard for serial, full-

on the RS422 Standard

A standard for serial, half-duplex (HDX) transmission of data based

RTN (Rtn) Return SETPT (Setpt) Setpoint Temperature SHLD (Shld) Shield SPDT Single Pole Double Throw, a type of switch SSOV Safety Shut Off Valve TEMP (Temp) Temperature

A resistor placed at each end of a daisy-chain or multi-drop network Terminating Resistor

in order to prevent reflections that may cause invalid

communication Tip-N-Tell A device that indicates if a package was tipped during shipping UL A business that tests and validates products VAC Volts, Alternating Current VDC Volts, Direct Current VFD Vacuum Fluor escent Display, also Variable Frequency Drive W Watt W.C. Water Column, a unit of pressure (1 W.C. = 249 Pa) µA Micro amp (1 millionth of an ampere)

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SECTION 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 Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

See section 1.4 for important information regarding installation of units within the Commonwealth of Massachusetts.

IMPORTANT!

This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.

WARNING!

• Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.

• 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.

• Before attempting to perform any maintenance on the unit, shut off all gas and electrical

inputs to the unit.

• The exhaust vent pipe of the unit operates under a positive pressure and therefore must be

completely sealed to prevent leakage of combustion products into living spaces.

• Electrical voltages up to 120 VAC may be used in this equipment. Therefore the cover on

the unit’s power box (located behind the front panel door) must be installed at all times, except during maintenance and servicing.

• A three-pole switch must be installed on the electrical supply line of the unit. The switch

must be installed in an easily accessible position to quickly and safely disconnect electrical service. Do not affix switch to unit sheet metal enclosures.

CAUTION!

• Many soaps used for gas pipe leak testing are corrosive to metals. The piping must be

rinsed thoroughly with clean water after leak checks have been completed.

• DO NOT use this boiler if any part has been under water. Call a qualified service technician

to inspect and replace any part that has been under water.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

VALVE

CLOSED

SECTION 1: SAFETY PRECAUTIONS

1.2 EMERGENCY SHUTDOWN

If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit.

NOTE:

The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

MANUAL GAS SHUT-OFF VALVE

VALVE

OPEN

Figure 1-1: Manual Gas Shutoff Valve

1.3 PROLONGED SHUTDOWN

After prolonged shutdown, it is recommended that the startup procedures and safety device test procedures, described in Section 4 and 5, respectively of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) be performed to verify all system-operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Requirements For Massachusetts Installations

Boiler Installations within the Commonwealth of Massachusetts must conform to the

l side wall horizontally vented gas fueled equipment installed in every dwelling,

monoxide detector with an alarm is installed on each additional level of the dwelling,

be the responsibility of the property owner to secure the services of qualified licensed

the above requirements; provided, however, that during said thirty (30) day period, a

Each carbon monoxide detector as

accordance with the above provisions shall comply with NFPA 720 and be

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)

SECTION 1: SAFETY PRECAUTIONS

1.4 IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS

following requirements:

• Boiler must be installed by a plumber or a gas fitter who is licensed within the

Commonwealth of Massachusetts.

• Prior to unit operation, the complete gas train and all connections must be leak

tested using a non-corrosive soap.

• The vent termination must be located a minimum of 4 feet above grade level. If

side-wall venting is used, the installation must conform to the following requirements extracted from 248 CMR 5.08 (2):

(a) For al building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon

building or structure served by the side wall horizontal vented gas fueled equipment. It shall

professionals for the installation of hard wired carbon monoxide detectors.

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. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with

battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS: required in

ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Requirements For Massachusetts Installations

observes carbon monoxide detectors and signage installed in accordance with the

venting system design or venting system components with the equipment, the instructions

When the manufacturer of a Product Approved side wall horizontally vented gas fueled

stems" shall be Product Approved by the Board, and the

SECTION 1: SAFETY PRECAUTIONS

4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector

provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a

provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting sy instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………

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SECTION 2: OPERATION

2.1 INTRODUCTION

The information in this section provides a guide to the operation of the Benchmark Boiler using the C-More Controller mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel. Operation prior to initial startup by factory trained personnel may void the equipment warranty. In addition, the following W AR NINGS and CAUTIONS must be observed at all times.

WARNING!

• ELECTRICAL VO LTAGES IN THIS SYSTEM INCLUDE 120 VAC (BMK 750 – 2000) and

208 or 460 VAC (BMK 2500/3000) and 24 volts AC. It must be serviced only by factory

certified service technicians.

• DO NOT ATTEMPT TO DRY FIRE THE UNIT. Starting the unit without a full water level

can seriously damage the unit and may result in injury to personnel or property damage. This situation will void any warranty.

CAUTION!

All of the installation procedures in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) must b e completed before attempti ng to start the unit.

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SECTION 2: OPERATION

2.2 C-MORE CONTROLLER DESCRIPTION

All Benchmark boilers utilize the C-More Controller shown in Figure 2-1. This panel contains all of the controls, indicators and displays necessary to operate, adjust and troubleshoot the boiler. These operating controls, indicators and displays are listed and described in Table 2-1. Additional information on these items is provided in the individual operating procedures and menu descriptions provided in this section.

Figure 2-1: C-More Controller Front View

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Segment LED display continuously displays the outlet

blinks when operating in the

On a BST Manager, display flashes & shows header temperature.

of displaying up to 16 alphanumeric characters. The information

trained personnel to monitor

communications, in combination with the RS232 Adaptor

LED indicator lights when a boiler alarm condition

be cleared by simply pressing this key. Troubleshooting

conditions have been satisfied.

opens the water level probe circuit and

SECTION 2: OPERATION

TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)

ITEM

CONTROL, INDICATOR

or DISPLAY

COMM =

MANUAL =

REMOTE =

DEMAND =

OUTLET TEMPERATURE

Display

Four Status LEDs indicate the current operating status as follows:

Lights when RS232 communication is occurring – see Item 4. Lights when the valve position (fire rate) is being controlled using the front

panel keypad. This mode of operation is for service technician use only. Lights when the unit is being controlled by an external signal from an Energy

Management System. Lights when there is a demand for heat.

FUNCTION

LED STATUS INDICATORS

3–Digit, 7– water temperature. The °F or °C LED next to the display lights to indicate whether the displayed temperature is in degrees Fahrenheit or degrees Celsius. The °F or °C DEADBAND mode.

Vacuum Fluorescent Display (VFD) consists of 2 lines each capable displayed includes:

VFD Display

RS232 Port

FAULT Indicator

CLEAR Key

READY Indicator ON/OFF switch

LOW WAT ER LEVEL

TEST/RESET

switches

• Startup Messages

• Fault Messages

• Operating Status Messages

• Menu Selection

• BST Messages

This port is used only by factoryonAER Cable (P/N 124675).

Red FAULT occurs. An alarm message will appear in the VFD.

Turns off the FAULT indicator and clears the alarm message if the alarm is no longer valid. Lockout type alarms will be latched and cannot may be required to clear these types of alarms.

Lights when ON/OFF switch is set to ON and when all Pre-Purge

Enables and disables boiler operation.

• Allows operator to test operation of the water level monitor.

• Pressing TEST

simulates a Low Water Level alarm.

• Pressing RESET resets the water level monitor circuit.

• Pressing the CLEAR key (item 6) resets the display.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Six (6) keys which provide the following functions for the C-More Controller menus:

Allows you to go back to the previous menu level without changing any information. Continuously pressing this key will bring you back to the

the top of a main menu category.

arrow key will

key is

ement the

Saves the modified menu settings in memory. The display will stop

SECTION 2: OPERATION

TABLE 2-1: Controls, Indicators, And Displays (ref. Figure 2-1)

ITEM

CONTROL, INDICATOR

or DISPLAY

BACK

▲

(UP)

Arrow

▼

(DOWN)

Arrow

Steps through the main menu categories shown in Figure 2-2. T he menu categories wrap around in the order shown.

default status display in the VFD. Also, this key allows you to go back to

When in one of the main menu categories (Figure 2-2), pressing the ▲ arrow key will select the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, pressing the ▲ increment the selected setting.

When in one of the main menu categories (Figure 2-2), pressing this key will select the displayed menu category. If the CHANGE k ey was pressed and the menu item is flashing, pressing the ▼ arrow key will decrement the selected setting.

FUNCTION

MENU KEYPAD

Permits a setting to be changed (edited). When the CHANGE

CHANGE

pressed, the displayed menu item will begin to flash. Pressing the ▲ or ▼ arrow key when the item is flashing will increment or decr displayed setting.

ENTER

AUTO/MAN switch

VALVE POSITION

Bargraph

flashing.

This switch toggles the boiler between the AUTOMATIC and MANUAL modes of operation. When in the MANUAL (MAN) mode, the front panel controls are enabled and the MANUAL status LED lights. Manual operation is for service only.

When in the AUTOMATIC (AUTO) mode, the MANUAL status LED will be off and the front panel controls disabled.

20 segment red LED bargraph continuously shows the Air/Fuel Valve position in 5% increments from 0 to 100%

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Menu Navigation and Processing Proce dure Instructions

menu, which is the next menu

in the

Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.

SECTION 2: OPERATION

2.3 C-MORE CONTROLLER MENUS

The C-More Controller incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual. These categories are shown in Figure 2-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by password levels to prevent unauthorized use.

Prior to entering the correct password, the options contained in the Operation, Setup, Configuration and Tuning menu categories can be viewed. However, with the exception of Internal Setpoint Temperature (Configuration menu), none of the viewable menu options can be changed.

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 (6817), which is used in initial startup (see Section 4: Initial Startup of the Benchmark 750 – 3000 I nstallation and Startup Guide, OMM-0121 (GF-205)), to perform combustion calibration prior to service use.

2.3.1 Menu Navigation and Processing Procedure

Accessing and initiating each menu and option is accomplished using the menu keys shown in Figure 2-1. Therefore, it is imperative that you be thoroughly familiar with the following basic steps before attempting to perform specific menu procedures:

1. The C-More Controller will normally be in the Operating menu and the VFD will display the

current unit status. Pressing the ▲ or ▼ arrow key will display the other available data

items in the Operating menu.

2. Press the MENU key. The display will show the Setup

category shown in Figure 2-2. This menu contains the Password option which must be entered if other menu options will be changed.

3. Continue pressing the MENU key until the desired menu is displayed.

4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option

selected menu will be displayed.

Pressing the ▲ arrow key will display the available menu options in the Top-Down sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.

The menu options will wrap-around after the first or last available option is reached.

6. To change the value or setting of a displayed menu option, press the CHANGE key. The

displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the available menu option choices for the option to be changed. The menu option choices do not wrap around.

7. To select and store a changed menu item, press the ENTER key.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 2: OPERATION

* Only if BST is enabled. BST is described in detail in Section 6 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

NOTE:

The following sections provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option. Refer to Appendix B for a list and descriptions of startup, status and error messages.

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Figure 2-2: Menu Structure

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-2: OPERATING Menu

Minimum

Maximum

30°F (-1.1°C)

240°F (115.6°C)

SECTION 2: OPERATION

2.4 OPERATING Menu

The Operating menu displays a number of key operating parameters for the unit. All items in this menu except O2 Monitor (item 15) are “Read-Only” and cannot be changed. T his menu can be accessed without entering a password.

A full description of each item appears in Appendix A-1.

MENU ITEM DISPLAY

Active Setpoint

Outlet Temp

Inlet Temp

Air Temp

Outdoor Temp

Valve Position In 0% 100%

Valve Position Out 0% 100% Configuration Menu

FFWD Temp

Exhaust Temp Displays current exhaust temperature

Flame Strength 0% 100%

Min Flame Str Not Used

O2 Monitor Enable Disable O2 Monitor = Enabled

Oxygen Level 0% 21%

Ignition Time 0.00 10.00

AVAILABLE CHOICES OR LIMIT

40°F (4.4°C) 240°F (116°C) 30°F (-1.1°C) 240°F (116°C) 30°F (-1.1°C) 240°F (116°C)

-70°F (-56.7°C) 245°F (118°C)

-70°F (-56.7°C) 130°F (54.4°C)

Appears Only If

Enabled in:

Configuration Menu

SSOV Time to OPN 0.00 10.00

Spark Current

Run Cycles 0 999,999,999

Run Hours 0 999,999,999

Fault Log 0 19

An additional parameter associated with the Operating menu, (Min = 0, Max = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Controller’s front face.

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0 amps 2.5 amps

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-3: SETUP Menu

Language

English

Time

12:00 am

11:59 pm

12:00

Unit of Temp

Fahrenheit or Celsius

Fahrenheit

Baud Rate

2400, 4800, 9600, 19.2K

9600

SECTION 2: OPERATION

2.5 SETUP Menu

The Setup menu permits the operator to enter the unit password (159) which is required to change the menu options. To prevent unauthorized use, the password will time-out after 1 hour. Therefore, the correct password must be reentered when required. In addition to permitting password entries, the Setup menu is also used to enter date and time, and units of temperature measurements. A view-only software version display is also provided to indicate the current CMore Controller software version.

A full description of each item appears in Appendix A-2.

MENU ITEM DISPLAY

AVAILABLE CHOICES OR LIMIT

Minimum Maximum

Password 0 9999 0

Date 01/01/00 12/31/99 01/01/00

Comm Address 0 127 0

onAER Mode Et hernet or SD Card Ethernet

Min Upload Timer 0 9,999 Sec 0

Unit Alpha E, G, H, R, N or A A

Unit Year 0 99 0

Unit Serial # 0 9999 0

Software Ver 0.00 Ver 9.99

Current software

DEFAULT

version

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

SECTION 2: OPERATION

2.6 CONFIGURATION Menu

The Configuration menu 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. This menu contains a number of other configuration settings which may or may not be displayed, depending on the current operating mode setting.

A full description of each item appears in Appendix A-3.

NOTE:

The Configuration menu set tings are Factory-Set in accordance with the requirements specified for each individual order. Under normal operating conditions, no changes will be required.

TABLE 2-4: CONFIGURATION Menu

MENU ITEM DISPLAY

Internal Setpt

Unit Type

Unit Size

(Only displays sizes available for the unit)

Fuel Type

Boiler Mode

Remote Signal (If Mode = Remote

Setpoint, Direct Drive or Combination)

40°F (4.4°C) 240°F (115.6°C)

BMK Blr Std, BMK Blr Std Dual,

BMK Blr LN, BMK Blr LN Dual

750 MBH (220 kW), 1000 MBH (293

kW), 1500 MBH (439.6 kW), 2000 MBH

(586.1 kW), 2500 MBH (732.6 kW), 3000

MBH (879.2 kW)

Natural Gas or Propane

Constant Setpoint, Remote Setpoint,

Direct Drive, Combination,

Outdoor Reset

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (Legacy BMS), Network

DEFAULT

130°F (54.4°

BMK Boiler LN

750 MBH (220 kW),

Natural Gas in

standard and dual fuel

models, Propane in

propane only models

Constant Setpoint

4 – 20 mA,

1-5V

Outdoor Sensor * Bldg Ref Temp

(If Mode = Outdoor Reset)

* Reset Ratio

(If Mode = Outdoor Reset)

* System Start Tmp

(If Outdoor Sensor = Enabled)

Setpt Lo Limit

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Enabled or Disabled Disabled

40°F

(4.4°C)

0.1 9.9 1.2

30°F

(-1.1°C)

40°F (4.4°C) Setpt Hi Limit 60°F (15.6°C)

230°F

(110°C)

100°F

(37.8°C)

70°F

(21.1°C)

60°F

(15.6°C)

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

(Do NOT change)

SECTION 2: OPERATION

TABLE 2-4: CONFIGURATION Menu

MENU ITEM DISPLAY

Setpt Hi Limit

Temp Hi Limit 40°F (4.4°

Max Valve Position

Pump Delay Timer

Aux Start On Dly

Failsafe Mode

17 18

Analog Output Low Fire Timer

Setpt Limiting

Setpt Limit Band

Network Timeout Shutoff Dly Temp 0°F (0°C) 25°F (13.75°C) 10°F (5.5°C)

Demand Offset

Deadband High

Setpt Lo Limit 210°F (98.9°C) 180°F (82.2°C)

C) 210°F (98.9°C) 195°F (90.6°C)

40% 100% 100% 0 min. 30 min. 0 min. 0 sec. 120 sec. 0 sec.

Shutdown or Constant Setpt Constant Setpt

Off, Setpoint, Outlet Temp, Valve Pos 4-

Valve Pos 0-10v

20mA, valve Pos 0-10v

2 sec. 600 sec. 2 sec.

Enabled or Disabled Disabled

0°F (0°C) 10°F (5.5°C) 5°F (2.75°C)

5 sec. 999 sec. 30 sec.

0°F (0°C) 25°F (13.75°C) 10°F (5.5°C) 0°F (0°C) 25°F (13.75°C) 5°F (2.75°C)

DEFAULT

Deadband Low

26 27

IGST Version

IGN Time Setting Displays 4 sec. or 7 sec. depending on wiring harness installed

Slow Shutdown Enabled or Disabled Disabled

Slow Sht Duration 0 sec. 9,999 sec. 60 sec. Slow Sht Threshold 40% 100% 60

O2 Warnings Enabled or Disabled Disabled

O2 Trim ID Displays 4 digit AERtrim ID

Fixed ID Displays unit’s fixed 4 dig it ID

O2 Trim Key Displays AERtrim 4 digit licens e key

O2 Trim Menu Enabled or Disabled Disabled

36 37

BST Menu Enabled or Disabled Disabled

0°F (0°C) 25°F (13.75°C) 5°F (2.75°C)

Displays current IGST version

V2.02

*NOTE

The Bldg Ref Temp and Reset Ratio menu Items are only displayed when the Outdoor Sensor, item # 7 is set to Enabled.

CAUTION!

DO NOT change the Analog Output menu item from its default setting (Valve Position 0-10V).

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-5: TUNING Menu

Prop Band

TABLE 2-6: COMBUSTION CAL Menu: BMK 750/1000

Natural gas

Propane

0.25

10.00

0.25

10.00

0.25

10.00

0.25

10.00

0.25

10.00

0.25

10.00

SECTION 2: OPERATION

2.7 TUNING Menu

The Tuning menu items are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by factory-trained personnel.

A full description of each item appears in Appendix A-4.

MENU ITEM DISPLAY MINIMUM MAXIMUM DEFAULT

1°F (0.55°C) 120°F (66°C) 70°F (38.5°C)

Integral Gain 0.00 2.00 1.00

Derivative Time 0.0 min 2.00 min 0.0min

Warmup Prop Band

1°F (0.55°C) 120°F (66°C) 95 °F (52°C) Warmup Int Gain 0.00 2.00 0.50 Warmup PID timer 0 sec. 240 sec. 20 sec. Reset Defaults? Yes, No, Are You Sure? No

2.8 COMBUSTION CAL Menu

The Com bustion Cal (Calibration) menu is protected by the level 2 password (6817) which must be entered to view or change the menu items shown in Table 2-6, 2-7 and 2-8. These menu items are used to vary the speed of the unit’s blower motor based on air temperature and air density at prescribed Air/Fuel Valve positions (% open). This is accomplished by providing a DC drive voltage to the motor, which then adjusts the rotational speed of the blower to maximize combustion efficiency and ensure the unit conforms to the Nitrogen Oxide (NO Monoxide (CO) emissions specified in the combustion calibration instructions in Section 4.4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

CAL Voltage values are factory adjusted for each unit prior to shipping, and so may differ from the defaults shown in the tables below. A full description of each item appears in Appendix A-5.

2.8.1 BMK 750/1000 COMBUSTION CAL Menu

) and Carbon

MENU ITEM DISPLAY

CAL Voltage 18% CAL Voltage 30% CAL Voltage 45% CAL Voltage 60% CAL Voltage 80% CAL Voltage 100% SET Valve Position 0% 100% 0% 0% Blower Output Monitor Blower Output Voltage 0.00 0.00 Set Stdby Volt 0 V 10.0 V 2.00 2.00 Oxygen Level 0% 25% 0.0 0.0

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MINIMUM MAXIMUM

DEFAULT

2.10 2.10

2.55 2.55

3.10 3.10

3.50 3.50

4.60 4.60

5.60 5.60

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SET Valve Position

100%

Variable

TABLE 2-7b: COMBUSTION CAL Menu: BMK 1500/2000

0.25

10.00

– – 1.20

2.10

0.25

10.00

2.60

4.50

2.30

3.50

0.25

10.00

3.20

4.50

2.80

3.90

0.25

10.00

4.10

4.80

3.50

4.10

0.25

10.00

8.30

9.80

7.70

8.90

10.0

2.00

Displays current value

SECTION 2: OPERATION

2.8.2 BMK 1500/2000 COMBUSTION CAL Menus

TABLE 2-7a: COMBUSTION CAL Menu: BMK 1500/2000 SINGLE FUEL – NATURAL GAS

MENU ITEM DISPLAY MINIMUM MAXIMUM

CAL Voltage 16%

CAL Voltage 18% – 1.40

CAL Voltage 30%

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100%

Blower Output Displays current value

Set Stdby Volt 0 10.00 V 2.00 V 2.00 V

Oxygen Level Displays current value

0.25 10.00

0.25 10.00 2.30 3.80

0.25 10.00 2.50 4.30

0.25 10.00 2.90 5.40

0.25 10.00 3.80 6.40

0.25 10.00 7.90 9.50

DUAL FUEL

DEFAULT

BMK 1500 BMK 2000

1.80 –

DEFAULT

MENU ITEM DISPLAY

CAL Voltage: 16%

CAL Voltage: 18%

CAL Voltage 30% CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100%

SET Valve Position

Blower Output

Set Stdby Volt Oxygen Level

MINIMUM MAXIMUM

0.25 10.00 1.50

0.25 10.00 3.30 4.50 3.00 4.10

0 100 Variable

NATURAL GAS *

BMK 1500 BMK 2000 BMK 1500 BMK 2000

2.10

Displays current value

PROPANE

– –

* The default values for Natural Gas on Dual Fuel units are different than the default values for

Natural Gas on Single Fuel units. These values do NOT apply to single fuel units.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-8a: COMBUSTION CAL Menu: BMK 2500/3000

SINGLE FUEL – NATURAL GAS

DEFAULT

BMK 2500

BMK 3000

TABLE 2-8b: COMBUSTION CAL Menu: BMK 2500/3000 DUAL FUEL

0.25

10.00

–

16%

0.25

10.00

–

0.25

10.00

2.10 – –

–

0.25

10.00 – –

2.00

–

0.25

10.00

5.40

3.30

4.40

0.25

10.00

–

7.00

–

5.70

0.25

10.00

6.60

–

5.60

–

0.25

10.00

8.00

–

7.00

0.25

10.00

8.70

7.90

8.60

100

Variable

10.0

2.00

Displays current value

SECTION 2: OPERATION

2.8.3 BMK 2500/3000 COMBUSTION CAL Menus

MENU ITEM DISPLAY MINIMUM MAXIMUM

CAL Voltage 16%

CAL Voltage 14% – 2.80

CAL Voltage 30%

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100%

SET Valve Position 0% 100% Variable

Blower Output Displays current value

Set Stdby Volt 0 10.00 V 2.00 V 2.00 V

Oxygen Level Displays current value

0.25 10.00

0.25 10.00 4.10 4.60

0.25 10.00 4.80 5.00

0.25 10.00 5.30 5.50

0.25 10.00 6.80 6.90

0.25 10.00 8.50 9.10

2.20 –

DEFAULT

MENU ITEM DISPLAY

CAL Voltage: 14% CAL Voltage:

CAL Voltage: 18% CAL Voltage: 20% CAL Voltage: 22%

CAL Voltage 30%

CAL Voltage 45%

CAL Voltage 65% CAL Voltage 70%

CAL Voltage 75% CAL Voltage 85%

CAL Voltage 100% SET Valve Position

Blower Output

Set Stdby Volt

Oxygen Level

MINIMUM MAXIMUM

0.25 10.00 –

0.25 10.00

NATURAL GAS

BMK 2500 BMK 3000 BMK 2500 BMK 3000

2.40

2.15

3.90

5.60

– –

8.50

Displays current value

– –

6.60 4.60 5.40

– – –

* The default values for Natural Gas on Dual Fuel units are different than the default values for

Natural Gas on Single Fuel units. These values shown DO NOT APPLY to single fuel units.

PROPANE

2.00 2.30

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

BST Mode

*BST SETUP MENU*

Disabled

Enabled

Disabled

Remote

Setpoint

Outdoor

Reset

0-20 mA/0-5

VDC

SECTION 2: OPERATION

2.9 BST (Boiler Sequencing Technology) Menu

The BST menu must be enabled in order to be displayed and accessed. The BST Menu item, located at the end of the Configuration menu (item 37 in Table 2-4), must be set to Enabled.

The BST menu contains all of the items required to configure, operate and monitor the functionality of the BST System. There are over 50 items in this menu, and selecting any particular item from the list, for inspection or modification, could be time consuming. As a result, the BST menu has been segmented into FIVE logical groups based on functionality.

The five Item groups are:

1. BST Monitor Items

2. *BST SETUP MENU*

3. *OPERATE MENU*

4. * TEMP CTRL MENU*

5. * BST COMM MENU*

These displayed item groups are displayed in UPPER CASE letters, and are bounded by an asterisk * in order to readily identify them within the item list.

The Items contained in group 1 (BST Monitor Items) are always displayed within the menu, as these items are critical for proper system operation. Therefore, the BST Monitor Items Header itself is not displayed.

The Items contained in groups 2-5 are not displayed unless that particular item g roup has been enabled from the C-More keypad.

MENU ITEM DISPLAY

BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130°F (54.4°C)

Header Temp Read Only – current Header temperature in °F N/A

BST Fire Rate 0 100% Fire rate %

BST Ave Fire Rate 0 100% Avg Fire Rate %

BST Outdoor Temp Read Only – current outdoor temperature in °F N/A

Units Available 0 8 Units Present

Units Ignited 0 8 Units firing BST Valve State 0 (CLOSED) 1 (OPEN) 0

1 BST Comm Errors 8 0 9 0

1 BST Units 8 0 – 8 (see * NOTE below) 0

Minimum Maximum

Off BST Client BST Manager Off

DEFAULT

BST Setpoint Mode

BST Remote Signl 4-20 mA/1-5 VDC

Head Temp Source Network FFWD Temp FFWD Temp

Mdbus Temp Units Degrees C or Degrees F Degrees C

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Constant Setpoint

Constant Setpt

Network Network

Page 27

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

Yes

feature.

On-Outlet

Temp

*OPERATE MENU*

*TEMP CTRL MENU*

SECTION 2: OPERATION

MENU ITEM DISPLAY

DEFAULT

Minimum Maximum

Header Temp Addr 0 255 240

Header Temp Point 0 255 14 BST Outdoor Sens Disabled Enabled Disabled

Outdr Tmp Source Outdoor Temp Network Outdoor Temp

Outdoor Tmp Addr 0 255 240

Outdoor Tmp Pnt 0 255 215

NOTE! A Modbus

BST Auto Mstr No

BST Auto Timer 10 sec 120 sec 30 sec

temperature transmitter must be installed in conjunction with this

Remote Intlk Use Boiler Shutdown System Shutdown System Shutdown

One Boiler Mode Off

1 Blr Threshold 10 35 25

On-Avg Temp Off

Setpoint Setback Disable Enable Disable

Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130°F (54.4°C)

Setback Start 12:00am 11:59pm 12.00am

Setback End 12:00am 11:59pm 12.00am Rate Threshold 1°F (0.55°C) 30°F (16.5°C) 15°F (8.25°C)

33 34 35

37 38 39

41 42 43

45 46 47

49 50

Disabled Enabled Disabled BST Next On VP 16% 100% 50% BST Max Boilers 1 8 8 BST On Delay 30 sec 300 sec 60 sec BST On Timeout 15 sec 300 sec 60 Sec Valve Override Off Closed Open Off Valve Off Delay 0 15 min 1 min BST Sequencing Run Hours Unit Size Select Lead Run Hours Select Lead Unit 0 127 0 Select Lag Unit 0 127 0 Lead/Lag Hours 25 hours 225 hours 72 hours

Disabled Enabled Disabled BST Temp Hi Limit 40°F (4.4°C) 210°F (98.9°C) 210°F (98.9°C) BST Setpt Lo Limit 40°F (4.4°C) BST Setpt HI Limit 60°F (15.5°C) BST Setpt HI Limit BST Setpt Lo Limit 220°F (104.4°C) 195°F (90.6°C) BST Prop Band 1°F (-17.2°C) 120°F (48.9°C) 100°F (37.8°C) BST Intgral Gain 0.00 2.00 0.50 BST Deriv Time 0.00 Min 2.00 Min 0.10 Min

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-9: BST Menu

AVAILABLE CHOICES OR LIMIT

*BST COMM MENU*

SECTION 2: OPERATION

MENU ITEM DISPLAY

BST Deadband Hi 0 25 1

BST Deadband Lo 0 25 1 Deadband En Time 0 120 Sec 30 Sec

BST FR Up Rate 1 120 20

BST Bldg Ref Tmp 40°F (4.4°C) 230°F (110°C) 70°F (21.1°C)

BST Reset Ratio 0.1 9.9 1.2 System Start Tmp 30°F (-1.1°C) 120°F (48.9°C) 60°F (15.6°C)

58 59

Comm Address 0 127 0

BST Min Addr 1 128 1 BST Max Addr 1 128 8

SSD Address 0 250 247

SSD Poll Control 0 1000 0

Err Threshold 1 9 5 SSD Temp Format Degrees Points Degrees

BST Upld Timer 0 9999 sec 0

Minimum Maximum

Disabled Enabled Disabled

DEFAULT

* NOTE:

The 1 BST Units 8

menu item shows the current status for each unit controlled by BST, up to

a maximum of 8 units. The possible characters displayed are:

- = Off Line * = Not Available (fault, etc.) 0 = Off 1 = On, A = Lead On a = Lead Off B = Lag On b = Lag Off S = Setpoint Limit Active

The following example shows the status of 5 units being controlled by BST where:

Unit 1 & 3 are On Unit 2 is Off Unit 4 is Not Available Unit 5 is Lead On Unit 6 is Lag Off

1 BST Units 8

1 0 1 * A b

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-10: CALIBRATION Menu

Minimum

Maximum

SECTION 2: OPERATION

2.10 CALIBRATION MENU

The Calibration menu is used by factory trained service personnel to adjust or reset the parameters listed below.

A full description of each item appears in Appendix A-6.

MENU ITEM DISPLAY

Stepper Fbk Cal 0%, Verify 50%, Cal 100% Cal 0 %

Purge Timer 5 sec. 60 sec Depends on unit type/size

Post Purge Timer 0 sec. 60 sec. 0 sec.

IGN Position 5% 60% Depends on unit type/size

Ign Pos Hold Tmr 0 sec. 60 sec. 0 sec.

FFWD Temp Disply Enabled or Disabled

Outlet Tmp Dsply Enabled or Disabled

Inlet Tmp Dsply Enabled or Disabled

Valv Pos Out Dsp Enabled or Disabled

Exhaust Tmp Dsp Enabled or Disabled

Exhaust Safety Enabled or Disabled

Flue Material PVC,CPVC; PolyPro; Stainless PVC,CPVC

Exhst Fault Temp 100 °F 500 °F 200 °F

Exhst Module Temp 100 °F 500 °F 190 °F

DEFAULT

Disabled Disabled Disabled

Enabled

Disabled

Enabled

AVAILABLE CHOICES OR LIMIT

Exhst Warn Temp 100 °F 500 °F 180 °F

Exhst Tmp VP Adj 0 10 5

Exhst Adj Rate 1 600 30

VP Change Rate 5 600 25

VP Up Rate 0.5 60.0 Depends on unit type/size

VP Down Rate 0.5 60.0 Depends on unit type/size

Purge Blwr Offst -1.0 8.0 Depends on unit type/size

4-20mA Purge Pct 60% 100% 70%

PWM In Adj -5.0% 5.0% 0.0%

Analog In Adj

Flow In Adj

Supply Gas Pressure In Adj

Gas Plate dp In Adj -5.0% 5.0% 0.0%

mA Out Adj -1.0 mA 1.0 mA 0.0 mA

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-5.0% 5.0% 0.0%

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 2-10: CALIBRATION Menu

AVAILABLE CHOICES OR LIMIT

Minimum

Maximum

SECTION 2: OPERATION

MENU ITEM DISPLAY

A/F Sensitivity 1% 5% 2%

Power Reset Automatic or Manual Automatic

Water Temp Reset Automatic or Manual Automatic

Gas Press Reset Automatic or Manual Manual

Min Off Time 0 Min 15 Min 1 Min

Heatr Tuning Dsp Enabled or Disabled Disabled

Heatr Bkpt Dsp Enabled or Disabled Disabled

Stop Level 0% Start Level 16

Start Level Stop Level 40% 22

Skip Range Cntr 10 95 40

Skip Range Span 0 3 0%

Skip Speed 0.5 2.0 0.5%

O2 Gain 0.500 1.500 1.000

O2 Offset -24.0 +2.0 1.0

DEFAULT

O2 Sensor Enabled or Disabled Depends on unit type/size

Cal Temp Sensors

FFWD Temp Offset -20 +20 0

Exhst Tmp Offset -20 +20 0

Outdr Air Offset -20 +20 0

Inlet Air Offset -20 +20 0

Inlet Wtr Offset -20 +20 0

Outlet Wtr Offset -20 +20 0

24 hr Max Cycles 0 9999 0

24 hr Max Ovrtemp 0 9999 0

0-10v Out Test 0.0 10.0 0.00

Spark Monitor Enabled or Disabled Depends on unit type/size

Min Spark Amps 0.0 Amps 2.5 Amps 0.10 Amps

Max Spark Amps 0.0 Amps 2.5 Amps 0.40 Amps

Off or Start Off

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 3 – MODES OF OPERATION

SECTION 3: MODES OF OPERATION

3.1 INTRODUCTION

The boiler is capable of being operated in any one of six different modes. The following sections provide descriptions of each of these operating modes. Each 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. However, it may be necessary to change certain parameters to customize the unit to the system environment. After reading this section, parameters can be customized to suit the needs of the specific application. A complete listing and descriptions of the temperature related parameters are included in Appendix A, while factory defaults are listed in Sections 2.4 – 2.10, above.

3.2 INDOOR/OUTDOOR RESET MODE

This mode of operation is based on outside air temperatures. As the outside air temperature decreases, the supply header temperature will increase and vice versa. For this mode, it is necessary to install an outside air sensor as well as select a building reference temperature and a reset ratio.

3.2.1 Reset Ratio

Reset ratio is an adjustable number from 0.1 to 9.9. Once adjusted, the supply header temperature will increase by that number for each degree that the outside air temperature decreases. For instance, if a reset ratio of 1.6 is used, for each degree that outside air temperature decreases the supply header temperature will increase by 1.6 degrees.

3.2.2 Building Reference Temperature

This is a temperature from 40°F to 230°F (4.4°C to 110°C). Once sel e ct ed , it is t h e t em p er a t ur e that the system references to begin increasing its temperature. For instance, if a reset ratio of

1.6 is used, and we select a building reference temperature of 70°F (21.1°C), then at an outside temperature of 69°F (20.6°C), the supply header temperature will increase by 1.6° to 71.6°F (0.9°C to 22°C).

3.2.3 Outdoor Air Temperature Sensor Installation

The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected. The sensor must be shielded from the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used, it must allow free air circulation. The sensor may be mounted up to 200 feet (61m) fr om the unit. Sensor connections are made at the Input/Output (I/O) Box on the front of the boiler. Connections are made at the terminals labeled OUTDOOR AIR IN and AIR SENSOR COM inside the I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is provided on the cover of the I/O Box. Refer to Section 2.10: AC Electrical Power Wiring of th e Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) for additional information on wiring.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Indoor / Outdoor Setup Instructions

Go down the left column of the chart to the coldest design outdoor air temperature

Once the design outdoor air temperature is chosen, go across the chart to the desired

BLDG REF

SECTION 3 – MODES OF OPERATION

3.2.4 Indoor/Outdoor Startup

Startup in the INDOOR/OUT DOOR RESET mode is accomplished as follows:

NOTE:

A design engineer typically provides design outdoor air temperature and supply header temperature data.

1. Refer to the Indoor/Outdoor reset ratio charts in Appendix E.

2. Choose the chart corresponding to the desired Building Reference Temperature.

3. expected in your area.

4. 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. Access the Configuration menu and scroll through it until the display shows

TEMP (Building Reference Temperature). If necessary, refer to Section 2.3: C-More Controller Menus, above, for detailed instructions on navigating the menus.

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.

3.3 CONSTANT SETPOINT MODE

The CONSTANT SETPOINT mode is used when a fixed header temperature is desired. Common uses of this mode of operation include water source heat pump loops, and indirect heat exchangers for potable hot water systems or processes.

No external sensors are required to operate in this mode. While it is necessary to set the desired setpoint temperature, it is not necessary to change any other temperature-related functions. The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. See Appendix A for des criptions of temperature-related functions, and Sections 2.4 – 2.10 for their range of values and factory defaults.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

keys (40°F to 240°F, 4.4°C to 115.6°C)

SECTION 3 – MODES OF OPERATION

3.3.1 Setting the Setpoint

The setpoint temperature of the unit is adjustable from 40°F to 240°F (4.4° C to 115.6°C). To set the unit for operation in the CONSTANT SETPOINT mode, you m ust set menu items Internal

Setpt and Boiler Mode in the Configuration menu as follows:

TABLE 3-1: Constant Setpoint Mode Settings

MENU OPTION SETTING

Internal Setpt Select desired setpoint using ▲ and ▼ arrow

Boiler Mode Constant Setpoint See Section 2.3: C-More Controller Menus for detailed instruct ions on changing menu options.

3.4 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 t he REMOTE SETPOI NT mode is 4 - 20 mA/1 - 5 VDC. W it h this setting, a 4 to 20 mA/1 to 5 VDC signal, sent by an EMS or BAS, is used to change the unit's setpoint. The 4 mA/1V signal is equal to a 40°F (4.4°C) setpoint while a 20 mA /5V signal is equal to a 240°F (115.6°C) setpoint. When a 0 to 20 mA/0 to 5 VDC signal is used, 0 mA is equal to a 40°F (4.4°C) setpoint.

In addition to the current and voltage signals described above, the REMOTE SETPOINT mode can also driven by a RS-485 Modbus Network signal from an EMS or BAS.

The REMOTE SETPOINT modes of operation can be used to drive single as well as multiple units.

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the PMC Board located in the C-More Controller. Contact your local AERCO representative for details.

In order to enable the REMO TE SET POINT mode, you must set menu items Boiler Mode and

Remote Signal in the Configuration menu as follows:

TABLE 3-2: Remote Setpoint Mode Settings

MENU OPTION SETTING

Boiler Mode Remote Setpoint Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network

Refer to section 2.3: C-More Controller Menus for detailed instructions on changing menu options.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 3 – MODES OF OPERATION If the Network setting is selected for RS-485 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. See Appendix A for descriptions of t emperature-related functions, and Sections 2.4 – 2.10 for their range of options and factory defaults.

3.4.1 Remote Setpoint Field Wiring

The only wiring connections necessary for the REMOTE SETPOINT mode are connection of the remote signal leads from the source to the unit’s I/O Box. The I/O Box is located on the front panel of the boiler. 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. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity 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.

3.4.2 Remote Setpoint Startup

Since this mode of operation is factory preset and the setpoint is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when the external signal is present.

To operate the unit in the MANUAL mode, press the AUTO/MAN s witch. The REMOTE LED will go off and the MANUAL LED will light.

To change back to the REMOTE SETPOINT mode, simply press the AUTO/MAN swit ch. T he REMOTE LED will again light and the MANUAL LED will go off.

3.5 DIRECT DRIVE MODES

The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically sent from an Energy Management System (EMS) or from a Building Automation System (BAS). The Direct Drive mode 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 fac tor y def ault set ting for t he DIRECT DRIVE mode is 4-2 0 mA /1-5 VDC. With this setting, a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0% to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to a 100% valve position. When a 0-20 mA/0 -5 VDC signal is used, zero is equal to a 0% valve position.

In addition to the current and voltage signals described above, the DIRECT DRIVE mode can also driven by a RS-485 Modbus Network signal from an EMS or BAS.

When in a DIRECT DRIVE mode, the unit is a slave to the EMS or BAS and does not have a role in temperature control. DIRECT DRIVE can be used to drive single, or multiple units.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 3 – MODES OF OPERATION

NOTE:

If a voltage, rather than current signal is used to control the remote setpoint, a DIP switch adjustment must be made on the CPU Board located in the C-More Controller. Contact your local AERCO representative for details.

To enable the DIRECT DRIVE mode, you must set menu items Boiler Mode and Remote

Signal in the Configuration menu as follows:

TABLE 3-3: Direct Drive Mode Settings

MENU OPTION SETTING

Boiler Mode Direct Drive Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network

Refer to section 2.3: C-More Controller Menus for instructions on changing menu options. If the Network setting is selected for RS-485 Modbus operation, a valid Comm Address must be

entered in the Setup menu. Refer to Modbus Communication Manual GF-114 for additional information.

3.5.1 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. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity 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.

3.5.2 Direct Drive Startup

Since this mode of operation is factory preset and the valve position is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will ligh t when the signal is present.

To operate the unit in MANUAL mode, press the AUTO/MAN switch. T he REMOTE LED will go off and the MANUAL LED will light.

To change back to the Direct Drive mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 3 – MODES OF OPERATION

3.6 AERCO CONTROL SYSTEM (ACS)

NOTE:

ACS is for installations with 9 or more boilers. It utilizes only RS-485 signaling to the boiler. Installations with 1 to 8 boilers can use Boiler Sequencing Technology (BST), as described in Section 6 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

The ACS mode of operation is used in conjunction with an AERCO Control System. T he ACS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet (0.61 and 3m) downstream of the LAST boiler in the boiler plant's supply water header. The ACS can control up to 40 boilers; Up to 32 via Modbus (RS-485) network communication. For ACS programming, operation, and Header Sensor installation details, see ACS Operations Guide, GF-131. For operation via an RS-485 Modbus network, refer to Modbus Communication Manual GF-114. To enable the ACS mode, you must set menu items Boiler Mode and Remote

Signal in the Configuration menu as follows:

TABLE 3-4: ACS Mode Settings

MENU OPTION SETTING

Boiler Mode Direct Drive Remote Signal Network (RS485)

Refer to section 2.3: C-More Controller Menus for instructions on changing menu options.

3.6.1 ACS External Field Wiring

Wiring connections for RS-485 Modbus control are made between the 485 A- and 485 B+ terminals on t he ACS (boilers 9 through 40) and the RS-485 COMM terminals in the I/O Box on the front of the boilers.

Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper polarity for the ACS RS-485 COMM wiring connections. Shields should be terminated only at the ACS and the boiler end must be left floating. Each unit’s wiring must conform to the above.

3.6.2 ACS Setup and Startup

This mode of operation is factory preset and the ACS controls the f iring rate (air/fuel valve % open position). There are no setup instructions for each individual unit.

To operate the unit in MANUAL mode, press the AUTO/MAN switch. The REMOTE LE D will go off and the MANUAL LED will light

To change back to the ACS mode, simply press the AUTO/MAN switch. The REMOTE LED will again light and the MANUAL LED will go off.

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SECTION 3 – MODES OF OPERATION

3.7 COMBINATION CONTROL SYSTEM (CCS)

NOTE:

Only ACS can be utilized for the Combination Control System.

A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. The theory behind this type of system is that the maximum space-heating load and the maximum domestic hot water load do not occur simultaneously. Therefore, boilers used for domestic hot water are capable of switching between constant setpoint and ACS control.

For a typical CCS, an adequate number of boilers are installed to cover the space-heating load on the design-day. However, one or more units are used for the domestic hot water load as well. These boilers are the combination units and are referred to as the combo boilers. The combo boilers heat water to a constant setpoint temperature. That water is then circulated through a heat exchanger in a domestic hot water storage tank.

Only the AERCO Control System (ACS) is necessary to configure this system if only a single valve is used to switch from space heating to domestic hot water. However, the ACS Relay Panel is r equired in combination with the ACS when there are up to two isolation valves, boiler interlocks, and/or a Domestic Hot Water (DHW) pump in a Combination heating plant where AERCO boilers are being used for both Building Heat and Domestic Hot Water heating.

The following two options are available for using a combination system; one that uses only the ACS, and one that requires the optional ACS Relay Box:

• OPTION 1 - T his option is selected when the ACS controls a boiler plant containing up to eight combination boilers that are Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG HEAT) boilers, and one hydronic isolation valve in the main header between the BLDG HEAT boilers and the DHW PRIORITY boilers.

• OPTION 2 – When this option is selected, the ACS Relay Panel must be used in conjunction with the ACS. For this option, the ACS controls a boiler plant containing up to eight combination boilers that are divided up into Building Priority (BLDG PRIORITY) boilers and Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG HEAT) boilers, and using two hydronic isolation valves in the main header, one between the BLDG HEAT and BLDG PRIORITY boilers, and the other between the BLDG PRIORITY and the DHW PRIORITY boilers.

In Option 2, when the space-heating load is such that when all the space-heating boilers are at the 100% valve position, the ACS will then ask the ACS Relay Box for the domestic boilers to become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become space-heating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the ACS Relay Box switches the combo units back to the domestic load. The ACS in combination with the ACS Relay Box will ask the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY boilers are not able to satisfy the domestic hot water demand.

When the combo units are satisfying the domestic load, they are in the CONST ANT SETPOINT mode of operation. When the combo units switch over to space heating, their mode of operation changes to follow the ACS command. For more information concerning the operation of the ACS, consult the ACS Operations Guide, GF-131. For more information on the ACS Relay Box, see section 2.14 in the same manual.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

SECTION 3 – MODES OF OPERATION

3.7.1 Combination Control System Field Wiring

Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above.

3.7.2 Combination Control System Setup and Startup

Setup for the COMBINATION mode requires entries to be made in the Configuration menu for boiler mode, remote signal type and setpoint (see Section 2.6: Configuration Menu f or detai ls). The setpoint is adjustable from 40°F to 190°F (4.4°C to 8 7.8°C) .

To enable the COMBINATION mode, you must set menu items Boiler M ode, Remote Signal and Internal Setpt in the Configuration menu as follows:

TABLE 3-5: Combination Mode Settings

MENU OPTION SETTING

Boiler Mode Combination Remote Signal Network Internal Setpt 40°F to 190°F (4.4°C to 87.8°C)

Refer to section 2.3: C-More Controller Menus for instructions on changing menu options. While it is possible to change other temperature-related functions for COMBINATION mode,

these f unctions are preset to their factory default values. These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Sections 2.4 – 2.10.

To set the unit to the MANUAL mode, press the AUTO/MAN switch. The MANUAL LED will light.

To set the unit back to the AUTO mode, press the AUTO/MAN switch. The MANUAL LED will go off and the REMOTE LED will light.

When the boiler is switched to ACS control, the ACS controls the valve position. There are no setup requirements to the boiler(s) in this mode.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

750-3000

58025-01

12 Month

Ignitor, Flame Rod & Condensate trap

58025-08

58025-01 plus: Burner, LWCO, Air Filter replacement

58025-17

Same as 58025-08 except clean Air Filter

58025-13

58025-01 plus: Burner, LWCO, Air Filter replacement

58025-19

Same as 58025-13 except clean Air Filter

58025-10

58025-01 plus: Burner, LWCO, Air Filter replacement

58025-18

Same as 58025-10 except clean Air Filter

LABOR

TIME

Igniter-Injector Kit (P/N

58023)

Inspect, replace

if necessary

Flame Detector Kit (P/N 24356-1)

Inspect, replace

if necessary

Lean O2 Sensor (P/N 61026)

Combustion Calibration

*Check

Check

1 hr.

See ASME

CSD-1 Chart

4.6

Inspect, Clean &

Gaskets

Inspect, Clean

Gaskets

4.8

SECTION 4 – MAINTENANCE

SECTION 4: MAINTENANCE

4.1 MAINTENANCE SCHEDULE

All Benchmark boilers require 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 4-1. For a complete inspection check list see ASME CSD-1 chart.

The following maintenance kits are available through your local AERCO Sales Representative:

Model Kit P/N Type Components Serviced

750-1000

1500-2000

2500-3000

24-Month Water/Fireside

WARNING!

Prior to servicing, ensure that the following guidelines are strictly observed:

• Disconnect the AC power supply by turning off the service switch and AC supply circuit

breaker.

• Shut off the gas supply at the manual shut-off valve provided with the unit

• Allow the unit to cool to a safe water temperature to prevent burning or scalding

TABLE 4-1: Maintenance Schedule

SEC

4.2

ITEM 6 MOS. 12 MOS. 24 MOS.

*Inspect

Replace 15 mins.

4.3

4.4

4.5

Testing of Safety Devices Burner Inspect 2 hrs.

4.7

Condensate Drain Trap *Inspect

Air Filter Clean Replace 15 mins.

* Only performed after initial 6 month period after initial startup. ** Combustion Calibration instructions are in Section 4.4 of OMM-0121 (GF-205)

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*Inspect

Replace 15 mins.

*Inspect Inspect 15 mins.

45 mins.

Replace

& Replace

30 mins.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

STAGED IGNITION SOLENOID

O2 SENSOR

BURNER PLATE

BURNER

AIR/FUEL VALVE

BLOWER

IGNITER-INJECTOR

FLAME DETECTOR

GAS FLEX HOSE

BLOWER PROOF SWITCH

BLOCKED INLET SWITCH

SECTION 4 – MAINTENANCE

4.2 IGNITER-INJECTOR

The igniter-injector (Kit P/N 58023) is located on the burner plate at the top of the boiler. In addition to providing the ignition spark required to light the burner, the igniter-injector also contains a gas injector tube which connects to the staged ignition assembly. Figure 4-1a through Figure 4-1c shows the complete burner assembly removed from the boiler and indicates the location of the igniter-injector flame detector and other related components.

Figure 4-1a: BMK 750/1000 Burner Assembly (Removed from Boiler)

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BLOWER

IGNITER-

FLAME PORT

AIR/FUEL VALVE

LEAN O2 SENSOR

A/F VALVE

FLAME DETECTOR

BURNER

FLAME OBSERVATION PORT

AIR/FUEL VALVE

BLOCKED

A/F VALVE

SECTION 4 – MAINTENANCE

PLENUM

INJECTOR

ASSEMBLY

BLOCKED

INLET

SWITCH

PLENUM

PLENUM FLANGE/

BURNER TOP PLATE

BURNER

Figure 4-1b: BMK 1500/2000 Burner Assembly (Removed from Boiler)

BLOWER

PLENUM

LEAN O2 SENSOR

BURNER

PLATE FLANGE

FLAME DETECTOR

OBSERVATION

PLENUM

IGNITOR-INJECTOR

ASSEMBLY

Figure 4-1c: BMK 2500/3000 Burner Assembly (Removed from Boiler)

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INLET

SWITCH

Page 42

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Igniter-Injector Maintenance Procedure Instructions

position. Disconnect AC

LEAN O2 SENSOR

STAGED

IGNITER-INJECTOR

INDEXING

(0-3 as required)

FLAME

BURNER

STAGED

FLAME

INJECTOR-IGNITER

(0-3 as needed)

LEAN O2 SENSOR

BLOWER PLENUM

COMPRESSION

SECTION 4 – MAINTENANCE The igniter-injector may be hot, therefore, care should be exercised to avoid burns. It is easier to

remove the igniter-injector from the unit after the unit has cooled to room temperature. To inspect/replace the Igniter:

1. Set the ON/OFF switch on the C-More Controller to the OFF power from the unit

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

3. Disconnect the cable from the igniter-injector (see Figure 4-1a – Figur e 4-1c, above).

4. Referring to Figure 4-2a – Figure 4-2c, below, use a 7/16” open-end wrench to disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly. Disconnect the staged ignition assembly from the igniter-injector.

DETECTOR

& GASKET

PLATE

& WASHER

IGNITION SOLENOID

(CLOCKING) WASHERS

Figure 4-2a: BMK 750/1000 Igniter-Injector & Flame Detector Mounting Details

FITTING & ELBOW

IGNITION

SOLENOID

ASSY WITH INDEXING

(CLOCKING) WASHERS

& WASHER

BURNER PLATE

FLANGE

Figure 4-2b: BMK 1500/2000 Igniter-Injector & Flame Detector Mounting Details

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FLAME OBSERVATION PORT

DETECTOR & GASKET

Page 43

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Igniter-Injector Maintenance Procedure Instructions

injector should be replaced. If carbon

injector by

FLAME

INJECTOR-IGNITOR

(0-3 as needed)

FLEX GAS

COMPRESSION BLOWER

PLENUM

SECTION 4 – MAINTENANCE

STAGED IGNITION

FITTING & ELBOW

SOLENOID

O2 SENSOR & WASHER

ASSY WITH INDEXING

(CLOCKING) WASHERS

BURNER PLATE FLANGE

DETECTOR & GASKET

HOSE NIPPLE

OBSERVATION PORT

Figure 4-2c: BMK 2500/3000 Igniter-Injector & Flame Detector Mounting Details

5. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench.

6. Check the igniter-injector for evidence of erosion or carbon build-up. If there is evidence of substantial erosion or carbon build-up, the igniterbuild-up is present, clean the component using fine emery cloth. Repeated carbon build-up is an indication that the combustion settings of the unit should be checked. To review combustion calibration procedures, refer to Section 4.4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

7. Prior to reinstalling the igniter-injector, apply a high temperature, conductive, anti-seize compound to the threads.

8. Reinstall the igniter-injector in the burner plate using 1 to 3 indexing washers, as needed, so that when the igniter-injector is tightened, its injector tube will be positioned within the approximately 120° arc shown in Figure 4-3a throug h 4-3c, below. Note, the recommended injection tube positioning differs for the positioning recommended in the past.

9. Torque the igniter-injector to 170 - 180 in-lbs (19.2 – 20.3 Nm). DO NOT over tighten.

NOTE:

If replacement igniter-injector (Kit P/N 58023) is being installed, a compression nut containing a built-in ferrule and 3 indexing washers are included with the kit.

10. Connect the staged ignition assembly to the gas injector tube of the ignitersecuring the compression nut to the elbow of the staged ignition assembly.

11. Reconnect the igniter-injector cable.

12. Reinstall the shroud on the unit.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Igniter-Injector Maintenance Procedure Instructions

IGNITER-INJECTOR

INJECTOR TUBE

BURNER PLATE

BLOWER

DETECTOR

O2 SENSOR

POSITION

INJECTOR TUBE

IGNITER-INJECTOR

INJECTOR TUBE

POSITION

SECTION 4 – MAINTENANCE

INJECTOR TUBE INSIDE THIS ARC

Figure 4-3a: BMK 750/1000 Igniter-Injector Orientation

INJECTOR TUBE INSIDE THIS ARC

FLAME

FLAME OBSERVATION

O2 SENSOR

PORT

Figure 4-3b: BMK 1500/2000 Igniter-Injector Orientation

INJECTOR TUBE INSIDE THIS ARC

IGNITER-INJECTOR

Figure 4-3c. BMK 2500/3000 Igniter-Injector Orientation

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FLAME OBSERVATION PORT

Page 45

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Flame Detector Maintenance Instructions

position. Disconnect AC power

Thoroughly inspect the flame detector. If eroded, the detector should be replaced.

O2 Sensor Maintenance Instructions

position. Disconnect AC

SECTION 4 – MAINTENANCE

4.3 FLAME DETECTOR

The flame detector (kit P/N 24356-1) is located on the burner plate at the top of the unit (see Figure 4-1a through 4-1c and 4-2a through 4-2c, above). The flame detector may be hot. Allow the unit to cool sufficiently before removing the flame detector. Inspect or replace the flame detector as follows:

1. Set the C-More Controller’s ON/OFF switch to the OFF from the unit.

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

3. Disconnect the flame detector lead wire.

4. Remove the two (2) screws securing the flame detector to the plate (Figure 4-2a – 4-2c).

5. Remove the flame detector and gasket from the burner plate.

6. Otherwise clean the detector with a fine emery cloth.

7. Reinstall the flame detector and flame detector gasket.

8. Reconnect the flame detector lead wire.

9. Reinstall the shroud on the unit.

4.4 O2 SENSOR

The Lean Oxygen Sensor (P/N 61026) is located on the burner plate at the top of the unit (see Figure 4-1a through 4-1c and Figure 4-2a through 4-2c). The sensor may be hot. Allow the unit

to cool sufficiently before removing or replacing the O

1. Set the ON/OFF switch on the C-More Controller to the OFF power from the unit.

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

3. Disconnect the O

s ensor lead wire by pushing in on the release tab and pulling apart the

connector.

4. Next, loosen and remove the O

sensor and crush washer from the burner plate using a

15/16" open-end wrench.

5. Thoroughly inspect the O

sensor. If eroded, the sensor should be replaced. Otherwise

clean the sensor with a fine emery cloth.

sensor.

6. Reinstall the O

sensor and crush washer on the burner plate.

7. Reconnect the sensor lead wire.

8. Reinstall the shroud on the unit.

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Page 46

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 750/1000 Burner Inspection Parts

BMK 1500/2000 Burner Inspection Parts

BMK 2500/3000 Burner Inspection Parts

SECTION 4 – MAINTENANCE

4.5 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 The Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205) for a description and instructions for performing these tests.

4.6 BURNER INSPECTION

The burner assembly is located at the top of the unit's heat exchanger. The burner assembly may be hot. Therefore, allow the unit to cool sufficiently before removing the burner assembly.

The following parts will be required for reassembly after burner inspection:

Part N o. Description

81143 Burner Gasket 81048 Flame Detector Gasket 81064 Blower Gasket

Part N o. Description

81166 Burner Gasket (1 each) 88183 Burner Release Gasket (1 each) 81186 Burner Lower Release Gasket (1 each) 81048 Flame Detector Gasket (1 each)

Part N o. Description

88173 Burner Upper Release Gasket 81180 Burner Gasket (Middle) 81185 Burner Lower Release Gasket 81048 Flame Detector Gasket (1 each)

NOTE:

Illustrations for the burner inspection procedure for all BMK models are presented first, starting on the next page, followed by the written instructions.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 750/1000 Burner Inspection Instructions

position. Disconnect AC

AIR/FUEL VALVE

BLOCKED INLET

BURNER GASKET

FLAME DETECTOR

O2 SENSOR

STAGED IGNITION

BURNER

BLOWER

BLOWER PROOF SWITCH

BURNER PLATE

3/16”–16 HEX NUTS (8)

IGNITER-INJECTOR

STAGED IGNITION

ASSEMBLY

BLOCKED INLET SWITCH

BLOWER PROOF

AIR FILTER

BLOWER

FRONT

1/2" BOLTS & NUTS (4)

REAR

IGNITER/INJECTOR

SECTION 4 – MAINTENANCE

4.6.1 BMK 750/1000 BURNER INSPECTION

SWITCH

(GAS TRAIN-to-A/F

VALVE)

Figure 4-4a: BMK 750/1000 Burner Assembly Mounting Details (Overhead View)

SWITCH

Figure 4-4b: BMK 750/1000 Burner Assembly (Exploded View)

1. Set the ON/OFF switch on the C-More Controller to the OFF power from the unit and turn off the gas supply.

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 750/1000 Burner Inspection Instructions

3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure

up. Also,

) using a 9/16”

reverse order that they were removed. When reinstalling the burner flange (removed in

hten all eight nuts, and

SECTION 4 – MAINTENANCE

4-4b.

4. Remove the two (2) screws securing the flame detector to the plate. The flame detector is secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.

5. Remove the flame detector and gasket from the burner plate.

6. Disconnect the cable from the igniter-injector.

7. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 4-1a). Disconnect the staged ignition assembly from the igniter-injector.

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 (Figure 4-4a and Figure 4-4b).

11. Disconnect the gas train from the air/fuel valve by removing the four (4) 1/2” bolts and nuts (Figure 4-4a).

12. Disconnect the flex hose from the air/fuel valve by loosening the hose clamp.

13. Remove the four 5/16-18 hex head screws securing the blower to the burner plate (Figure 4-4b).

14. Remove the blower and air/fuel valve from the burner plate by lifting straight remove the blower gasket.

15. Remove the eight (8) 3/8-16 nuts from the burner flange (Figure 4-4a wrench.

NOTE:

The burner assembly weighs approximately 25 pounds (11.3 kg).

16. Remove the burner assembly from burner flange by pulling stra ight up.

17. Remove and replace the burner gasket.

NOTE:

During reassembly, apply a light coating of 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 4-3a. Torque the ig niter-injector to 14 - 15 ft-lbs. (19.0 - 20.3 Nm).

18. Beginning with the burner assembly removed in step 16, reinstall all the components in the step 15), tighten the 3/8-16 nuts using a typical torque pattern. For example, loosely tighten

one nut, then loosely tighten a second nut on the opposite side, a third at 90 degrees to the first two, and a fourth opposite the third, and then repeat this pattern with the remaining four nuts. Repeat the entire pattern a second time to partially tig then repeat a third time until all eight nuts are fully torqued to 30 ft. lbs. (40.7 Nm).

19. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange.

This completes the Benchmark 750/1000 burner inspection.

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Page 49

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 1500-3000 Burner Inspection Instructions

5/16” x 1-3/4” BOLTS, NYLOCK NUTS (4 each)

BLOWER

PLENUM

A/F VALVE BLOWER

3/8”-16

(8 each)

IGNITER-

1/2” NUTS

3/8”-16 (8 each)

A/F VALVE PLENUM

GAS

TRAIN

GAS INLET PIPE

BLOWER PROOF

BLOWER

MANUAL SHUT-

SECTION 4 – MAINTENANCE

4.6.2 BMK 1500 – 3000 BURNER INSPECTION

INJECTOR

ASSEMBLY

HEX NUTS

5/16” WASHERS &

BURNER PLATE

PLENUM

& BOLTS (4 ea.)

Figure 4-5a: BMK 1500/2000 Burner Assembly Mounting Details

5/16” x 1-3/4” BOLTS, 5/16”

WASHERS & NYLOCK

NUTS (4 each)

SWITCH

AIR/FUEL VALVE

BLOWER PLENUM

AIR FILTER

HEX NUTS

OFF VALVE

BLOCKED INLET

SWITCH

AIR

FILTER

Figure 4-5b: BMK 1500/2000 Burner Assembly Mounting Details

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 1500-3000 Burner Inspection Instructions

BLOWER PLENUM GAS TRAIN

AIR FILTER

A/F VALVE BLOWER

3/8”-16

(8 each)

IGNITER-

1/2” NUTS & BOLTS (4 each)

3/8”-16 (8 each)

AIR/FUEL

GAS

TRAIN

BLOWER

GAS INLET PIPE

BLOWER

MANUAL

SECTION 4 – MAINTENANCE

INJECTOR

ASSEMBLY

5/16” x 1-3/4” BOLTS, 5/16” WASHERS & NYLOCK NUTS (4 each)

PLENUM

BURNER PLATE

HEX NUTS

Figure 4-5c: BMK 2500/3000 Burner Assembly Mounting Details

PLENUM

5/16” x 1-3/4” BOLTS,

5/16” WASHERS &

NYLOCK NUTS

(4 each)

AIR/FUEL VALVE FILTER

HEX NUTS

A/F VALVE

PLENUM

PROOF

SWITCH

VALVE

BLOCKED INLET

SWITCH

AIR

FILTER

Figure 4-5d: BMK 2500/3000 Burner Assembly Mounting Details

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SHUT-OFF VALVE

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 1500-3000 Burner Inspection Instructions

position. Disconnect AC

sensor and flame observation port remain assembled to the

SECTION 4 – MAINTENANCE

1. Set the ON/OFF switch on the C-More Controller to the OFF power from the unit and turn off the gas supply.

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure 4-2b (BMK 1500/2000) or Figure 4-2c (BMK 2500/3000).

4. Remove the two (2) screws securing the flame detector to the pla te. The f lame det ector is secured to the burner plate with one (1) #10-32 screw and one (1) #8-32 screw.

5. Remove the flame detector and gasket from the burner plate.

6. Disconnect the cable from the igniter-injector.

7. Using a 7/16” open-end wrench, disconnect the compression nut securing the gas injector tube of the igniter-injector to the elbow of the staged ignition assembly (see Figure 4-2b (BMK 1500/2000) or Figure 4-2c (BMK 2500/3000). Disconnect the staged ignition assembly from the igniter-injector.

8. Next, loosen and remove the igniter-injector from the burner plate using a 1" open-end wrench.

9. Loosen and remove the four 5/16 x 1-3/4” bolts, washers, and nuts from the blower plenum where it attaches to the blower. See Figure 4-5a & 4-5b (BMK 1500/2000) or Figure 4-5c & 4-5d (BMK 2500/3000).

10. You must either rig a support for the blower to hold it in place or remove the blower from the unit and set it aside for later reassembly.

11. Remove the eight (8) 3/8-16 nuts, using a 9/16” wrench, attaching the blower plenum to the burner. See Figure 4-5a & 4-5b (BMK 1500/2000) or Figure 4-5c & 4-5d (BMK 2500/3000).

12. Remove the blower plenum from between the blower and the burner and set it aside for later reassembly. The O

plenum flange.

13. Remove the burner by pulling straight up.

NOTE:

The burner assembly weighs approximately 65 lbs. (29.5 kg).

14. Remove and replace the burner gasket(s) (see Figure 4-6, below).

IMPORTANT!

ALL THREE gaskets provided for maintenance MUST be installed during this procedure, as shown in Figure 4-6, even if there is only one existing gasket being replaced. Note that the LOWER RELEASE GASKET has tabs, which the others do not.

NOTE:

During reassembly, apply a light coating of 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 4-3b or Figure 4-3c. Torque t he ig niter -inje ctor to 14 - 15 ft-lbs. (19.0 - 20.3 Nm).

(Continued)

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 1500-3000 Burner Inspection Instructions

e nut, then

a fourth opposite the third, and then repeat this pattern with the remaining four nuts.

BARE

SECTION 4 – MAINTENANCE

NOTE:

The LOWER RELEASE GASKET (P/N 81186) features four tabs around its periphery.

81183 – UPPER RELEASE GASKET 81166 – MIDDLE BURNER GASKET 81186 – LOWER RELEASE GASKET

BURNER

INSTALLED IN

HEAT

EXCHANGER

ASSY.

Use ALL THREE gaskets provided, even if there is only one existing gasket being replaced.

IMPORTANT!

Figure 4-6: Bare Burner and Replacement Gaskets Location

15. Beginning with the burner assembly, reinstall all the components in the reverse order that they were removed. When reinstalling the blower plenum (removed in step 11), tighten the 3/8-16 nuts using a typical torque pattern (for example, loosely tighten on loosely tighten a second nut on the opposite side, a third at 90 degrees to the first two, and

Repeat the entire pattern a second time to partially tighten all eight nuts, and then repeat a third time until all eight nuts are fully torqued to 35 ft. lbs. (47.5 Nm).

16. Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange.

This completes the Benchmark 1500/3000 burner inspection.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Condensate Drain Trap Maintenance Instructions

CROSS-SECTION

Thumb

Screw

O-Rings

INLET

3/4" NPT Port

OUTLET

FLOAT

THUMB SCREWS (4)

CONDENSATE (P/N 84017)

3/4" NPT Port

EXPLODED

COVER

SECTION 4 – MAINTENANCE

4.7 CONDENSATE DRAIN TRAP

Benchmark boilers contain a condensate trap (P/N 24441), located external to the unit and attached to the drain connection from the exhaust manifold at the rear of the unit (shown in Figure 2-6a and 2-6b of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205)). This trap should be inspected and cleaned in accordance with the maintenance schedule shown in Table 4-1, above, to ensure proper operation.

To inspect and clean the trap, proceed as follows:

1. Disconnect the external condensate trap by loosening and then removing connections on the inlet and outlet sides of the condensate trap (see Figure 4-7).

2. Loosen the four (4) thumbscrews securing the trap’s cover and then remove the cover and the O-ring from under the cover.

3. Remove the float and then thoroughly clean the trap and float. Also inspect the drain piping for blockage. If the trap cannot be thoroughly cleaned, replace the entire trap (P/N 24441).

4. Replace the float, install the O-ring (P/N 84017), and then replace the trap cover.

5. Reassemble all piping and hose connections to the condensate trap inlet and outlet.

TRAP O-RING

(2)

VIEW

Figure 4-7: External Condensate Trap – Cross-Section & Exploded View

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE 4-2: Available Air Filters

Air Filter Cleaning and Replacement Instructions

GAS TRAIN

AIR FILTER

MANUAL SHUT-

SECTION 4 – MAINTENANCE

4.8 AIR FILTER CLEANING and REPLACEMENT

The Benchmark boiler is equipped with an air filter which should be cleaned and re-oiled every 12 months and replaced every 24 months. The air filter is located at the air fuel valve inlet, as shown in Figure 4-8.

Benchmark Model Part Number

750, 1000 59139 1500, 2000 59138 2500, 3000 88014

To inspect/replace the air filter, proceed as follows:

1. Set the ON/OFF switch on the C-More Controller to the OFF position. Disconnect AC power from the unit.

2. Remove the top shroud from the unit by grasping the top handle and lifting straight up. This will disengage the shroud from the four (4) pins in the side panels.

3. Refer to Figure 4-8 and locate the air filter attached to the air/fuel valve inlet.

AIR/FUEL VALVE

AIR FILTER

OFF VALVE

HOSE CLAMP

Figure 4-8: Air Filter Location (BMK 1500/2000 Shown)

4. Using a flat-tip screwdriver or 5/16” nut driver, loosen the clamp securing the filter t o the inlet flange of the air/fuel valve. Remove the filter and clamp.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Air Filter Cleaning and Replacement Instructions

The filter may be cleaned in hot soapy water to remove oil and dirt. It should then be

Each replacement air filter is equipped with its own clamp. Therefore, simply install the

LWCO Probe

Capacitor Assembly

Connector

Plastic Acorn Nut

LWCO Probe

Hot Water

Rear

SECTION 4 – MAINTENANCE

5. thoroughly dried and then sprayed with a light coating of K&N® Air Filter Oil (or equivalent specifically formulated for air filters) prior to reinstallation. Do NOT use WD-40.

6. replacement air filter on inlet flange of the air fuel valve and tighten the clamp with a flat-tip screwdriver or 5/16” nut driver.

7. Replace the top shroud on the unit and return boiler to service use.

4.9 WATER CUTOFF (LWCO) CAPACITOR INTEGRITY TEST

The LWCO cap acitor sho uld be tested for elect rical shorts every 12 mon ths and repl aced, then tested, every 24 months. The LWCO capacitor integrity test consists of two parts as described in the next two sections. The first procedure explains how to test for e lectrical shorting of the LWCO probe c apacitor, w hi le the secon d procedure instructs how to perform the standard Low Water Cutoff test using the C-More Controller.

Refer to Figure 4-9 for an illustration of the LWCO probe assembly and its typical installation.

Panel

(Covered By Large Shrink Tubing)

Outlet Pipe

Terminal

(to Shell Harness)

Figure 4-9: LWCO Probe Location (BMK1500 Shown)

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

UNPLUG SHELL HARNESS CABLE FROM P5 CONNECTOR

CONNECT 2ND LEAD

19-PIN SHELL HARNESS

CABLE CONNECTOR

LWCO PROBE

ASSEMBLY CONNECTOR

OHMMETER

CONNECT 1ST LEAD

SECTION 4 – MAINTENANCE

4.9.1 Low Water Cutoff (LWCO) - Capacitor Electrical Short Test

This test determines if there is an electrical short between the LWCO capacitor and the heat exchanger. Perform the capacitor electrical short test as described below.

Low Water Cutoff – Capacitor Electrical Short Test Instructions

Turn the AC power to the unit to OFF

WARNING!

High voltages are used to power these units and so it is required that power applied to these units is removed first before performing the procedure described in this instruction. Serious personal injury or death may occur if this warning is not observed.

Remove the Shell Harness Cable (male) connector from the P-5 (female) connector on the rear panel of the C-More Controller (see Figure 4-10).

Figure 4-10: Removing Shell Harness Cable from P5 Conn. on C-More Rear Panel

Using an ohmmeter, connect one ohmmeter probe to the LWCO capacitor terminal on the unit shell as shown on le ft in Figure 4-11.

Connect the second ohmmeter probe to Pin #6 of Shell Harness C onnector (rem oved from the C-More Controller) as shown on right in Figure 4-11.

Figure 4-11: Connecting Ohmmeter between LWCO Probe & Shell Harness Cable

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TO LWCO TERMINAL

TO PIN #6

Page 57

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Low Water Cutoff (LWCO) - Standard C-More Test Instructions

Shutting Boiler Down For An Extended Period Instructions

Instructions

SECTION 4 – MAINTENANCE

4.9.2 Low Water Cutoff (LWCO) - Standard C-More Test

Perform the standard Low Water Cutoff test using the C-More Controller as described below.

Turn the AC power to the unit to the ON position. Press the TEST switch on the C-More Controller and confirm that the blinking LOW

2. WATER LEVEL message appears

Press the RESET key, followed by the Clear button, and confirm that the LOW WATER

LEVEL message is cleared.

on the C-More display within 4 seconds.

4.10 SHUTTING BOILER DOWN FOR EXTENDED PERIOD

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 C-More Controller to the OFF position to shut down the boiler’s operating controls.

2. Disconnect AC power from the unit.

3. Close the water supply and return valves to isolate boiler.

4. Close external gas supply valve.

5. Open relief valve to vent water pressure.

4.11 PLACING THE BOILER BACK IN SERVICE AFTER A

PROLONGED SHUTDOWN

After a prolonged shutdown (one year or more), the following procedures must be followed:

Placing The Boiler Back In Service After A Prolonged Shutdown

1. Review installation requirements included in Section 2 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

2. Inspect all piping and connections to the unit.

3. Inspect exhaust vent and air inlet duct work (if applicable).

4. Perform initial startup per Section 4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

5. Perform safety device testing and scheduled maintenance procedures per Sections 4 and 5 of this manual.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Ignition Wire 140

Wire 140

SECTION 4 – MAINTENANCE

4.12 SPARK MONITOR (AC CURRENT TRANSDUCER)

The spark monitor (P/N 61034) evaluates the strength of the current between the ignition transformer and igniter-injector. W ire# 140, connected to the ignition transformer (see Figure 4-

12), passes through the monitor’s orifice. If an adequate AC current is not detected in the wire

during ignition, the unit automatically shuts down. The monitor’s wires are connected to the

board’s Spark Signal

terminals

(see section 2.11.4 in the

and Startup Guide, OMM-0121 (GF-205) for details

Spark

Monitor

)

Transformer

Benchmark 750 – 3000 Installation

I/O

To I/O

Board

Tab

Figure 4-12: Spark Detector Sensor (AC Current Transducer) P/N 61034

If the spark monitor needs to be replaced, open the monitor’s orif ice by pulling on the tab at the side, remove Wire# 140, disconnect the monitor ’s wires are from the I/O board, remove the old monitor from its position, install a new monitor in its place, route wire# 140 through the new sensor orifice, and connect the wires to the I/O board’s Spark Signal terminals, red wire to the positive (+) terminal and black to negative (-).

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Page 59

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Fault Correction Instructions

Perform the checks and procedures listed in the Corrective Action column for the first Probable

additional troubleshooting information which may apply when a no fault

SECTION 5 – TROUBLESHOOTING GUIDE

SECTION 5: TROUBLESHOOTING GUIDE

5.1 INTRODUCTION

This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in Benchmark 750 through 3000 boilers. 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. For example, Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.

When a fault occurs in the unit, proceed as follows to isolate and correct the fault:

1. Observe the fault messages displayed in the C-More Controller display.

2. Refer to the Fault Indication column in Troubleshooting Table 5-1 which follows and locate the Fault that best describes the existing conditions.

3. Proceed to the Probable Cause column and start with the first item (1) listed for the Fault Indication.

4. Cause candidate.

5. Continue checking each additional Probable Cause for the existing fault until the fault is corrected.

6. Section 5-2 contains message is displayed.

If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative.

NOTE:

The front panel of the C-More Controller cont ains an RS232 port. This port is used only by factory-trained personnel to monitor onAER communications via a portable computer.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

AIRFLOW FAULT DURING IGNITION

Blower stopped running due to thermal or

current overload.

2. Blocked Blower inlet or inlet air filter.

3. Blockage in Blower Proof switch.

4. Blockage in Blocked Inlet switch.

5. Defective Blower Proof switch.

6. Defective Blocked Inlet switch.

7. Loose temperature to AUX connection in I/O

Box.

8. Defective temperature sensor.

9. Loose wire connection between the 0-10V

signal from I/O box to the Blower input.

10. Defective I/O Box.

11. Wrong 0-10V output selection on the C-More

Controller.

12. Defective Air-Fuel Valve potentiometer.

13. Hard light.

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 the air filter at

the air/fuel valve for signs of blockage.

3. Remove the Blower Proof switch and inspect for signs of blockage,

clean or replace as necessary.

4. Remove the Blocked Inlet switch and inspect for signs of blockage,

clean or replace as necessary.

5. Check the continuity of the Blower Proof switch with the combustion

blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

6. Turn off unit and check the continuity of the Blocked Inlet switch. If

there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

7. Check the actual inlet air temperature and measure voltage at AUX

input in the I/O Box. Verify that the voltage conforms to the values shown in Appendix C.

8. Refer to CORRECTIVE ACTION 7 and verify that the voltage

conforms to the values shown in Appendix C.

9. Check wire connection from I/O Box 0-10V signal to the Blower

Motor.

10. Measure voltage at the I/O box 0-10V output. A voltage of 10V

equates to a 100% open valve position.

11. Check the Analog Out option on the C-More Configuration menu.

Valve Position 0-10V should be selected.

12. Check Air/Fuel Valve position at 0%, 50% and 100% open

positions. The positions on the VALVE POSITION bargraph should match the readings on the Air/Fuel Valve dial.

13. Check igniter-injector for soot or erosion of electrode. Check

injector solenoid valve to insure proper open/close operation.

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SECTION 5 – TROUBLESHOOTING GUIDE

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

AIRFLOW FAULT DURING PURGE

Blower not running or running too slow.

2. Defective Blocked Inlet switch.

3. Blockage in air filter or Blocked Inlet switch.

4. Blocked blower inlet or inlet ductwork.

5. No voltage to Blocked Inlet switch from C-More

Controller.

6. PROBABLE CAUSES from 3 to 12 for

AIRFLOW FAULT DURING IGNITION apply for

this fault.

Start the unit. If the blower does not run check the blower solid state

relay for input and output voltage. If the relay is OK, check the blower.

2. Start the unit. If the blower runs, turn off unit and check the Blocked

Inlet switch for continuity. Replace the switch if continuity does not exist.

3. Remove the air filter and Blocked Inlet switch and inspect for signs

of blockage. Clean or replace as necessary.

4. Inspect the inlet to the combustion blower including any ductwork

leading up to the combustion blower for signs of blockage.

5. During the start sequence, verify that 24 VAC is present between

each side of the switch and ground. If 24 VAC is not present, refer fault to qualified service personnel.

6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT

DURING IGNITION.

AIRFLOW FAULT DURING RUN

Blower stopped running due to thermal or

current overload.

2. Blocked Blower inlet or inlet ductwork.

3. Blockage in air filter or Blocked Inlet switch.

4. Defective Blocked Inlet switch.

5. Combustion oscillations.

6. Probable causes from 3 to 16 for AIRFLOW

FAULT DURING IGNITION applies for this fault.

Check combustion blower for signs of excessive heat or high

current draw 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. Remove the air filter and Blocked Inlet switch and inspect for signs

of blockage, clean or replace as necessary.

4. Verify that 24 VAC is present between each side of the switch and

ground. If 24 VAC is not present at both sides, replace switch.

5. Run unit to full fire. If the unit rumbles or runs rough, perform

combustion calibration.

6. See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW FAULT

DURING IGNITION.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

DELAYED INTERLOCK OPEN

1. Delayed Interlock Jumper not properly installed

or missing.

2. Device proving switch hooked to interlocks is

not closed.

1. Check to insure jumper is 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 proving device (such as a pump, louver, etc.) is tied these interlocks. Ensure that the device and/or its end switch is functional. A jumper may be temporarily installed to test the

interlock.

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. C-More Controller signal type selection switches

not set for correct signal type (voltage or

current).

1. Check I/O Box to ensure signal is hooked up.

--Hook up if not installed.

--If installed, check polarity.

--Measure signal level.

--Check wiring continuity between source and unit.

2. Check signal at source to ensure it is isolated.

3. Check DIP switch on PMC board to ensure it is set correctly for the

type of signal being sent. Check control signal type set in

Configuration menu.

FLAME LOSS DURING IGN

1. Worn Flame Detector .

2. No spark from Spark Igniter.

3. Defective Ignition Transformer.

4. Defective Ignition/Stepper (IGST) Board.

5. Defective SSOV.

1. Remove and inspect the Flame Detector for signs of wear. Replace

if necessary.

2. Close the internal gas valve in the unit. Install and arc a spark igniter

outside the unit.

3. If there is no spark, check for 120VAC at the primary side to the

ignition transformer during the ignition cycle.

4. If 120VAC is not present, the IGST Board in the C-More Controller

may be defective. Refer fault to qualified service personnel.

5. While externally arcing the spark igniter, observe the open/close

indicator in the Safety Shut-Off Valve to ensure it is opening. If the valve does not open, check for 120VAC at the valve input terminals. If 120VAC is not present, the IGST board in the C-More Controller may be defective. Refer fault to qualified service personnel.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

FLAME LOSS DURING RUN

1. Worn Flame Detector or crack ed ceramic.

2. Defective Regulator.

3. Poor combustion calibration.

4. Debris on burner.

5. Blocked condensate drain.

1. Remove and inspect the Flame Detector for signs of wear or

cracked ceramic. Replace if necessary.

2. Check gas pressure readings using a gauge or manometer into and

out of the Air/Fuel Valve to ensure that the gas pressure into and out of the valve is correct.

3. Check combustion calibration using the procedures in Section 4.4 of

the Benchmark 750 – 3000 Installation and Startup Guide, OMM0121 (GF-205).

4. Remove the burner and inspect for any carbon build-up or debris.

Clean and reinstall.

5. Remove blockage in condensate drain.

HEAT DEMAND FAILURE

1. The Heat Demand Relays on the

Ignition/Stepper (IGST) board failed to activate when commanded.

2. Relay is activated when not in Demand.

1. Press CLEAR button and restart the unit. If the fault persists,

replace Ignition/Stepper (IGST) Board.

2. Defective relay. Replace IGST Board.

HIGH EXHAUST TEMPERATURE

1. Poor combustion calibration.

2. Carboned heat exchanger due to incorrect

combustion calibration.

1. Check combustion calibration using procedures in Section 4.4 of the

Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

2. If exhaust temperature is greater than 200

F (93.3oC), check

combustion calibration. Calibrate or repair as necessary.

HIGH GAS PRESSURE

1. Incorrect supply gas pressure.

2. Defective SSOV Actuator.

3. Defective High Gas Pressure switch.

1. Check to ensure gas pressure at inlet of SSOV does not exceed

14” W.C. (3.49 kPa).

2. If gas supply pressure downstream of SSOV Actuator cannot be

lowered to the range specified in Table 4-1 (Natural Gas) or Table 4-4 (Propane) in Section 4.4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205), the SSOV Actuator may be defective.

3. Remove the leads from the High Gas Pressure switch. Measure

continuity across the common (C) and normally closed (NC) terminals with the unit not firing. Replace the switch if continuity

does not exist.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

HIGH WATER TEMP SWITCH OPEN

1. Faulty Water temperature switch.

2. Incorrect PID settings.

3. Faulty shell temperature sensor.

4. Unit in MANUAL mode.

5. Unit setpoint is greater than Over Temperature

switch setpoint.

6. System flow rate changes are occurring faster

than units can respond.

1. Test the temperature switch to insure it trips at its actual water

temperature setting.

2. Check PID settings (see Section 2-7: Tuning Menu, items 1 -3, for

details). If the settings have been changed, record the current readings then reset them to the default values.

3. Using the resistance charts in Appendix C, measure the resistance

of Shell sensor and BTU sensor at a known water temperature.

4. If unit is in MANUAL mode, switch to AUTO mode.

5. Check setpoint of unit and setpoint of Temperature switch; Ensure

that the temperature switch is set higher than the unit’s setpoint.

6. If the system is a variable flow system, monitor system flow changes

to ensure that the rate of flow change is not faster than what the

units can respond to.

HIGH WATER TEMPERATURE

1. See HIGH WATER TEMPERATURE SWITCH

OPEN.

2. Temp HI Limit setting is too low.

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Check Temp HI Limit setting.

IGN BOARD

COMM FAULT

1. Communication fault has occurred between the

PMC board and Ignition/Stepper (IGST) board.

1. Press CLEAR button and restart unit. If fault persists, contact

qualified Service Personnel.

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SECTION 5 – TROUBLESHOOTING GUIDE

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

IGN SWTCH CLOSED DURING PURGE

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.

1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)

position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air-Fuel Valve or the C-More Controller. Refer to qualified service personnel.

2. If the Air/Fuel Valve does rotate to purge, check the ignition switch

for continuity between the N.O. and COM terminals. If the switch shows continuity when not in contact with the cam replace the switch.

3. Check to ensure that the switch is wired correctly (correct wire

numbers on the normally open terminals). If the switch is wired correctly, replace the switch.

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not

steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace 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.

1. Start the unit. The Air/Fuel Valve should rotate to the purge (open)

position, then back to ignition position (towards closed) during the ignition cycle. If the valve does not rotate back to the ignition position, check the Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air/Fuel Valve or the C-More Controller. Refer fault to qualified service personnel.

2. If the Air/Fuel Valve does rotate to the ignition position, check the

ignition position switch for continuity between the N.O. and COM terminals when in contact with the cam.

3. Check DS1 & DS2 LEDs on Power Supply Board. If they are not

steady ON, replace Power Supply Board.

4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace IGST Board.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

INTERLOCK OPEN

Interlock jumper not installed or removed.

2. Energy Management System does not have unit

enabled.

3. Device proving switch hooked to interlocks is

not closed.

Check for a jumper properly installed across the interlock terminals

in the I/O box.

2. If there are two external wires on these terminals check any Energy

Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning).

3. Check that proving switch for any device hooked to the interlock

circuit is closing and that the device is operational.

LINE VOLTAGE OUT OF PHASE

Line and Neutral switched in AC Power Box.

2. Incorrect power supply transformer wiring.

Check hot and neutral in AC Power Box to ensure they are not

reversed.

2. Check transformer wiring, in AC Power Box, against the power box

transformer wiring diagram to ensure it is wired correctly.

LOW GAS PRESSURE

Incorrect supply gas pressure.

2. Defective Low Gas Pressure switch.

Measure gas pressure upstream of the SSOV Actuator(s) with the

unit firing. Ensure it is above the values in Table 5-1 (BMK 750-

2500) or above the value calculated in step 4 in section 5.2.2 (BMK

3000)of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

2. Measure gas pressure at the Low Gas Pressure switch. If it is

greater than 1 inch above the Low Gas Pressure switch setting (see Table 5-1 (BMK 750-2500) or above the value calculated in step 4 in section 5.2.2 (BMK 3000) in section 5.2 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205))

measure continuity across the switch and replace if necessary.

LOW WATER LEVEL

Insufficient water level in system.

2. Defective water level circuitry.

3. Defective water level probe.

Check system for sufficient water level.

2. Test water level circuitry using the C-More Controller front panel

LOW WATER TEST and RESET buttons. Replace water level circuitry if it does not respond.

3. Check continuity of probe end to the shell, change probe if there is

no continuity.

MODBUS COMMFAULT

Unit not seeing information from Modbus network.

Check network connections. If fault persists, contact qualified Service Personnel.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

PRG SWTCH CLOSED DURING IGNITION

A/F Valve rotated open to purge and did not

rotate to ignition position.

Start the unit. The Air/Fuel Valve should rotate to the purge (open)

Refer fault to qualified service personnel.

2. Defective or shorted switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse.

5. Defective IGST Board.

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. If the switch shows continuity when not in contact with the cam, check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals).

3. If the switch is wired correctly, replace the switch.

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not

steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace IGST Board.

PRG SWTCH OPEN DURING PURGE

1. Defective Purge switch.

2. No voltage present at switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board.

1. If the air-fuel valve does rotate, check Purge switch for continuity

when closing. Replace switch if continuity does not exist.

2. Measure for 24 VAC from each side of the switch to ground. If

24VAC is not present, refer fault to qualified service personnel.

3. Check to ensure that the switch is wired correctly (correct wire

numbers on the normally open terminals).

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not

steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace IGST Board.

OUTDOOR TEMP SENSOR

FAULT

1. Loose or broken wiring.

2. Defective Sensor.

3. Incorrect Sensor.

1. Inspect Outdoor Temperature sensor for loose or broken wiring.

2. Check resistance of sensor to determine if it is within specification.

3. Ensure that the correct sensor is installed.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

O2 % OUT OF RANGE

1. Combustion Calibration incorrect.

2. Blocked inlet air duct or louver.

1. Check Combustion Analyzer and recalibrate the boiler.

2. Unblock air inlet and measure open area for combustion air to the

room.

RECIRC PUMP

FAILURE

1. Internal recirculation pu mp failed.

1. Replace recirculation pump.

REMOTE SETPT SIGNAL FAULT

1. Remote setpoint signal not present:

Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

2. Signal is not isolated (floating) if 4 to 20 mA.

3. C-More Controller signal type selection switches

not set for correct signal type (voltage or current).

1. Check I/O Box to ensure s ignal is hooked up.

Hook up if not installed. If installed, check polarity. Measure signal level. Check continuity of wiring betw een source and unit.

2. Check signal at source to ensur e it is isolated.

3. Check DIP switch on PMC board to ensure it is set correctly for the

type of signal being sent. Check control signal type set in item 6 of the

Configuration menu (see Secti on 2. 6: C onfiguration Menu).

RESIDUAL FLAME

1. Defective Flame Detect or.

2. SSOV not fully closed.

1. Replace Flame Detector .

2. Check open/close indicator window of Safety Shut-Off Valv e (SSO V)

and ensure that the SSOV is fully closed. I f not f ul ly closed, replace the valve and or actuator.

Close the Gas Shut-Off Valve downstrea m of SSOV (see Section 1, Figure 1-1). Install a manometer or gauge at the leak detection por t between the SSOV and Gas Shut O ff Valv e. If a gas pressure reading is observed replace the SSOV Valve and/or Actuator.

SSOV FAULT DURING

PURGE

See SSOV SWITCH OPEN

SSOV FAULT

DURING RUN

SSOV switch closed for 15 seconds during run.

Replace or adjust micro-switch in SSOV actuator. If fault persists,

replace actuator.

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TABLE 5-1: Boiler Troubleshooting Procedures

Fault Indication

Probable Causes Corrective Action

SSOV RELAY FAILURE

SSOV relay failed on IGST board.

2. Floating Neutral.

3. Hot and Neutral reversed at SSOV.

Press CLEAR button and restart unit. If fault persists, replace

Ignition/Stepper (IGST) Board.

2. The Neutral and Earth Ground are not connec t ed at the source and

therefore there is a voltage measured between the two. Normally this measurement should be near zer o or no more than a few millivolts.

3. Check SSOV power wiring.

SSOV SWITCH OPEN

1. Actuator not allowing for full closure of gas

valve.

2. SSOV powered when it should not be

3. Defective switch or Actuator.

4. Incorrectly wired switch.

1. Observe operation of the Safety Shut-Off Valve (SSOV) through

indicator on the Valve actuator and ensure that the valve is fully and not partially closing.

2. If the SSOV never closes, it may be powered continuously. Close

the gas supply and remove power from the unit. Refer fault to qualified service personnel.

3. Remove the electrical cover from the SSOV and check switch

continuity. If the switch does not show continuity with the gas valve closed, either adjust or replace the switch or actuator.

4. Ensure that the SSOV Proof of Closure switch is correctly wired.

STEPPER MOTOR FAILURE

1. Air/Fuel Valve out of calibration.

2. Air/Fuel Valve unplugged.

3. Loose wiring connection to the stepper motor.

4. Defective Air/Fuel Valve stepper motor.

5. Defective Power Supply Board or fuse.

6. Defective IGST Board.

1. Refer to the C-More User Manual OMM-0032 (GF-112) and perform

the Stepper Feedback Calibration procedure in Section 6, section

6.2.1.

2. Check that the Air/Fuel Valve is connected to the C-More Controller.

3. Inspect for loose connections between the Air/Fuel Valve motor and

the wiring harness.

4. Replace stepper motor.

5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not

steady ON, replace Power Supply Board.

6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF

every second. If not, replace IGST Board.

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SECTION 5 – TROUBLESHOOTING GUIDE

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5.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Refer to Table 5-2 to troubleshoot faults which may occur without a specific fault message being displayed.

TABLE 5-2: Boiler Troubleshooting With No Fault Message Displayed

Observed Incident Probable Causes Corrective Action

Hard Light-Off

1. Clogged/damaged Gas Injector

on Igniter-Injector (Figure 4-1a through Figure 4-1c).

Defective Staged Ignition Solenoid (Figure 4-1a through Figure 4-1c).

1. Disconnect the Staged Ignition Assembly solenoid from the Gas

injector Tube of the Igniter-Injector (Figure 4-1a through Figure 4-1c) and inspect Gas Injector to ensure it is not clogged or damaged.

2. Close the Manual Shutoff Valve. Attempt to start the unit and listen for

a “clicking” sound that the Staged Ignition Solenoid makes during Ignition Trial. If “clicking” sound is not heard after 2 or 3 attempts, replace the Staged Ignition Solenoid.

Fluctuating Gas Pressure

1. Gas pressure going into unit is

fluctuating.

2. Damping Orifice not installed.

1. Stabilize gas pressure going into unit. If necessary, troubleshoot

Building Supply Regulator.

2. Check if the gas train is supposed to have a Damping Orifice, and if

so, ensure that it is installed in the SSOV Actuator shown in Figure 51, below. For DBB Gas Trains, the Damping Orifice is installed in the downstream SSOV Actuator).

Air/Fuel Valve “hunting” at the 70% Valve Position

1. IGST and Power Supply Boards

in C-More Controller are outdated.

1. Check to ensure that the IGST and Power Supply Boards are Rev. E

or higher.

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SECTION 5 – TROUBLESHOOTING GUIDE

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Figure 5-1: SSOV Actuator With Gas Pressure Adjustment (SKP25)

BRASS HEX HEAD

(Remove to access the Gas Pressure Adjustment Screw).

DAMPING ORIFICE

COVER SCREW

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Displays the outlet water temperature.

Displays the inlet water temperature.

) level (%)

APPENDIX A: BOILER MENU DESCRIPTIONS

Appendix A: BOILER MENU ITEM DESCRIPTIONS

TABLE A-1: OPERATING MENU ITEM DESCRIPTIONS

See section 2-4 OPERATING Menu for a range of choices and the default values.

TABLE A-1: OPERATING Menu Item Descriptions

MENU OPTIONS DESCRIPTION

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,

Active Setpoint

Outlet Temp

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. When in the Outdoor Reset Mode, this is the derived value from the charts in Appendix E.

Inlet Temp

Air Temp is the air temperature at the input to the Air/Fuel

Air Temp

Outdoor Temp

Valve Position In

Valve Position Out Displays actual real time Valve Position.

FFWD Temp Displays BST header temperature

Exhaust Temp Displays the exhaust temperature in °F (default) or ºC.

Flame Strength Displays flame strength from 0% to 100%.

Min Flame Str Not Used

O2 Monitor Enables or disables the O2 Monitor.

Oxygen Level

Valve. This reading is one of the parameters used to control the Blower Motor speed.

Outdoor temperature is displayed in ºF or ºC, only if outdoor temperature sensor is installed and enabled.

Desired input valve position. This would normally be the same as the fire valve position shown on the bar graph (valve position out) when the boiler is operating.

Displays the real-time combustion oxygen (O measured by the O2 sensor.

Ignition Time

SSOV Time to OPN

Spark Current Displays the current going to the ignition transformer.

Run Cycles Displays the total number of run cycles.

Run Hours

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Displays the elapsed time between confirmation of gas valve opening (POC) until a stable flame is detected.

Displays the elapsed time between 120VAC being applied to the Gas Valve and confirmation of gas valve opening (POC).

Displays total run time of unit in hours.

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APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-1: OPERATING Menu Item Descriptions

MENU OPTIONS DESCRIPTION

Fault Log Displays information on the last 20 faults.

An additional parameter associated with the Operating menu, Manual Valve Pos (Min = 0, Max = 100) does not appear in this menu, but can be displayed by pushing the Auto/Man button on the C-More Controller’s front face.

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TABLE A-2: SETUP Menu Item Descriptions

1234

APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-2: SETUP MENU ITEM DESCRIPTIONS

See section 2-5 SETUP Menu for a range of choices and the default values.

MENU OPTIONS DESCRIPTION

Allows Level 1 or Level 2 password to be entered. Entering the Level 1 Password (159) allows options in the Setup,

Password

Configuration and Tuning menus to be modified. Entering the Level 2 Password (6817) allows options in the

Calibration and Diagnostics Menus to be changed or activated, in addition to all Level 1 Menu options.

Language

Time Allows user to set the time, from 12:00 am to 11:59 pm.

Date Allows user to set the date, from 01/01/00 to 12/31/99

Unit of Temp

Comm Address

Baud Rate

onAER Mode

Min Upload Timer

Unit Alpha

Unit Year

Permits selection of the language of displayed messages. English is the only option at this time.

Permits selection of temperature displays in degrees Fahrenheit (°F) or degrees Celsius (°C).

For RS-485 communications. RS232 should have its own (programmable) password.

Allows communications Baud Rate to be set (2400 to 19.2K). Default is 9600.

Allows selection of either Ethernet or SD Card. Mandatory for AERCO onAER Remote Data Collection (ORDC) .

This parameter enables ORDC and defines the minimum amount of time between heartbeat data uploads in seconds. The COMM LED will light during the upload.

Mandatory for AERCO onAER Remote Data Collection. This value must match the first alpha digit on the Code Plate, e.g.,

Mandatory for AERCO onAER Remote Data Collection. This value must match the 2-digit year on the Code Plate, e.g., G-

-12-1234.

-1234.

Unit Serial #

Software Version Identifies the current software version of the C-More Controller.

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Mandatory for AERCO onAER. Remote Data Collection. This value must match the 4-digit serial # on the Code Plate, e.g., G-12-

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TABLE A-3: CONFIGURATION Menu Item Descriptions

APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-3: CONFIGURATION MENU ITEM DESCRIPTIONS

See section 2-6 CONFIGURATION Menu for a range of choices and the default values. The Configuration menu settings are Factory-Set in accordance with the requirements specified

with each individual order. No changes will be required under normal operating conditions.

MENU OPTIONS DESCRIPTION

Internal Setpoint

Unit Type

Allows internal setpoint to be set from Lo Temp Limit of 40°F to Hi Temp Limit of 240°F (4.4°C to 115.6°C).

Can be one of the following: BMK Blr Std, BMK Blr Std Dual, BMK Blr LN, BMK Blr LN Dual.

Sets unit size, depending on the Unit Type:

Unit Size

750 MBH (220 kW), 1000 MBH (293 kW), 1500 MBH (439.6 kW), 2000 MBH (586.1 kW), 2500 MBH (732.6 kW), 3000 MBH (879.2 kW)

Fuel Type Allows selection of Natural Gas or Propane.

Only available if Un it Type = Boile r.

Boiler Mode

Constant Setpoint, Remote Setpoint, Direct Drive, Combination, or Outdoor Reset Mode.

Only available if Mode = Remote Setpoint, Direct Drive or

Remote Signal

Combination. Used to set the type of external signal which will be used when operating in the Remote Setpoint, Direct Drive or Combination Mode.

Outdoor Sensor

Allows outdoor sensor function to be set to Enabled or Disabled.

Only available if Boiler Mode = Outdoor Reset. Allows the

Bldg Ref Temp

building reference temperature to be set when operating a boiler in the Outdoor Reset Mode.

Allows selection of:

Only available if Boiler Mode = Outdoor Reset. Permits setting

Reset Ratio

of Reset Ratio when operating boiler in the Outdoor Reset Mode.

System Start Tmp

Setpt Lo Limit

Setpt Hi Limit

Only if Outdoor Sensor = Enabled. This menu item allows the system start temperature to be set.

Used to set the minimum allowable setpoint, from 40°F (4.4 up to the Setpt Hi Limit.

Used to set the maximum allowable setpoint, from the Setpt Lo Limit up to 210°F (98.9

This is the maximum allowable outlet temperature, up to 210°F

°C). Any temperature above this setting will turn off the

Temp Hi Limit

(98.9 unit. The temperature must then drop 5°F (2.75 setting to allow the unit to run.

Max Valve Position Sets the maximum allowable valve position for the unit.

Pump Delay Timer

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Specifies the amount of time, up to 30 minutes, to keep the pump running after the unit turns off.

°C)

°C).

°C) below this

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TABLE A-3: CONFIGURATION Menu Item Descriptions

excessive cycling. This specifies the temperature value the

etpoint before

APPENDIX A: BOILER MENU DESCRIPTIONS

MENU OPTIONS DESCRIPTION

Specifies the amount of time to wait, up to 120 seconds,

Aux Start On Dly

between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler.

Failsafe Mode

Analog Output

Lo Fire Timer

Setpt Limiting Setpoint Limiting can be Enabled or Disabled.

Setpt Limit Band

Network Timeout

Allows the Failsafe mode to be set to either Constant Setpoint or Shutdown.

Must be set to Valve Pos 0-10V for all Benchmark models. DO NOT CHANGE from its default value.

Specifies how long, from 2 to 600 seconds, to remain in the low fire position after ignition, before going to the desired output.

The Setpoint Limit Band can be set from 0

5.5°C)

Specifies the timeout value in seconds before a Modbus fault is declared, up to 999 seconds.

This feature delays the shutdown of a boiler in order to reduce

Shutoff Dly Temp

Outlet Temperature is permitted to rise above s being shut down.

This entry will reduce excessive ON/OFF cycling in AUTO mode. When this entry is a non-zero value, the unit will not turn on again until Valve Position In (Operating menu item 7) reaches the Start Level value AND the Outlet Temperature goes below the Active Setpoint – Demand Offset. In addition,

Demand Offset

the boiler will fire at the 29% Valve Position level or below for a period of one minute.

When this entry is set to zero, the unit will turn on again as soon as the Valve Position In reaches the Start Level value (Calibration menu item 37). There will not be a one minute delay when firing at the 29% Valve Position level.

°F to 10°F (0°C to

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TABLE A-3: CONFIGURATION Menu Item Descriptions

, sets the time a boiler will

APPENDIX A: BOILER MENU DESCRIPTIONS

MENU OPTIONS DESCRIPTION

Deadband High and Deadband Low settings create an “Outlet Temperature” Zone in which no Valve Position corrections will be attempted.

The Deadband ZONE is defined as operating with an Outlet Temperature between Active Setpoint + Deadband High and Active Setpoint – Deadband Low.

Deadband High

Deadband Low

When the Outlet Temperature reaches Active Setpoint and remains there for a period of 15 seconds, the unit will go into a DEADBAND MODE at which point no Valve Position corrections will be attempted while the Outlet Temperature remains anywhere within the Deadband ZONE. When the unit is in the DEADBAND MODE, the °F or °C LED will f las h o n and off. When the Outlet Temperature drifts out of the Deadband ZONE, the DEADBAND MODE will be terminated and the PID LOOP will again attempt Valve Position corrections.

Setting range is 0°F (0°C) to 25°F (13.75°C). Default is 5°F (2.75°C) for both Deadband High and Deadband Low).

IGST Version Displays the version of the IGST Board installed.

IGN Time Setting

Slow Shutdown Set the Slow Shutdown feature to Enabled or Disabled.

Displays the MAX Ignition time of 4 Seconds or 7 Seconds as set in the Safety String Harness.

If Slow Shutdown = Enabled

Slow Sht Dur ation

continue to run at the Stop Level after running above the Slow Sht Threshold level, up to 9,999 seconds.

Slow Sht Threshold

O2 Warnings

O2 Trim ID

Fixed ID

O2 Trim Key

O2 Trim Menu

BST Menu

Sets the Fire Rate above which a boiler will trigger the Slow Shutdown feature.

Enables or disables AERtrim warning messages. Displays 4 digit AERtrim ID number. Pr e-populated on all units.

Changes each time the unit is powered up. Displays the unit’s fixed 4 digit ID number. Pre-populated on all

units. Does not change. Displays the value of the AERtrim 4 digit license key. Pre-

populated on all units. When set to Enabled, the AERtrim menu options appears.

When set to Enabled, the BST menu options appears.

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TABLE A-4: TUNING Menu Item Descriptions

Timer

APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-4: TUNING MENU ITEM DESCRIPTIONS

See section 2-7 TUNING Menu for a range of choices and the default values.

MENU OPTIONS DESCRIPTION

Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature.

Prop Band

Integral Gain

Derivative Time

If the actual error is less than the proportional band setting (1°F to 120°F, 0.55°C to 66°C), 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%.

This sets the fraction of the output, due to setpoint error, to add or subtract from the output each minute to move towards the setpoint. Gain is adjustable from 0.00 to 1.00 (Default is 1.0).

This value (0.0 to 2.0 min.) responds to the rate of change of the setpoint error. This is the time that this action advances the output.

Warmup – The feature embodied in menu items 4, 5 and 6 eliminates Temperature Overshoots during the “Warmup” period of a cold ignition cycle on all boilers by temporarily modifying the PID Gain parameter during warmup and for a period defined in the Tuning menu.

Warmu p Prop

Band

Warmup Int Gain Range = 0.00 – 2.00 Default = .50 Warmu p PID

Reset Defaults?

Range = 1 – 120°F (0.55°C to 66°C)

Default = 95 (52°C)

Range = 0 - 240 seconds Def ault = 20 seconds

Allows Tuning menu options to be reset to their Factory Default values.

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TABLE A-5: COMBUSTION CAL Menu Item Descriptions

APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-5: COMBUSTION CALIBRATION MENU ITEM DESCRIPTIONS

See section 2-8 COMBUSTION CAL Menu for a range of choices and the default values.

NOTE:

The Level 2 Password must be entered to view the options in the Combustion Cal menu. T his Menu is used during the Combustion Calibration procedures described in Section 4.4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

MENU OPTION DESCRIPTION

CAL Voltage:

BMK 750 = 18% BMK 1000 = 18%

BMK 1500 = 16% BMK 2000 = 18% BMK 2500 = 16% BMK 3000 = 14%

CAL Voltage 30%

Displays the default DC drive voltage provided to the blower at each Air/Fuel Valve position (Items 1 – 6). This drive voltage adjusts the rotational speed of the blower to maximize combustion efficienc y.

CAL Voltage 40%

CAL Voltage 50%

CAL Voltage 70%

CAL Voltage 100%

Set Valve Position

Blower Output Permits the DC drive voltage to the blower to be monitored.

Set Stby V out Permits the Standby Voltage to be set from 0 to 4.00 Volts.

Oxygen Level

Permits selection of the Air/Fuel Valve position (% open) to be set from 0 to 100%.

Permits the combustion oxygen level to be displayed (0% to 25%)

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TABLE A-6: CALIBRATION Menu Item Descriptions

Allows adjustment of the valve position (Fire Rate) during the ignition sequence.

APPENDIX A: BOILER MENU DESCRIPTIONS

TABLE A-6: CALIBRATION MENU ITEM DESCRIPTIONS

See section 2-10 CALIBRATION Menu for a range of choices and the default values.

MENU OPTION DESCRIPTION

Allows the Air/Fuel Valve stepper motor feedback current to be calibrated at

Stepper Fbk

the 0% (fully closed) and 100% (fully open) positions. Verification can also be accomplished at the 50% position.

Purge Timer

Post Purge Timer

IGN Position

Ign Pos Hold Tmr

FFWD Temp Disply

Outlet Tmp Dsply

Inlet Tmp Dsply

Valv Pos Out Dsp

Exhaust Tmp Dsp

Exhaust Safety

Flue Material

13 Exhst Fault Temp 14 Exhst Module Temp 15 Exhst Warn Temp 16

Exhst Tmp VP Adj

Allows adjustment of the pre-ignition purge time. Allows adjustment of the purge time when a unit shuts down.

Enabled or Disabled. Enabled or Disabled. Enabled or Disabled. Enabled or Disabled. Enabled or Disabled.

Enabled or Disabled. Select flue material: PVC, Polypropylene, or stainless Fault threshold temperature Decreases Valve Position to lower exhaust temperature. Flue temperature high warning VP adjust value

17 Exhst Ad j Rate 18 VP Chang e Rate

19 VP Up Rate

20 VP Down Rate

21 Purge Blwr Offst

22 4-20m A Purge Pct

23 PWM In Adj 24 Analog In Adj 25

Flow In Adj

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VP adjust rate

Allows adjustment of the Valve Position (Fire Rate) increase rate when raising the Valve Position. VP Up Rate is defined as Seconds per Step.

Allows adjustment of the Valve Position (Fire Rate) decrease rate when lowering the Valve Position. VP Down Rate is defined as Seconds per Step.

Allows adjustment of the blower speed (Blower Output Voltage) during the Purge cycle.

Allows adjustment of the blower speed (Blower Output Voltage) during the Purge cycle when using an Emerson VFD Drive to control the Blower Motor.

Allows the Pulse Width Modulation (PWM) duty cycle to be adjusted from -

5.0% to +5.0% in 0.1% increments. Allows adjustment of the analog input from -5.0% to +5.0%. Allows adjustment of the water Flow Rate Input from

-5.0% to +5.0%.

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TABLE A-6: CALIBRATION Menu Item Descriptions

instance when a unit emits an objectionable noise at a certain Fire Rate and no other remedy solves the

APPENDIX A: BOILER MENU DESCRIPTIONS

MENU OPTION DESCRIPTION

Supply Gas Pressure

In Adj

27 G as Plat e dp In Adj

mA Out Adj

A/F Sensitivity

Power Reset

Water Temp Reset

Gas Press Reset

Min Off Time

Heatr Tuning Dsp

Heatr Bkpt Dsp

Stop Level

Start Level

Allows adjustment of the Supply Gas Pressure level from

-5.0% to +5.0% in 0.1 % increments. Allows adjustment of the Gas Plate dp level from -5.0% to +5.0% in 0.1%

increments. Allows adjustment of the milliamp output from -5.0 mA to +5.0 mA. Allows adjustment of the Air/Fuel (A/F) Valve stepper motor sensitivity to be

adjusted from 1% to 5% in 1% increments. Allows the Power Reset Option to be set to AUTO or MANUAL. Allows the Water Temperature Reset function to be set to AUTO or

MANUAL. Allows the Gas Pressure Reset function to be set to AUTO or MANUAL. Allows the minimum Off time to be set from 0 to 10 minutes. Allows Heater Tuning Display to be Enabled or Disabled. Allows Heater Breakpoint Display to be Enabled or Disabled. When Enabled,

Breakpoints can be viewed and/or changed. Allows the Stop Level to be set to a valve position ranging from 0% to the

presently set Start Level. Allows the Start Level to be set to a valve position ranging from the presently

set Stop Level to a maximum of 40%.

SKIP FEATURE: Items 38 – 40 em body a feature that allows the user to define a Fire Z one the C-More will avoid. In the rare

problem, a Fire Rate skip zone may be defined to command the C-More to Skip-Over the defined Fire Rate.

38 39 40

O2 Settings:

Items 41 – 43 allow calibration of oxygen readings.

42 43 44

Temperature Channel Offset:

Items 45 – 50 embody the feature, which allow the user to field calibrate all six temperature channels by entering an offset corresponding to the desired temperature channel.

– Skip Range CNTR – Skip Range Span – Skip Speed

– O2 Gain – O2 Offset – O2 Sensor

Cal Temp Sensors

Defines the Center (Fire Rate) of the skip band. Defines the + and – band of the Skip Zone Size. Defines the speed (Seconds/Fire Rate) at which the band will be skipped.

Range = 0.5 to 1.5. (Unity Gain, No Mods) Range = -3.0 to +3.0. Enables the O2 Sensor Allows calibration of the temperature sensor

– FFWD Tem p O ffset

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Range: -20 to + 20 (either ºF or °C)

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TABLE A-6: CALIBRATION Menu Item Descriptions

APPENDIX A: BOILER MENU DESCRIPTIONS

MENU OPTION DESCRIPTION

46 47 48 49 50

– Exhst Tmp Ofset – Outdr Air Offset – Inlet Air Offset – Inlet Wtr Offset

– Outlet Wtr Offset

51 24 hr Max Cycles

24 hr Max Ovrtemp

0-10v Out Test

Spark Monitor

Min Spark Amps

Max Spark Amps

Range: -20 to + 20 (either ºF or °C) Range: -20 to + 20 (either ºF or °C) Range: -20 to + 20 (either ºF or °C) Range: -20 to + 20 (either ºF or °C) Range: -20 to + 20 (either ºF or °C)

Maximum cycles in 24 hour period. Maximum over-temp in 24 hour period. Set the blower voltage at 0-10v for testing.

Enables or disables the Spark Monitor function, which displays the AC current on the input of the Ignition Transformer.

Allows the adjustment of the minimum spark current required at the spark transformer input.

Allows the adjustment of the maximum spark current required at the spark transformer input.

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APPENDIX A: BOILER MENU DESCRIPTIONS

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TABLE B-1: Startup and Status Messages

APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES

Appendix B: STARTUP, STATUS, & FAULT MESSAGES

TABLE B-1: STARTUP AND STATUS MESSAGES

MESSAGE DESCRIPTION

DEMAND DELAY XX sec

DISABLED HH:MM pm, pm

MM/DD/YY FLAME PROVEN

IGNITION TRIA L XX sec

PURGING XX sec

STANDBY

Displayed if Demand Delay is active.

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.

Displayed after flame has been detected for a period of 2 seconds. Initially, the flame strength is shown in %. After 5 seconds has elapsed, the time and date are shown in place of flame strength.

Displayed during ignition trial of startup sequence. The duration of cycle counts up in seconds.

Displayed during the purge cycle during startup. The duration of the purge cycle counts up in seconds.

Displayed when ON/OFF switch is in the ON position, but there is

no demand for heat. The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP

XX sec

Displayed for 2 minutes during the initial warm-up only.

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE B-2: Fault Messages

DURING RUN

APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES

TABLE B-2: FAULT MESSAGES

FAULT MESSAGE FAULT DESCRIPTION

AIRFLOW FAULT DURING PURGE

AIRFLOW FAULT DURING IGN

AIRFLOW FAULT

DELAYED INTERLOCK OPEN

DIRECT DRIVE SIGNAL FAULT

FFWD TEMP SENSOR FAULT

FLAME LOSS DURING IGN

FLAME LOSS DURING RUN

HEAT DEMAND FAILURE

HIGH EXHAUST TEMPERATURE

The Blower Proof switch opened during purge, or air inlet is blocked.

The Blower Proof switch opened during ignition.

The Blower Proof switch opened during run.

The Delayed Interlock is open.

The direct drive signal is not present or is out of range. The temperature measured by the Feed Forward (FFWD) Sensor

is out of range. The Flame signal was not seen during ignition or lost within 5

seconds after ignition. The Flame signal was lost during run. The Heat Demand Relays on the Ignition board failed to activate

when commanded. The Exhaust Temperature has exceeded 200°F (93.3

°C).

GAS PRESSURE FAULT

HIGH WATER TEMPERATURE

HIGH WATER TEMP SWITCH OPEN

IGN BOARD COMM FAULT

IGN SWTCH CLOSED DURING PURGE

IGN SWTCH OPEN DURING IGNITION

INTERLOCK OPEN

LINE VOLTAGE OUT OF PHASE

Page 86 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 11/29/2017 Ph.: 800-526-0288 GF-206

The High Gas Pressure Limit switch is open or the Low Gas Pressure Limit switch is open.

The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting.

The High Water Temperature Limit switch is open. A communication fault has occurred between the PMC board and

Ignition board. The Ignition Position Limit switch on the Air/Fuel Valve closed

during purge. The Ignition Position Limit switch on the Air/Fuel Valve opened

during ignition. The Remote Interlock is open.

The Line (Hot) and Neutral wires are reversed.

Page 87

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

TABLE B-2: Fault Messages

OUTLET TEMPERATURE display = SHt Indicates

OUTLET TEMPERATURE display = Opn indicates

SIGNAL FAULT

DURING RUN

APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES

FAULT MESSAGE FAULT DESCRIPTION

LOW WATER LEVEL

NETWORK COMM FAULT

The Low Water Cutoff board is indicating low water level.

The RS-485 network information is not present or is corrupted.

O2 % OUT OF RANGE The O OUTDOOR TEMP

SENSOR FAULT

The temperat ure measured by the Outdoor Air Sensor is out of range.

The temperature measured by the Outlet Sensor is out of range:

•

OUTLET TEMP SENSOR FAULT

•

PRG SWTCH CLOSED DURING IGNITION

PRG SWTCH OPEN DURING PURGE

REMOTE SETPT

The Purge Position Limit switch on the Air/Fuel Valve closed during ignition.

The Purge Position Limit switch on the Air/Fuel Valve opened during purge.

The Remote Setpoint signal is not present or is out of range.

% has gone below 3% or above 8%.

sensor is shorted

sensor is open-circuited

RESIDUAL FLAME

SSOV SWITCH OPEN

SSOV FAULT DURING PURGE

SSOV FAULT DURING IGN

SSOV FAULT

SSOV RELAY FAILURE

STEPPER MOTOR FAILURE

The Flame signal was seen for more than 60 seconds during standby.

The SSOV switch opened during standby.

The SSOV switch opened dug purge.

The SSOV switch closed or failed to open during ignition.

The SSOV switch closed for more than 15 seconds during run. A failure has been detected in one of the relays that control the

SSOV. The Stepper Motor failed to move the Air/Fuel Valve to the desired

position.

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Page 88

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

APPENDIX B – STARTUP, STATUS, AND FAULT MESSAGES

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Page 89

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Temperature Sensor Resistance Voltage Chart (BALCO)

APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART

Appendix C: SENSOR RESISTANCE/VOLTAGE CHART

TEMPERATURE

RES (OHMS) VOLTS*

°F °C

-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

-40

-34.4

-28.9

-23.3

-17.2

-12.2

-6.7

-1.1

4.4 10

15.5

21.1

26.7

32.2

37.8

43.3

48.9

54.4 60

65.6

71.1

76.7

82.2

87.8

93.3

98.9

104.4 110

115.6

121.1

779.0

797.5

816.3

835.4

854.8

874.6

894.7

915.1

935.9

956.9

978.3

1000.0

1022.0

1044.4

1067.0

1090.0

1113.3

1137.0

1160.9

1185.2

1209.5

1234.7

1260.0

1285.6

1311.4

1337.7

1364.2

1391.0

1418.2

1445.7

1.93

1.96

1.99

2.02

2.05

2.07

2.10

2.12

2.15

2.17

2.20

2.23

2.25

2.27

2.30

2.32

2.34

2.36

2.39

2.41

2.43

2.45

2.47

2.50

2.52

2.54

2.56

2.58

OMM-0122_0C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 89 of 164 GF-206 Ph.: 800-526-0288 11/29/2017

Page 90

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART

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Page 91

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Recommended Periodic Testing

APPENDIX D – RECOMMENDED PERIODIC TESTING

Appendix D: RECOMMENDED PERIODIC TESTING

WARNING!

Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage. 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.

ITEM FREQUENCY ACTION BY REMARKS

NOTE: Refer to indicated sections of this manual and the Benchmark 750 – 3000 Installation and Startup Guide OMM-0121 (GF-205) for detailed procedures.

Gauges, monitors and indicators

Instrument and equipment settings

Firing Rate Control

Flue, vent, stack or intake air duct

Spark Igniter-Injector Weekly Operator See Section 4.2. Air/Fuel Valv e

position

SSOV Leakage test Annually Service Technician

Flame failure Weekly Operator

Daily Operator

Weekly Operator Verify factory settings

Semi-Annually Service Technician Verify factory settings

Annually Service Technician

Monthly Operator

Weekly Operator

Visual inspection and record readings in operator log

Visual check against factory recommended specifications

Check with combustion calibration test equipment (see Section 4.4 of the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205)), and the O Section 4.4 of this guide.

Visually inspection condition and check for obstructions

Check position indicator dial. See Section 3.2 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

Check for leakage in accordance with the SSOV manufacturer’s (Siemens) recommendations.

Close manual gas shutoff valve and check safety shutdown. See Section 5.7 in the

Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

sensor in

Flame signal strength

Low water level cut off and alarm

Slow drain test Semi-Annually Operator

High water temp. safety control test

OMM-0122_0C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 91 of 164 GF-206 Ph.: 800-526-0288 11/29/2017

Weekly Operator

Annually Service Technician

Check flame strength using the C-More Controller’s Operating menu (see section 2.4).

See section 5.4 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

Perform a slow drain test in accordance with ASME Boiler and Pressure Vessel Code, Section IV.

See section 5.5 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

Page 92

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Recommended Periodic Testing

APPENDIX D – RECOMMENDED PERIODIC TESTING

ITEM FREQUENCY ACTION BY REMARKS

Operating controls Annually Operator See section 2.2.

See section 5.8 in the Benchmark 750 – 3000

Low air fl ow Monthly Operator

Installation and Startup Guide, OMM-0121 (GF-205).

High and low gas pressure interlocks

Air/Fuel Valve purge position switch

Air/Fuel Valv e ignition position switch

Safety valves As required Operator

Inspect burner components

Condensate Trap

Oxygen (O2) Level Monthly Operator

Monthly Operator

Annually Service Technician

Semi-Annually Service Technician

Semi-

Annually

Operator See section 4.7.

See sections 5.2 and 5.3 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM-0121 (GF-205).

See section 5.10 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM0121 (GF-205).

See section 5.11 in the Benchmark 750 – 3000 Installation and Startup Guide, OMM0121 (GF-205).

Check per A.S.M.E. Boiler and Press ure Vessel Code, Section IV.

See section 4.6.

Verify oxygen level is between 3% and 8% during boiler operation.

Page 92 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 11/29/2017 Ph.: 800-526-0288 GF-206

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

10.0

7.2

4.4

1.7

-1.1

-3.9

100

105

110

-6.7

104

110

116

122

-9.4

106

113

120

127

134

-12.2

106

114

122

130

138

146

-15.0

104

113

122

131

140

149

158

-17.8

100

110

120

130

140

150

160

170

-5

-20.6

105

116

127

138

149

160

171

182

-10

-23.3

110

122

134

146

158

170

182

194

-15

-26.1

102

115

128

141

154

167

180

193

206

-20

-28.9

106

120

134

148

162

176

190

204

218

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

15.6

12.8

10.0

7.2

4.4

100

104

108

1.7

100

105

110

115

120

-1.1

102

108

114

120

126

132

-3.9

102

109

116

123

130

137

144

-6.7

100

108

116

124

132

140

148

156

-9.4

105

114

123

132

141

150

159

168

-12.2

100

110

120

130

140

150

160

170

180

-15.0

104

115

126

137

148

159

170

181

192

-17.8

108

120

132

144

156

168

180

192

204

-5

-20.6

112

125

138

151

164

177

190

203

216

-10

-23.3

102

116

130

144

158

172

186

200

214

-15

-26.1

105

120

135

150

165

180

195

210

-20

-28.9

108

124

140

156

172

188

204

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS

Appendix E: INDOOR/OUTDOOR RESET RATIO CHARTS

Header Temperature for a Building Reference Temperature = 50°F (10.0°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Header Temperature for a Building Reference Temperature = 60°F (15.6°C)

AIR TEMP RESET RATIO

°F °C

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

18.3

15.6

12.8

10.0

101

7.2

101

105

109

113

4.4

100

105

110

115

120

125

1.7

101

107

113

119

125

131

137

-1.1

100

107

114

121

128

135

142

149

-3.9

105

113

121

129

137

145

153

161

-6.7

101

110

119

128

137

146

155

164

173

-9.4

105

115

125

135

145

155

165

175

185

-12.2

109

120

131

142

153

164

175

186

197

-15.0

101

113

125

137

149

161

173

185

197

209

-17.8

104

117

130

143

156

169

182

195

208

-5

-20.6

107

121

135

149

163

177

191

205

219

-10

-23.3

110

125

140

155

170

185

200

215

-15

-26.1

113

129

145

161

177

193

209 -20

-28.9

116

133

150

167

201

218

21.1

18.3

15.6

12.8

100

103

106

10.0

102

106

110

114

118

7.2

100

105

110

115

120

125

130

4.4

100

106

112

118

124

130

136

142

1.7

105

112

119

126

133

140

147

154

-1.1

102

110

118

126

134

142

150

158

166

-3.9

106

115

124

133

142

151

160

169

178

-6.7

100

110

120

130

140

150

160

170

180

190

-9.4

103

114

125

136

147

158

169

180

191

202

-12.2

106

118

130

142

154

166

178

190

202

214

-15.0

109

122

135

148

161

174

187

200

213

-17.8

112

126

140

154

168

182

196

210

-5

-20.6

115

130

145

160

175

190

205

-10

-23.3

118

134

150

166

182

198

214 -15

-26.1

121

138

155

172

189

206

-20

-28.9

124

142

160

178

196

214

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS

Header Temperature for a Building Reference Temperature = 65°F (18.3°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Header Temperature for a Building Reference Temperature = 70°F (21.1°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

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Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

23.9

21.1

18.3

15.6

102

105

108

111

12.8

103

107

111

115

119

123

10.0

100

105

110

115

120

125

130

135

7.2

105

111

117

123

129

135

141

4.4

103

110

117

124

131

138

145

152

159

1.7

107

115

123

131

139

147

155

163

171

-1.1

102

111

120

129

138

147

156

165

174

183

-3.9

105

115

125

135

145

155

165

175

185

195

-6.7

108

119

130

141

152

163

174

185

196

207

-9.4

111

123

135

147

159

171

183

195

207

219

-12.2

114

127

140

153

166

179

192

205

218

-15.0

117

131

145

159

173

187

201

215 0 -17.8

120

135

150

165

180

195

210

-5

-20.6

123

139

155

171

187

203

219 -10

-23.3

126

143

160

177

194

211

-15

-26.1

129

147

165

183

201

219

26.7

23.9

21.1

100

102

104

18.3

101

104

107

110

113

116

15.6

100

104

108

112

116

120

124

128

12.8

100

105

110

115

120

125

130

135

140

10.0

104

110

116

122

128

134

140

146

152

7.2

101

108

115

122

129

136

143

150

157

164

4.4

104

112

120

128

136

144

152

160

168

176

1.7

107

116

125

134

143

152

161

170

179

188

-1.1

110

120

130

140

150

160

170

180

190

200

-3.9

113

124

135

146

157

168

174

190

201

212

-6.7

116

128

140

152

164

176

188

200

212 15

-9.4

119

132

145

158

171

184

197

210

-12.2

122

136

150

164

178

192

206 5

-15.0

125

140

155

170

185

200

215

-17.8

128

144

160

176

192

208

-5

-20.6

131

148

165

182

199

216

-10

-23.3

134

152

170

188

206

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS

Header Temperature for a Building Reference Temperature = 75°F (23.9°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Header Temperature for a Building Reference Temperature = 80°F (26.7°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

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Page 96

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

32.2

29.4

100

101

102

26.7

100

102

104

106

108

110

112

114

23.9

102

105

108

111

114

117

120

123

126

21.1

102

106

110

114

118

122

126

130

134

138

18.3

105

110

115

120

125

130

135

140

145

150

15.6

108

114

120

126

132

138

144

150

156

162

12.8

111

118

125

132

139

146

153

160

167

174

10.0

114

122

130

138

146

154

162

170

178

186

7.2

117

126

135

144

153

162

171

180

189

198

4.4

120

130

140

150

160

170

180

190

200

210

1.7

123

134

145

156

167

178

189

200

-1.1

126

138

150

162

174

186

198

210

-3.9

129

142

155

168

181

194

207

-6.7

132

146

160

174

188

202

216 15

-9.4

135

150

165

180

195

210

-12.2

138

154

170

186

202

218 5 -15.0

141

158

175

192

209

-17.8

144

162

180

198

216

APPENDIX E: INDOOR/OUTDOOR RESET RATIO CHARTS

Header Temperature for a Building Reference Temperature = 90°F (32.2°C)

AIR TEMP RESET RATIO

°F °C 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

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Page 97

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Item #

Qty

Part #

Description

EXHAUST MANIFOLD

1 1 43086

MANIFOLD: EXHAUST

2 1 84045

SEAL: EXHAUST MANIFOLD

GAS TRAIN ASSEMBLY

22140-1

STD FM GAS TRAIN ASSY

22140-2

DBB GAS TRAIN ASSY

22140-3

PROPANE GAS TRAIN ASSY

5 1 81155

GASKET: 1 1/4" PIPE FLANGE

BURNER, AIR/FUEL VALVE, HEAT EXCHANGER

8 1 24276-TAB

BURNER A/F ASSEMBLY

10 1 46026

BURNER

24367-1

BMK 1000 A/F Valve Replacement Kit

24367-2

BMK 750 A/F Valve Replacement Kit

13 1 24277

STAGED IGNITION ASSY

14 1 81143

GASKET: BURNER

BMK 750 HEAT EXCHANGER (Single Inlet)

BMK 1000 HEAT EXCHANGER (Single Inlet)

HOSES & INSULATION

18 1 97087-20

TUBE: FLEXIBLE GAS 20" (50.8 cm)

19 1 80080

INSULATION: SHELL

BLOWER

20 1 58061

BLOWER BMK 750/100 Replacement Kit

24 1 24356-1

FLAME DETECTOR Replacement Kit

25 1 61026

LEAN OXYGEN SENSOR

58023

IGNITER-INJECTOR Replacement Kit

27 1 59139

AIR FILTER: 6" X 4.5 (11.4 cm) LG

CONTROLS

28 1 123966

SWITCH: OVER TEMP-AUTO RESET

29 1 123552

SWITCH: OVER TEMP-MANUAL RESET

30 1 60011-4

BLOWER PROOF SWITCH ASSY:

31 1 61002-5

BLOCKED INLET SWITCH -4.5 W.C.

32 1 65085

IGNITION TRANSFORMER

33 1 61034

SPARK MONITOR (AC Transducer)

34 1 60026

CIRCUIT BREAKER 2 POLE 20A

35 1 64081

ECU

36 1 65011

TRANSFORMER 115V/24V 100VA

37 1 65109

12V POWER SUPPLY

39 2 65120

TERMINAL BLOCK: DIN MOUNTED: BLK

TERMINAL BLOCK: DIN MOUNTED: WHT

TERMINAL GROUND BLOCK: DIN MOUNTED

42 2 65118

FUSE TERMINAL: DIN MOUNTED

43 1 64088

LIMIT CONTROL TEMPERATURE

45 1 24327

ASSEMBLY: POWER SUPPLY COVER

46 1 69102-2

BENCHMARK PUMP RELAY

47 2 124512

FUSE: 4 AMP

48 2 123449

SENSOR: TEMPERATURE

49 1 58132

THERMOWELL Replacement Kit

C-MORE CONTROLLER

52 1 69172

I/O (PCB) ASSEMBLY

60 1 65156

FLAME ROD SIGNAL AMPLIFIER

61 1 61030

OUTLET TEMP SENSOR

62 1 61024

AIR INLET TEMPERATURE SENSOR

24V POWER SUPPLY (SEQUENCING VALVE)

SHEET METAL/PANEL ASSEMBLY

70 1 37155

PANEL: LEFT (Black)

71 1 37156

PANEL: RIGHT (Black)

72 1 37154

TOP COVER ASSY (Black)

73 1 25087

FRONT FRAME ASSY. (Black)

74 1 25085-3

FRONT PANEL

76 2 59179

HANDLE, CONCEALED PULL

77 4 59133

LATCH: COMPRESSION

78 1 50010

LATCH: DRAW

79 1 50011

KEEPER: DRAW LATCH

82 1 39217

AIR INLET ADAPTER: 6" PVC (Black)

OTHER ACCESSORIES / PARTS

89 1 122843

LOW WATER CUTOFF

90 1 123863

VALVE: BALL 1/8" NPT

91 1 92094

BOILER DRAIN VALVE: 3/4 MNPT x GHT

94 1 59178

VENT: AIR 1/8 NPT

BMK 750 28321-TAB rev F

BMK 1000 28253-TAB rev F

APPENDIX F – BENCHMARK 750/1000 PART LIST

Appendix F: BENCHMARK 750/1000 PART LIST

Benchmark 750 and Benchmark 1000 Part List

12 1

17 1

69 1 65162

28576

28586

65121

65122

69186-4

AERCO International,

Inc. Blauvelt, NY

10913

Page 97 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 10/25/2017 Ph.: 800-526-0288 GF-206

 Not shown on drawing

Benchmark 750/1000 Part List

09/28/2017

Sheet 1 of 6

Page 98

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

Benchmark 750/100 0 Sp are Part s Kit P/N 58037-TAB

58037-1

Apollo

58037-2

Conbraco

58037-3

Apollo

58037-4

Watts

58037-5

Watts

58037-6

Watts

58037-7

Watts

58037-8

Kunkle

24286

6” Exhaust Kit

1 1 1 1 1 1 1 1 24441

Condensate Trap Assy.

1 1 1 1 1 1 1 1 92006-5

1” Ball Valve

1 1 1 1 1 1 1 1 123675-2

Tridicator

1 1 123675-3

Tridicator

1 1 1 1 123675-4

Tridicator

1 1 92014

Pressure Relief Valve

1 92015-13

Pressure Relief Valve

92015-15

Pressure Relief Valve

92015-16

Pressure Relief Valve

92015-20

Pressure Relief Valve

92015-484

Pressure Relief Valve

92015-361

Pressure Relief Valve

123659

Pressure Relief Valve

9-234

¾” Close Nipple

1 1 1 1 1 1

Part #

Description

63182

HARNESS: SHELL

63083

HARNESS: O2 SENSOR

63085

HARNESS: CONTROL

63090

HARNESS: TEMPERATURE LIMIT CONTROL

63097

HARNESS: I/O SENSOR/COMM

63147

HARNESS: WIRING: GAS TRAIN

63150

HARNESS: FLAME ROD

65104

CABLE: H.V. IGNITION

124327

HARNESS: INTERLOCK

Part #

Description

27086-1

ACTUATOR: SSOV w/o P.O.C. SWITCH Replacement Kit

64048

SSOV WITH PRESSURE REGULATOR Replacement Kit

Part #

Description

92084-6

MOTORIZED SEQUENCING VALVE

BMK 750 28321-TAB rev F

BMK 1000 28253-TAB rev F

APPENDIX F – BENCHMARK 750/1000 PART LIST

Part Number

Description

30 PSI

50 PSI

Wiring Harnesses (not shown in figures below)

75 PSI

100 PSI

150 PSI

60 PSI

125 PSI

160 PSI

Additional Benchmark 750/1000 Kits Available

Other Accessories / Parts (Optional)

AERCO International,

Inc. Blauvelt, NY

10913

Page 98 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 11/29/2017 Ph.: 800-526-0288 GF-206

Benchmark 750/1000 Part List

09/28/2017

Sheet 2 of 6

Page 99

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 750 28321-TAB rev F

BMK 1000 28253-TAB rev F

FRONT VIEW

LEFT-REAR VIEW

RIGHT-REAR VIEW

APPENDIX F – BENCHMARK 750/1000 PART LIST

Benchmark 750/1000

Gas Trains

FM Gas Train 22140-1 Propane Gas Train 22140-3 DBB Gas Train 22140-2

AERCO International,

Inc. Blauvelt, NY

10913

Page 99 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 10/25/2017 Ph.: 800-526-0288 GF-206

Benchmark 750/1000 Part List

09/28/2017

Sheet 3 of 6

Page 100

Benchmark 750-3000 Boiler Operation, Service & Maintenance Guide

BMK 750 28321-TAB rev F

BMK 1000 28253-TAB rev F

APPENDIX F – BENCHMARK 750/1000 PART LIST

AERCO International,

Inc. Blauvelt, NY

10913

Page 100 of 164 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0122_0C 11/29/2017 Ph.: 800-526-0288 GF-206

Burner – Air/Fuel Valve Assembly

Benchmark 750/1000 Part List

Benchmark 750/1000

P/N 24276-TAB

Full Diagram Below

09/28/2017

Sheet 4 of 6