AERCO BMK 2.0 LN Dual Fuel User Manual
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Instruction
No.
GF-127
Installation, Operation
& Maintenance Instructions
Benchmark 2.0LN
Dual-Fuel Series
Gas Fired
Boiler System
Natural Gas or Propane Fired
Condensing, Modulating,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Appicable for Serial Numbers G-10-0631 and above
Printed in U.S.A. NOVEMBER 10, 2010
Telephone Support
Direct to AERCO Technical Support
(8 am to 5 pm EST, Monday - Friday):
1-800-526-0288
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco,com
© AERCO International, Inc., 2010
The information contained in this
installation, operation and maintenance manual is subject to change
without notice from AERCO International, Inc.
AERCO makes no warranty of any
kind with respect to this material,
including, but not limited to, implied
warranties of merchant-ability and
fitness for a particular application.
AERCO International is not liable for
errors appearing in this manual, nor
for incidental or consequential
damages occurring in connection
with the furnishing, performance, or
use of this material.
FOREWORD
Foreword
The AERCO Benchmark 2.0LN Dual-Fuel, Low NOx Boiler is a modulating unit. It repr esents 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 fluctuat ing system loads. The Benchmark 2.0LN, with
its 20:1 turn down ratio and condensing capability, provides extremely high efficiencies and
makes it ideally suited for modern low temper ature, as well as, conventional heating systems.
The Benchmark 2.0 operates at inputs rang ing f rom 100,000 BT U/hr. to 2,000,000 BTU/ hr. The
output of the boiler is a f unction of the unit’s firing rate and return water temperat ure. Output
ranges from 99,000 BT U/hr. to 1,933,000 BTU/hr . , depending on operating conditions.
When installed and operated on natural gas in accordance with this Instruction Manual, the
Benchmark 2.0LN Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or m odular arrangement s, the Benchmark 2.0LN off ers the maximum
flexibility in venting with minimum installation space requirements. The Benchmark 's advanced
electronics are available in several selectable modes of operation offering the most efficient
operating methods and energy manag em ent system integration.
For service or parts, contact your local sales represent at ive or AERCO I NTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________
A
CONTENTS
GF-127 - BENCHMARK 2.0 LN DUAL-FUEL GAS FIRED BOILER
Operating & Maintenance Instructions
FOREWORD A
Chapter 1 – SAFETY PRECAUTIONS 1-1
Para. Subject Page
1-1 Warnings & Cautions 1-1
1-2 Emergency Shutdown 1-2
Chapter 2 – INSTALLATION 2-1
Para. Subject Page
2.1 Introduction 2-1
2.2 Receiving the Unit 2-1
2.3 Unpacking 2-1
2.4 Site Preparation 2-1
2.5 Supply and Return Piping 2-3
2.6 Condensate Drain 2-3
2.7 Gas Supply Piping 2-4
2.8 AC Elec tric a l Po wer Wiring 2-5
Para. Subject Page
1-3 Prolonged Shutdown 1-2
Para. Subject Page
2.9 Modes of Operation and Field
Control Wiring
2.10 I/O Box Connections 2-8
2.11 Auxiliary Relay Contacts 2-10
2.12 Flue Gas Vent Installation 2-10
2.13 Combustion Air 2-10
2-6
Chapter 3 – CONTROL PANEL OPERATING PROCEDURES 3-1
Para. Subject Page
3.1 Introduction 3-1
3.2 Control Panel Description 3-1
3.3 Control Panel Menus 3-4
3.4 Operating Menu 3-5
3.5 Setup Menu 3-5
Para. Subject Page
3.6 Configuration Menu 3-6
3.7 Tuning Menu 3-7
3.8 Combustion Cal Menu 3-8
3.9 Start Sequence 3-9
3.10 Start/Stop Levels 3-11
Chapter 4 – INITIAL START-UP 4-1
Para. Subject Page
4.1 Initial Startup Requirements 4-1
4.2 Tools and Instruments for
Combustion Calibration
4.3 Natural Gas Combustion
Calibration
4-1
4-2
Para. Subject Page
4.4 Propane Combustion Calibration 4-6
4.5 Unit Reassembly
4.6 Over-Temperature Limit
Switches
4-9
4-9
i
CONTENTS
Chapter 5 – MODE OF OPERATION 5-1
Para. Subject Page
5.1 Introduction 5-1
5.2 Indoor/Outdoor Reset Mode 5-1
5.3 Constant Setpoint Mode 5-2
5.4 Remote Setpoint Mode 5-2
5.5 Direct Drive Modes 5-3
Para. Subject Page
5.6 Boiler Management System
(BMS)
5.7 Combination Control System
(CCS)
5-4
5-5
Chapter 6 – SAFETY DEVICE TESTING PROCEDURES 6-1
Para. Subject Page
6.1 Testing of Safety Devices 6-1
6.2 Natural Gas Low Gas Pressure
Fault Test
6.3 Pr opa ne Lo w Gas Pres sur e
Fault Test
6.4 Natural Gas High Gas Pressure
Test
6.5 Propane High Gas Pressure
Test
6.6 Low Water Level Fault Test 6-3
6.7 Water Temperature Fault Test 6-3
6-1
6-2
6-2
6-2
Para. Subject Page
6.8 Interlock Tests 6-4
6.9 Flame Fault Test 6-4
6.10 Air Flow Fault Test 6-5
6.11 SSOV Proof of Closure Switch 6-6
6.12 Purge Switch Open During
Purge
6.13 Ignition Switch Open During
Ignition
6.14 Safety Pressure Relief Valve
Test
6-6
6-7
6-7
Chapter 7 – MAINTENANCE REQUIREMENTS 7-1
Para. Subject Page
7.1 Maintenance Schedule 7-1
7.2 Ignitor-Injector 7-2
7.3 Flame Detector 7-3
7.4 Combustion Calibration 7-3
7.5 Safety Device Testing 7-3
7.6 Burner Assembly Inspection 7-3
Para. Subject Page
7.7 Condensate Trap 7-5
7.8 Shutting the Boiler Down For An
Extended Period of Time
7.9 Placing The Boiler Back In
Service After A Prolong ed
Shutdown
7-6
7-6
Chapter 8 – TROUBLESHOOTING GUIDE 8-1
Para. Subject Page
8.1 Introduction 8-1
Para. Subject Page
ii
CONTENTS
Chapter 9 - RS232 COMMUNICATION 9-1
Para. Subject Page
9.1 Introduction 9-1
9-2 RS232 Communication Setup 9-1
APPENDICES
App Subject Page
A Boiler Menu Item Descriptions A-1
B Startup, Status and Fault
Messages
C Temperature Sensor Resistance
Voltage Chart
D Indoor/Outdoor Reset Ratio
Charts
E Boiler Default Settings E-1
B-1
C-1
D-1
Para. Subject Page
9-3 Menu Processing Utilizing
RS232 Communication
9-4 Data Logging 9-2
App Subject Page
F Dimensionals and Parts Lists F-1
G Piping Diagrams G-1
H Wiring Schematics H-1
I Recommended Periodic Testing
Checklist
J Benchmark Control Panel Views J-1
K Benchmark 2.0LN Dual-Fuel
Switchover Instructions
L Recommended Spare Parts List L-1
9-1
I-1
K-1
WARRANTY W-1
iii
SAFETY PRECAUTIONS
CHAPTER 1 SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operat ing personnel MUST, at all
times, observe all safety regulations. The
following warnings an d cautions are gener al 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 Publ ication No. NFPA-
54). Where ASME CSD-1 is required by local
jurisdiction, the installation must conform to
CSD-1.
Where applicable, the equipment shall be
installed in accordance with the current
Installation Code for Gas Burning Appliances
and Equipment, CGA B149, and applicable
Provincial regulat io ns f or th e c las s; which should
be carefully followed in all cases. Authorities
having jurisdiction should be consulted before
installations are made.
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.
WARNINGS!
MUST BE OBSERVED TO PREVENT
SERIOUS INJURY.
WARNING!
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHUT OFF ALL GAS AND
ELECTRICAL INPUTS TO THE UNIT.
WARNING!
DO NOT USE MATCHES, CANDLES,
FLAMES, OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS
LEAKS.
WARNING!
FLUIDS UNDER PRESSURE MAY
CAUSE INJURY TO PERSONNEL
OR DAMAGE TO EQUIPMENT
WHEN RELEASED. BE SURE TO
SHUT OFF ALL INCOMING AND
OUTGOING WATER SHUTOFF
VALVES. CAREFULLY DECREASE
ALL TRAPPED PRESSURES TO
ZERO BEFORE PERFORMING
MAINTENANCE.
WARNING!
ELECTRICAL VOLTAGES UP TO
120 VAC ARE 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.
CAUTIONS!
Must be observed to prevent equipment damage or loss of operating
effectiveness.
CAUTION!
Many soaps used for gas pipe leak
testing are corrosive to metals. The
piping must
clean water after leak checks have
been completed.
be rinsed thoroughly with
WARNING!
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.
CAUTION!
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.
1-1
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.
IMPORTANT
The Installer must identify and indicate
the location of the emergency shutdown
manual gas valve to operating personnel.
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended
that the startup proce dures in Chapter 4 and the
safety device test procedures in Chapter 6 of
this manual be performed, to verify all systemoperating param eters. If ther e is an em ergenc y,
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.
MANUAL GAS SHUTOFF VALVE
VALVE OPEN
Figure 1-1
Manual Gas Shutoff Valve
VALVE CLOSED
1-2
INSTALLATION
CHAPTER 2 INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and
procedures necessary to unpack, inspect and
install the AERCO Benc hmark 2.0LN Dual-Fuel
Boiler. Brief descriptions are also provided for
each available mode of operation. Detailed
procedures for implementing these modes are
provided in Chapter 5.
2.2 RECEIVING THE UNIT
Each Benchmark 2.0LN S ystem is shipped as a
single crated unit. The shipping weight is
approximately 1600 pounds. The unit must be
moved with the proper rigging equipment for
safety and to avoid equipment dam age. The unit
should be complete ly inspected for evidence of
shipping damage and ship ment com pleteness at
the time of receipt from the carrier and before
the bill of lading is signed.
NOTE
AERCO is not responsible for lost or
damaged freight.
Each unit has a Tip-N-Tell indicator on the
outside of the crate. T his indic ates if the un it has
been turned on its side during shipment. If the
Tip-N-Tell indicat or is trip ped, do not s ign for the
shipment. Note the information on the carrier’s
paperwork and request a freight claim and
inspection by a claims adjuster before
proceeding. Any other visual damage to the
packaging materials s hould also be made clear
to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit taking care not to
damage the unit enclosure when cutting away
packaging materials
A close inspection of the unit s hould be made to
ensure that there is no evidence of dam age not
indicated by the T ip-N-Tell indicator. The f reight
carrier should be notified immediately if any
damage is detected.
IMPORTANT
After unpacking, take off the unit top
panel and remove the strap and packing
material at the top of the h eat exchanger.
The packing material is located in the
area of the ignitor-injector and staged
ignition solenoid on the burner assembly.
The following accessories come standard with
each unit and are either packed separately
within the unit’s pack ing container or are fac tory
installed on the boiler:
• Pressure/Temperature Gauge
• Spare Spark Igniter
• Spare Flame Detector
• ASME Pressure Relief Valve
• Condensate Drain Trap
• 2” Gas Supply Shutoff Valve
When ordered, optional accessories may be
packed separately, packed within the boiler
shipping container, or may be installed on the
boiler. Any standard or optional accessories
shipped loose should b e identified and s tored in
a safe place until ready for installation or use.
2.4 SITE PREPARATION.
Ensure that the site selected for installation of
the Benchmark 2.0LN Boiler includes:
• Access to AC Input Power at 120 VAC,
Single-Phase, 60 Hz @ 20 A mps
• Access to Natural Gas line at a minimum
supply gas pressure of 8.5" W.C.
• Access to Propane l ine at a minimum supply
gas pressure of 8.5” W.C.
2.4.1 Installation Clearances
The unit must be installed with the prescribed
clearances for service as shown in Figure 2-1.
The minimum
AERCO, are listed below. However, if Local
Building Codes require additional clearances,
these codes shall supersede AERCO’s
requirements. Minimum acceptable clearances
required are:
• Sides: 24 inches
• Front : 24 inches
• Rear: 30 inches
• Top: 18 inches
All gas piping, water piping and el ec tric al c on du it
or cable must be arranged so that they do not
interfere with the removal of any panels, or
inhibit service or maintenance of the unit.
clearance dimens ions , requir ed by
2-1
INSTALLATION
Figure 2-1 Benchmark 2.0LN Boiler Clearances
WARNING
KEEP THE UNIT AREA CLEAR AND
FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE
VAPORS OR LIQUIDS
.
CAUTION
While packaged in the shipping
container, the boiler must be moved
by pallet jack or forklift from the
FRONT ONLY.
2.4.2 Setting the Unit
The unit must be installed on a 4 inch to 6 inch
housekeeping pad to e nsure proper conde nsate
drainage. If anchoring the unit, refer to the
dimensional drawings in Appendix F for anchor
locations. Two lifting t abs ar e provided a t the top
of the heat exchanger as shown in Figure 2-2.
USE THE TABS SHOWN IN FIGURE 2-2 TO
LIFT AND MOVE THE UNIT. Remove the top
panel from the unit to provide access to the
lifting tabs. Remove the four (4) lag screws
securing the unit to the shipping skid. Lift the
unit off the shipping sk id and position it on the 4
inch to 6 inch housekeeping concrete pad
(required) in the desired location.
LIFTING
TABS (2)
Figure 2-2
View Showing Lifting Tab Locations
In multiple unit installations, it is important to
plan the position of each unit in advance.
Sufficient space for piping connections and
future service/maintenance requirements must
also be taken into cons ider ation. All pipin g m ust
include ample provisions for expansion.
2-2
If installing a Combina tion Control Panel (CCP)
system, it is important to identify the
Combination Mode B oilers in adv ance and plac e
them in the proper physical location. Refer to
Chapter 5 for inform ation on Combination Mode
Boilers.
2.5 SUPPLY AND RETURN PIPING
The Benchmark 2.0LN Boiler utilizes 4” 150#
flanges for the water system supply and return
piping connectio ns. The physical location of the
supply and return p iping connections are on the
rear of the unit as shown in Figure 2-3. Ref er to
Appendix F, Drawing AP-A-798 for additional
dimensional data.
BOILER
RETURN
EXHAUST
MANIFOLD
1/2” NPT
CONDENSATE
DRAIN
CONNECTION
HOUSE-
KEEPING
PAD
INSTALLATION
Figure 2-4
Condensate Drain Connection Location
A condensate drain trap (part no. 24060) is
shipped loose and m ust be installed
of the unit. The trap inlet and outlet contain
tapped 3/4” NPT ports. The actual installation
details for the condensate trap will depend on
the available clearances, housekeeping pad
height/dimensions and other prevailing conditions at the site. However, the following
guidelines must be observed to ensure proper
condensate trap operation:
• The condensate trap inlet (Figure 2-5) must
be level with, or lower than the exhaust
manifold drain port.
at the rear
Figure 2-3
Supply and Return Locations
2.6 CONDENSATE DRAIN AND PIPING
The Boiler is designe d to condense water va por
from the flue produc ts. Therefore, the ins t al lat ion
must have provisions for suitable drainage or
collection. A 1/2” NPT drain connection is
provided on the exhaust manifold as shown in
Figure 2-4.
• The condensate trap must be supported to
ensure that its base is level (horizontal).
• The trap must be removable for routine
maintenance. AERCO recommends that a
union be utilized between the exhaust
manifold condensate drain port and the trap
inlet port.
1. While observing the above guidelines,
connect the condensate trap inlet to the
exhaust manifold dra in connection using th e
appropriate piping components (nipples,
reducers, elbows, etc.) for the boiler
installation site.
2. At the condensate trap outlet, install a 3/4”
NPT nipple.
3. Connect a length of 1” I.D polypropylene
hose to the trap outlet and secure with a
hose clamp.
4. Route the hose on the trap outlet to a
nearby floor drain.
2-3
INSTALLATION
R
If a floor drain is not available, a condensate
pump can be used to remove the condens ate to
drain. The max imum condensate f low rate is 20
GPH. The condensate drain trap, associated
fittings and drain line must be removable for
routine maintenance.
FLOAT
3/4 NPT
PORT
OUTLET
COVE
THUMB
SCREWS
(4)
INLET
3/4 NPT
PORT
Figure 2-5
Condensate Trap Cut-Away View
2.7 GAS SUPPLY PIPING
The AERCO Benchmark 2.0LN Gas
Components and Supply Design Guide, GF2030LN must be consu lted prior to designing or
installing any gas supply piping.
WARNING
NEVER USE MATCHES, CANDLES,
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS
LEAKS
Many soaps used for gas pipe leak
testing are corrosive to metals. Therefore, piping must be rinsed thoroughly
with clean water after leak checks
have been completed.
All gas piping m ust be arranged so that it
does not interfere with removal of any
covers, inhibit service/maintenance, or
restrict access between the unit and
walls, or another unit.
.
CAUTION
NOTE
Benchmark 2.0LN Dual-F uel units contain t wo 2
inch gas inlet connectio ns on the rear of the unit
as shown in Figure 2-3.
Prior to installation, all pipes should be deburred and internall y cleared of any scale, m etal
chips or other foreign particles. Do Not install
any flexible connectors or unapproved gas
fittings. Piping must be s upported from the floor,
ceiling or walls onl y and must not be supported
by the unit.
A suitable piping compound, approved for use
with natural gas and/or propane, should be
used. Any excess m ust be wiped off to prevent
clogging of components.
To avoid unit damage whe n pres sur e tes ting gas
piping, isolate the unit from the gas supply
piping. At no time should the gas pressure
applied to the unit exceed 2 psi. Leak test all
external piping thoroughly using a soap and
water solution or suitable equivalent. The gas
piping used must meet all applicable codes.
2.7.1 Gas Supply Specifications.
The maximum static gas supply pressure to the
unit must not exceed 2 psi. The specifications
for natural gas and propane are as follows:
Natural Gas:
The gas supply pr essure to the unit m ust be
of sufficient capacity to provide 2000 cfh
while maintaining the gas pressure at 8.5"
W.C.
Propane:
The gas supply pr essure to the unit m ust be
of sufficient capacit y to provide 800 cfh while
maintaining the gas pressure at 8.5" W.C.
The maximum static pressure to the unit must
not exceed 2 psi. The minimum operating gas
pressure for natural gas and propane is 8.5
inches W.C. for both FM and IRI gas trains when
the unit is firing at maximum input.
2.7.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in th e
gas supply line upstream of the Boiler as shown
in Figure 2-6. M aximum allowable gas pressure
to the Boiler is 2 psi.
2-4
PROPANE
SUPPLY
NATURAL
GAS SUPPLY
2" MANUAL
SHUTOFF
VALVES
DIRT
TRAPS
Figure 2-6
Manual Gas ve Location
2
.7.3 IRI Gas Train Kit
The IRI gas train is an
configuration which is r e qui red i n s ome areas for
code compliance or for insurance purposes.
The IRI gas train is factor y pre-piped and wired.
See Appendix F, Drawing AP- A-843 for details.
Shut-Off Val
optional gas train
2.8 AC ELECTRICAL POWER WIRING
The AERCO Benchm ark 2.0LN Electr ical Powe
Wiring Guide, GF-2060LN, must be consulted
prior to connecting an y AC power wiring to the
unit. External AC power connections ar e made
to the unit inside the Power Box on the front
panel of the unit. Rem ove the front door of the
unit to access the Power Box mounted directly
above the Control Box. Loosen the four Power
Box cover screws and remove cover to access
the AC terminal connections inside the Power
Box (Figure 2-7).
r
INSTALLATION
TERMINAL BLOCK
UPPER RIGHT CORNER OF FRONT PANEL
Figure 2-7
AC Input Terminal Block Location
2.8.1 Electrical Power Requirements
The AERCO Benchmark 2.0LN Boiler accepts
120 VAC, single-phase, 60 Hz @ 20A. The
Power Box contains a ter minal block as shown
in Figure 2-8. In addition, a wiring diagram
showing the required AC power connections is
provided on the front cover of the Power Box.
Each Boiler must be connected to a dedicated
electrical circuit. NO OTHER DEVICES
SHOULD BE ON THE SAME ELECTRICAL
CIRCUIT AS THE BOILER. A means for
disconnecting AC po wer f rom the unit (such as a
service switch) must be installed near the unit
for normal operation and maintenance. All
electrical connections should be made in
accordance with the National Electrical Code
and/or with any applicable local codes.
For electrical power wiring diagrams, see the
AERCO Benchmark 2.0LN Electrical Power
Wiring Guide, (GF-2060LN).
NOTE
All elec rdware must
be installed so that it does not interfere
with the removal of any un it cover s, inh ibit
service/maintenance, or prevent access
between the unit and walls or another
unit.
trical conduit and ha
2-5
INSTALLATION
120 VAC, 1 PHASE
GND
NEU
L1
Figure 2-8
AC Terminal Block Configurations
2.9 MODES OF OPERATION AN D FIELD CONTROL WIRING
The Benchmark 2.0LN Boiler is available in
several different modes of operation. While
each unit is fac tory configured and wired f or its
intended mode, som e additional field wiring may
be required to complete the installation. This
wiring is typicall y connected to the Input/Output
(I/O) Box located on the lower por tion of the unit
front panel (Figure 2-9) behind the removable
front door.
To access the I/O Box terminal strips shown in
Figure 2-9, loosen the four cover screws and
remove the cover. All field wiring is installed
from the rear of the panel by routing the wires
through one of the four bushings provided.
Refer to the wiring diagram provided on the
cover of the I/O Box (Figur e 2-10) when making
all wiring connections.
Brief descriptions of each mode of operation,
and their wiring requirements, are provided in
the following paragr aphs. Additional information
concerning field wiring is prov ided in paragr aphs
2.10.1 through 2.10.10. Refer to Chapter 5 for
detailed information on the available modes of
operation.
2.9.1 Constant Setpoint Mode
The Constant Setpoi nt Mode is used when it is
desired to have a fixed setpoint that does not
deviate. No wiring connections, other than AC
electrical power connections, are required for
this mode. However, if desired, fault monitor ing
or enable/disable in terlock wiring c an be utilized
(see paragraphs 2.10.9.1 and 2.10.10).
TERMINAL
STRIPS
LOWER RIGHT CORNER
OF FRONT PANEL
Figure 2-9.
Input/Output (I/O) Box Location
2.9.2 Indoor/Outdoor Reset Mode
This mode of operation increases supply water
temperature as outdoor te mperatures decrease.
An outside air temperatur e sensor (AERCO Part
No. 122790) is requ ired. The sensor MUST BE
wired to the I/O Box wiring term inals (see Figure
2-10). Refer to paragraph 2.10.1 for additional
information on outside air temperature sensor
installation.
2-6
INSTALLATION
OUTDOOR SENSOR IN
SENSOR COMMON
(AIR) AUX SENSOR IN
B.M.S. (PWM) IN
NOT USED
ANALOG IN
SHIELD
mA OUT
RS-485
COMM.
NOT USED
0 – 10V
AGND
+
+
-
+
+
G
-
Figure 2-10. I/O Box Terminal Strip
REMOTE INTL'K IN
EXHAUST SWITCH IN
DELAYED INTL'K IN
NOT USED
NC
COM
NO
NC
COM
NO
NOT USED
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
FAULT RELAY
120 VAC, 5A, RES
AUX RELAY
120 VAC, 5A, RES
2.9.3 Boiler Management System Mode NOTE
BMS Model 168 can utilize either pulse
width modulation (PWM) or RS485
Modbus signaling to the Boiler. BMS II
Model 5R5-384 can utilize only RS485
signaling to the Boiler.
When using an AERCO Boiler Management
System (BMS), the field wiring is connected
between the BMS Panel and each Boiler’s I/O
Box terminal strip (Figure 2-10). Twisted
shielded pair wire f rom 18 to 22 AWG must be
utilized for the connections. The BMS Mode can
utilize either pulse width modulation (PWM)
signaling, or RS485 Modbu s s ignaling. F or PWM
signaling, connections are made from the
AERCO Boiler Management System to the
B.M.S. (PWM) IN terminals on the I/O Box
terminal strip. For RS485 Modus signaling,
connections are made from the BMS to the
RS485 COMM term inals on the I/O Box ter minal
strip. Polarity m ust be maintain ed and the shie ld
must be connected only at the AERCO BMS.
The boiler end of the shield must be left floating.
For additional instructions, refer to Chapter 5,
paragraph 5.6 in this manual. Also, refer to
GF-108M (BMS Mode l 1 68 ) and G F- 1 24 ( BMS II
Model 5R5-384), BMS -Operations Guides.
2.9.4 Remote Setpoint and Direct Drive Modes
The boiler can accept several types of signal
formats from an Energy Management System
(EMS), Building Automation System (BAS) or
other source, to control either the setpoint
(Remote Setpoint Mode) or valve position
(Direct Drive Mode) of the Boi ler . T hes e f ormats
are:
• 4 to 20 mA/1 to 5 VDC
• 0 to 20 mA/0 to 5 VDC
• PWM – (Pulse W idth Modulated signal. See
para. 2.10.4)
• Network (RS485 Modbus. See para. 2.10.7)
While it is possible to c ontrol a boiler or boilers
using one of the previously described m odes of
operation, it ma y not be the method best suited
for the application. Prior to selecting one of
these modes of operation, it is recommended
that you consult with your local AERCO
representative or the factory for the mode of
operation that will work best with your
application. For m ore information on wir ing the
4 to 20 mA / 1 to 5VDC or the 0 to 20 mA / 0 to 5
VDC, see paragraph 2.9.3.
2-7
INSTALLATION
2.9.5 Combination Mode NOTE
Only BMS Model 168 can be utilized for
the Combination Mode, not the BMS II
(Model 5R5-384).
With a Combination Mode unit, field wiring is
between the unit’s I/O Box wiring terminals, the
CCP (Combination Contr ol Panel), an d the BMS
(Boiler Management System). The wiring must
be accomplished using twisted-shielded pair
wire from 18 to 22 AWG. Polarity must be
maintained. For further instructions and wiring
diagrams, refer to the GF-108M Boiler
Management System Operations Guide and the
CCP-1 data sheet.
2.10 I/O BOX CONNECTIONS
The types of input and output signals and
devices to be connecte d to the I/O Box terminals
shown in Figure 2-10 are described in the
following paragraphs.
CAUTION
DO NOT make any connections to the
I/O Box terminals labeled “NOT
USED”. Attempting to do so may
cause equipment damage.
2.10.1 OUTDOOR SENSOR IN
An outdoor air temperature sensor (AERCO Part
No. 122790) will be required primarily for the
Indoor/Outdoor reset m ode of operation. It can
also be used with anoth er m ode if it is desired to
use the outdoor sensor enable/disable feature.
This feature allows the boiler to be enabled or
disabled based on the outdoor air temperature.
The factory default for the outdoor sensor is
DISABLED. To enable the sensor and/or select
an enable/disable o utdoor temperature, see the
Configuration menu in Chapter 3.
The outdoor sensor m ay be wired up t o 200 feet
from the boiler. It is connected to the OU T D OO R
SENSOR IN and SENSOR COMMON terminals
in the I/O Box (see Figures 2- 9 and 2-10). Wire
the sensor using a twisted shielded pair wire
from 18 to 22 AWG. There is no polarity to
observe when terminating these wires. The
shield is to be connected only to the terminals
labeled SHIELD in the I/O Box. The sensor end
of the shield must be left free and ungrounded.
When mounting the sensor, it must be located
on the North side of the building where an
average outside air temperature is expected.
The sensor must be shield ed f r om dir ect sunli ght
as well as impingement by the elements. If a
shield is used, it must allow for free air
circulation.
2.10.2 AIR SENSOR IN
The AIR SENSOR IN is connected to the AUX
SENSOR IN and SENSOR COMMON terminals
on the I/O board. The AIR SENSOR measures
the temperature of the air input to the Air/Fuel
Valve. This temperature reading is one of the
components used to calculate the rotational
speed of the blower used in the combustion
Calibration process (Chapter 4).
The AUX SENSOR IN terminals can b e used to
add an additional temperature sensor for
monitoring purposes. This input is always
enabled and is a view-only input that can be
seen in the Operating Menu. The sensor must
be wired to the AUX S ENSOR IN and SENSOR
COMMON terminals and must be similar to
AERCO BALCO wire se nsor Part No. 124 49. A
resistance chart for this sensor is provided in
Appendix C.
2.10.3 ANALOG IN
The ANALOG IN + and – terminals are used
when an external signal is used to drive the
air/fuel valve position (Direct Drive Mode) or
change the setpoint (R emote Setpoint Mode) of
the Boiler.
Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/
0 to 5 VDC signal may be used to vary the
setpoint or valve position. The factory default
setting is for 4 to 20 mA / 1 to 5 VDC, however
this may be changed to 0 t o 20 mA / 0 to 5 VDC
using the Configuration Menu described in
Chapter 3. If voltage rather than current is
selected as the dr ive signal, a DIP switch mus t
be set on the PMC Board located inside the
Control Box. Contact the AERCO factory for
information on setting DIP switches.
All of the supplied signals must be floating
(ungrounded) signals . Connectio ns bet ween the
signal source and the Boiler’s I/O Box must be
made using twiste d shiel ded pa ir wire fr om 18 to
22 AWG, such as Belden 9841 (see Figure
2-10). Polarity mu st be maintained. The shi eld
must be connected only at the source end and
must be left floating (not connected) at the
Boiler’s I/O Box.
Regardless of whether volt age or curr ent is used
for the drive signal, the y are linearly mapped to
a 40°F to 240°F s etpoint or a 0% to 100% v alve
position. No scaling for these signals is provided
2-8
INSTALLATION
2.10.4 B.M.S. (PWM) IN NOTE
Only BMS Model 168 can utilize Pulse
Width Modulation (PW M), not the BMS II
(Model 5R5-384).
These terminals are used to connect the
AERCO Boiler Management System (BMS) to
the unit. The BMS utilizes a 12 millisecond,
ON/OFF duty cycle. This duty cycle is Pulse
Width Modulated (PWM) to control the air/fuel
valve position. A 0% (open) air/fuel valve
position = a 5% ON pulse and a 100% open
valve position = a 95% ON pulse.
2.10.5 SHIELD
The SHIELD terminals are us ed to terminate any
shields used on sensor wires connected to the
unit. Only shields m ust be connected to these
terminals.
IMPORTANT
DO NOT USE the mA OUT output to
remotely monitor Set point, O utlet Tem p or
Fire Rate Out.
2.10.6 mA OUT
These terminals provide a 4 to 20 mA output to
a VFD (if so equipped) to control the rotationa l
speed of the blower. T his function is enable d in
the Configuration Menu (Chapter 3, Table 3-4).
2.10.7 0 – 10V OUT
These terminals provide a 0 to 10V output to
control the rotational speed of the blower. This
function is enabled in the Configuration Menu
(Chapter 3, Table 3-4).
2.10.8 RS-485 COMM
These terminals are used for RS-485 MODBUS
serial communication between the unit and an
external “Master” suc h as a Boiler Management
System (BMS), Energy Management System
(EMS), Building Automation System (BAS) or
other suitable device.
2.10.9 EXHAUST SWITCH IN
These terminals permit an external exhaust
switch to be connected to the exhaust manifold
of the boiler. The exhaust switch should be a
normally open t ype s witc h (such as AERCO Par t
No. 123463) that closes (trips) at 500°F.
2.10.10 INTERLOCKS
The unit offers two interlock circuits for
interfacing with Energy Management Systems
and auxiliary equipment such as pumps or
louvers. These interlock s are called the Rem ote
Interlock and Delayed Interlock (Figure 2-10).
The wiring terminals for these interlocks are
located inside the I/O Box on the unit front
panel. The I/O Box cover contains a wiring
diagram which s hows th e ter m inal str ip locat ions
for these interlocks (REMOTE INTL’K IN and
DELAYED INTL’K IN). Both interlocks,
described below, are fac tory wired in the closed
position.
NOTE
Both the Remote Interlock and Delayed
Interlock MUST be in the closed position
to allow the unit to fire.
2.10.10.1
The remote interlock circuit is provided to
remotely start (enable) and stop (disable) the
Boiler, if desired. T he circuit is labeled REMO TE
INTL’K IN and is located inside the I/O Box on
the front panel. The circuit is 24 VAC and is
factory pre-wired in the closed (jumpered)
position.
2.10.10.2
The delayed interlock is typically used in
conjunction with the aux iliary relay described in
paragraph 2.10. This interlock circuit is located
in the purge section of the start string. It can be
connected to the proving device (end switch,
flow switch etc.) of an auxiliary piece of
equipment started b y the Boiler’s a uxiliary rela y.
The delayed interlock must be closed for the
boiler to fire.
If the delayed interl ock is connec ted t o a pr oving
device that requir es tim e to clos e (mak e), a tim e
delay (Aux Start On Dly) that holds the start
sequence of the boiler lon g enoug h for a proving
switch to make can be progr amm ed. Should the
proving switch not prove within the programm ed
time frame, the boiler will shut down. The Aux
Start On Dly can be progr ammed from 0 to 120
seconds. This option is locate in the
Configuration Menu (Chapter 3, Table 3-4).
REMOTE INTERLOCK IN
DELAYED INTERLOCK IN
2-9
INSTALLATION
2.10.11 FAULT RELAY
The fault relay is a single pole double throw
(SPDT) relay having a normally open and
normally closed set of relay contacts that are
rated for 5 amps at 12 0 VAC and 5 amps at 30
VDC. The relay energizes when any fault
condition occurs and remains energized until the
fault is cleared and the CLEAR button is
depressed. The fault relay connections are
shown in Figure 2-10.
2.11 AUXILI ARY RELAY CONTACTS
Each Boiler is equipped with a single pole
double throw (SPDT) relay that is energized
when there is a demand for heat and deenergized after the dem and for heat is satisf ied.
The relay is prov ided for the control of auxiliary
equipment, such as pumps and louvers, or can
be used as a Boiler status indictor (firing or n ot
firing). Its contacts are r ated for 120 VAC @ 5
amps. Refer to Figure 2- 10 to locate the AUX
RELAY terminals for wiring connections.
2.12 FLUE GAS VENT INSTALLATION
The minimum allowable vent diameter for a
single Benchmark 2.0LN Boiler is 8 inches.
The AERCO Benchmark Venting and
Combustion Air Guide, GF-2050, must be
consulted before any flue gas vent or inlet air
venting is designed or installed. U/L listed,
positive pressure, watertight vent materials as
specified in AERCO’s GF-2050, must be used
for safety and code com pliance. S ince the u nit is
capable of dischar ging low temperature ex haust
gases, horizontal sections of the flue vent
system must be pitched back to the unit a
minimum of 1/4 inch per foot to avoid
condensate pooling and allow for proper
drainage.
The combined pressure drop of vent and
combustion air systems must not exceed 140
equivalent feet of 8 inc h ducting. Fittings as we ll
as pipe lengths must be calculate d as part of the
equivalent length.
For a natural draf t installation the draf t must not
exceed ±0.25 inch W .C. These factors must be
planned into the vent installation. If the
maximum allowabl e equivalent lengt hs of piping
are exceeded, the unit will not operate properly
or reliably.
2.13 COMBUSTIO N AIR
The AERCO Benchmark Venting and
Combustion Air Guide, GF-2050 MUST be
consulted before any flue or com bustion supply
air venting is designed or implemented.
Combustion air supp ly is a direct r equirem ent of
ANSI 223.1, NFPA-54, and local codes. These
codes should be consulted before a permanent
design is determined.
The combustion air must be free of chlorine,
halogenated hydrocarbons, or other chemicals
that can become ha zardous when used in gasfired equipment. Common sources of these
compounds are swimming pools, degreasing
compounds, plastic proc essing and refrigerants.
Whenever the env ironment c ontains thes e t ypes
of chemicals, combustion air must be supplied
from a clean area outdoors for the protection
and longevity of the equipment.
The AERCO Benchmark 2.0LN Boiler is UL
listed for 100% sealed combustion. It can also
be installed us ing room air, provid ed there is an
adequate supply. (See para. 2.13.3 for more
information concerning sealed combustion air).
If the sealed com bustion air option is not be ing
used, an inlet screen will be attached at the air
inlet on the top of the unit
The more common methods of supplying
combustion air are outlined below. For more
information concerning combustion air, refer to
the AERCO Benchmark Venting and Combustion Air Guide, GF-2050.
2.13.1 Combustion Air From Outside the Building
Air supplied from outside the building must be
provided through two perm anent openings. Each
opening must have a free area of not less than
one square inch for each 4000 BTU/H boiler
input. The free area must take into account
restrictions such as louvers and bird screens.
2.13.2 Combustion Air From Inside the Building
When combustion air is provided f rom within the
building, it must be supplied through two
permanent openings in an interior wall. Each
opening must have a free area of not less than
one square inch per 1000 BTU/H of total boiler
input. The free area must take into ac count any
restrictions such as louvers.
2-10
INSTALLATION
2.13.3 Sealed Combustion
The AERCO Benchmark 2.0LN Boiler is UL
listed for 100%-sealed combustion. For sealed
combustion installations, the screen on the air
inlet duct of the unit m ust be removed. T he inlet
air ductwork must then be attached directly to
the unit’s air inlet.
In a sealed combustion air application, the
combustion air ducting pre ssure losses must be
taken into account when calculating the total
maximum allowable venting run. See the
AERCO Benchmark Venting and Combustion
Air Guide, GF-20 50. When using the bo iler in a
sealed combustion air configuration, each unit
must have a minimum 8 inch diameter
connection at the unit.
2.13.4 Temporary Combustion Air
Filtering During Construction
When the AERCO Benchmark 2.0LN Boiler is
used to provide heat tem porarily during on going
building constructio n, accumulated drywall dust,
sawdust and similar par ticles can accumulate in
the unit’s combustion air intake filter and block
combustion air flow. In thes e situations, AERCO
recommends that a d isposable air intak e f ilter b e
installed, temporarily, above the boiler
combustion air inlet.
AERCO recommends that the temporary air filter
be cut from a McMaster- Carr part no. 2122K3 15
Polyester Air Filter Roll Tackfield, ½” thick, 16”
wide, or equivalent. Cov er the unit air inlet with
the blue side of the filter material fac ing outward
to hold the dust on the outside surface.
Maximize the surf ace area of the filter cover ing
the 8" diameter openin g by creating a dom e out
of the filter material.
Cover the flared duct op ening with the b lue side
facing outward. During construction check the
filter for dust accumulation and replace it when
the accumulation becomes noticeable.
2-11
CONTROL PANEL OPERATING PROCEDURES
CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES
3.1 INTRODUCTION
The information in this Chapter provides a guide
to the operation of the Benchmark 2.0LN Boiler
using the Control Panel mounted on the front of
the unit. It is imperative that the initial startup of
this unit be performed by factory trained
personnel. Operation prior to initial startup by
factory trained personnel will void the equipment
warranty. In addition, the following WARNINGS
and CAUTIONS must be observed at all times.
CAUTION
All of the installation procedures in
Chapter 2 must be completed before
attempting to start the unit.
WARNING
ELECTRICAL VOLTAGES IN THIS
SYSTEM MAY INCLUDE 460, 208
AND 24 VOLTS AC. IT MUST BE
SERVICED ONLY BY FACTORY
CERTIFIED SERVICE TECHNICIANS
2
1
3
4
12
11
10
5
6
7
WARNING
DO NOT ATTEMPT TO DRY FIRE
THE BOILER. 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.
3.2 CONTROL PANEL DESCRIPTION
The Benchmark 2.0LN Control Panel shown in
Figure 3-1 contains all of the controls, indicators
and displays necessary to operate, adjust and
troubleshoot the Benchmark 2.0LN Boiler.
These operating controls, indicators and
displays are listed and described in Table 3-1.
Additional information on these items are
provided in the individual operating procedures
provided in this Chapter.
8
9
Figure 3-1.
Control Panel Front View
3-1
CONTROL PANEL OPERATING PROCEDURES
Table 3-1 Operating Controls, Indicators and Displays
ITEM
NO.
CONTROL, INDICATOR
OR DISPLAY
1 LED Status Indicators Four Status LEDs indicate the current operating status as
follows:
COMM
MANUAL
REMOTE
DEMAND
OUTLET
2
TEMPERATURE
Display
3 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines each
Lights when RS-232 communication is occurring
Lights when the unit is being controlled using the front panel
keypad.
Lights when the unit is being controlled by an external signal
from an Energy Management System
Lights when there is a demand for heat.
3–Digit, 7–Segment LED display continuously displays the
outlet 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 blinks
when operating in the Deadband Mode.
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
Startup Messages
Fault Messages
FUNCTION
Operating Status Messages
Menu Selection
RS-232 Port
4
FAULT Indicator Red FAULT LED indicator lights when a boiler alarm
5
CLEAR Key Turns off the FAULT indicator and clears the alarm message
6
READY Indicator
7
ON/OFF Switch
8
LOW WATER LEVEL
9
TEST/RESET Switches
Port permits a Laptop Computer or External Modem to be
connected to the unit’s Control Panel.
condition occurs. An alarm message will appear in the VFD.
if the alarm is no longer valid. Lockout type alarms will be
latched and cannot be cleared by simply pressing this key.
Troubleshooting may be required to clear these types of
alarms.
Lights ON/OFF switch is set to ON and all Pre-Purge
conditions have been satisfied.
Enables and disables boiler operation.
Allows operator to test operation of the water level monitor.
Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
3-2
CONTROL PANEL OPERATING PROCEDURES
Table 3-1 Operating Controls, Indicators and Displays – Continued
ITEM
NO.
10 MENU Keypad Consists of 6 keys which provide the following functions for
CONTROL, INDICATOR
OR DISPLAY
the Control Panel Menus:
MENU
BACK
▲ (UP) Arrow When in one of the main menu categories (Figure 3-2),
▼ (DOWN) Arrow When in one of the main menu categories (Figure 3-2),
CHANGE
Steps through the main menu categories shown in Figure 3-
2. The Menu categories wrap around in the order shown.
Allows you to go back to the previous menu level without
changing any information. Continuously pressing this key
will bring you back to the default status display in the VFD.
Also, this key allows you to go back to the top of a main
menu category.
pressing the ▲ arrow key will select the displayed menu
category. If the CHANGE key was pressed and the menu
item is flashing, pressing the ▲ arrow key will increment the
selected setting.
pressing this key will select the displayed menu category. If
the CHANGE key was pressed and the menu item is
flashing, pressing the ▼ arrow key will decrement the
selected setting.
Permits a setting to be changed (edited). When the
CHANGE key is pressed, the displayed menu item will begin
to flash. Pressing the ▲ or ▼ arrow key when the item is
flashing will increment or decrement the displayed setting.
FUNCTION
11
12
ENTER
AUTO/MAN Switch
VALVE POSITION
Bargraph
Saves the modified menu settings in memory. The display
will stop 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.
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%
open.
3-3
CONTROL PANEL OPERATING PROCEDURES
3.3 CONTROL PANEL MENUS
The Control Panel incorporates an extensive
menu structure which permits the operator to set
up, and configure the unit. The menu structure
consists of five major menu categories which are
applicable to this manual. These categories are
shown in Figure 3-2. Each of the menus shown,
contain options which permit operating
parameters to be viewed or changed. The
menus are protected by a 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 which
is used in Chapter 4 to perform combustion
calibration prior to service use.
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 wraparound 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.
3.3.1 Menu Processing Procedure
Accessing and initiating each menu and option
is accomplished using the Menu Keys shown in
Figure 3-1. Therefore, it is imperative that you
be thoroughly familiar with the following basic
steps before attempting to perform specific
menu procedures.
1. The Control Panel 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 Menu, which is the next menu
category shown in Figure 3-2. 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 in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key
until the desired menu option is displayed.
Pressing the ▲ arrow key will display the
3-4
Figure 3-2. Menu Structure
CONTROL PANEL OPERATING PROCEDURES
NOTE
The following paragraphs provide brief
descriptions of the options contained in each
menu. Refer to Appendix A for detailed
descriptions of each menu option. Refer to
Appendix B for listings and descriptions of
displayed startup, status and error
messages.
3.4 OPERATING MENU
The Operating Menu displays a number of key
operating parameters for the unit as listed in
Table 3-2. This menu is “Read-Only” and does
not allow personnel to change or adjust any
displayed items. Since this menu is “Read-Only”,
it can be viewed at any time without entering a
password. Pressing the ▲ arrow key to display
the menu items in the order listed (Top-Down).
Pressing the ▼ arrow key will display the menu
items in reverse order (Bottom-Up).
3.5 SETUP MENU
The Setup Menu (Table 3-3) 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,
units of temperature measurements and entries
required for external communication and control
of the unit via the RS-232 port. A view-only
software version display is also provided to
indicate the current Control Box software
version.
NOTE
The Outdoor Temp display item shown with
an asterisk in Table 3-2 will not be displayed
unless the Outdoor Sensor function has
been enabled in the Configuration Menu
(Table 3-4).
Table 3-2. Operating Menu
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Status Message
Active Setpoint 40°F 240°F
AIR Temp -70°F 245°F
Outdoor Temp* -70°F 130°F
Valve Position In 0% 100% Valve
Position
Flame Strength 0% 100%
Run Cycles 0 999,999,999
Run Hours 0 999,999,999
Fault Log 0 19 0
3-5
CONTROL PANEL OPERATING PROCEDURES
Table 3-3. Setup Menu
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Passsword 0 9999 0
Language English English
Time 12:00 am 11:59 pm
Date 01/01/00 12/31/99
Unit of Temp Fahrenheit or Celsius Fahrenheit
Comm Address 0 127 0
Baud Rate 2400, 4800, 9600, 19.2K 9600
Software Ver 0.00 Ver 9.99
3.6 CONFIGURATION M ENU
The Configuration Menu shown in Table 3-4
permits adjustment of the Internal Setpoint
(Setpt) temperature regardless of whether the
valid password has been entered. Setpt is
required for operation in the Constant Setpoint
mode. The remaining options in this menu
require the valid password to be entered, prior to
changing existing entries. This menu contains a
number of other configuration settings which
may or may not be displayed, depending on the
current operating mode setting.
Table 3-4. Configuration Menu
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Internal Setpt Lo Temp Limit Hi Temp Limit 130°F
Unit Type KC Boiler, KC Boiler LN,
BMK Boiler, BMK Boiler LN,
BMK Boiler Dual, KC Water
Heater, KC Water Heater LN,
Water Heater 2010
Unit Size 0.5 MBTU, 1.0 MBTU
1.5 MBTU, 2.0 MBTU
3.0 MBTU, 3.5 MBTU
4.0 MBTU, 5.0 MBTU
Fuel Type Natural Gas, Propane Natural Gas
Boiler Mode Constant Setpoint,
Remote Setpoint,
Combination
Outdoor Reset
NOTE
The Configuration Menu settings shown in
Table 3-4 are Factory-Set in accordance
with the requirements specified for each
individual order. Therefore, under normal
operating conditions, no changes will be
required.
BMK Boiler
LN
2.0 MBTU
6.0 MBTU
Constant
Setpoint
Direct Drive
3-6
CONTROL PANEL OPERATING PROCEDURES
Table 3-4. Configuration Menu - Continued
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
Bldg Ref Temp
(If Mode = Outdoor
Reset)
Reset Ratio
(If Mode = Outdoor
Reset)
Outdoor Sensor Enabled or Disabled Disabled
System Start Tmp
(If Outdoor Sensor =
Enabled)
Setpt Lo Limit 40°F Setpt Hi Limit 60°F
Setpt Hi Limit Setpt Lo Limit 220°F 200°F
Temp Hi Limit 40°F 240°F 210°F
Max Valve Position 40% 100% 100%
Pump Delay Timer 0 min. 30 min. 0 min.
Aux Start On Dly 0 sec. 120 sec. 0 sec.
Failsafe Mode Shutdown or Constant Setpt Shutdown
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input (BMS)
Network
40°F 230°F 70°F
0.1 9.9 1.2
30°F 100°F 60°F
4 – 20 mA,
1-5V
*Analog Output
(See CAUTION at
end of Table 3-4 )
Low Fire Timer 2 sec. 600 sec. 2 sec.
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 5°F
Network Timeout 5 Sec 999 Sec 30 Sec
HI DB Setpt EN 0% 100% 30%
Demand Offsert 0 25 10
Deadband High 0 25 2
Deadband Low 0 25 2
*CAUTION:
DO NOT CHANGE the Analog Output Menu Item from its Default setting
(Valve Position 0-10V).
Off, Setpoint, Outlet Temp,
Valve Position 4-20 mA,
Valve Position 0-10V
*Valve
Position
0-10V
3-7
CONTROL PANEL OPERATING PROCEDURES
3.7 TUNING MENU
The Tuning Menu items in Table 3-5 are Factory
set for each individual unit. Do not change
these menu entries unless specifically requested
to do so by Factory-Trained personnel.
3.8 COMBUSTION CAL MENU
The Combustion Cal (Calibration) Menu items in
Table 3-6 (Natural Gas) and Table 3-7
(Propane) are used to vary the speed of the
unit’s blower motor based on air temperature
Table 3-5. Tuning Menu
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Prop Band 1°F 120°F 70°F
Integral Gain 0.00 2.00 1.00
Derivative Time 0.0 min 2.00 min 0.00 min
Reset Defaults? Yes, No, Are You Sure? No
Table 3-6. Combustion Cal Menu – Natural Gas (NEED DATA!)
and air density at prescribed Air/Fuel Valve
positions (% open). This is accomplished by
providing a DC drive voltage to the motor which
adjusts the rotational speed of the blower to
maximize combustion efficiency and ensure the
unit conforms to the Nitrogen Oxide (NOx) and
Carbon Monoxide (CO) emissions specified in
Chapter 4. The valve position (%) and default
drive voltages are listed in Tables 3-6 and 3-7..
Available Choices or Limits
Menu Item Display Minimum Maximum Default
CAL Voltage 20% .25 Vdc 10.0 Vdc 1.00 Vdc
CAL Voltage 30% .25 Vdc 10.0 Vdc 2.30 Vdc
CAL Voltage 45% .25 Vdc 10.0 Vdc 2.9 Vdc
CAL Voltage 60% .25 Vdc 10.0 Vdc 3.60 Vdc
CAL Voltage 80% .25 Vdc 10.0 Vdc 5.30 Vdc
CAL Voltage 100% .25 Vdc 10.0 Vdc 9.10 Vdc
SET Valve Position 0% 100% 0%
Blower Output Monitor Blower Output Voltage .00
Table 3-7. Combustion Cal Menu – Propane (NEED DATA!)
Available Choices or Limits
Menu Item Display Minimum Maximum Default
CAL Voltage 21% .25 Vdc 10.0 Vdc 1.10 Vdc
CAL Voltage 30% .25 Vdc 10.0 Vdc 1.95 Vdc
CAL Voltage 45% .25 Vdc 10.0 Vdc 3.00 Vdc
CAL Voltage 60% .25 Vdc 10.0 Vdc 3.00 Vdc
CAL Voltage 80% .25 Vdc 10.0 Vdc 4.45 Vdc
CAL Voltage 91% .25 Vdc 10.0 Vdc 8.20 Vdc
SET Valve Position 0% 91% 0%
Blower Output Monitor Blower Output Voltage .00
3-8
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