AERCO BMK 2.0 LN for Mass User Manual
Instruction
GF-110LN-M
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Benchmark™
Series
Gas Fired
Low NOx
Boiler System
Condensing, Modulating
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable To Serial Numbers G-05-1393 and above
Patent # : 2.155.12
Printed in U.S.A. REVISED JANUARY, 2009
Telephone Support
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through
Friday)
(800) 526-0288
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco.com
© AERCO International, Inc., 2008
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 merchantability 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.
CONTENTS
GF-110LN-M - AERCO BENCHMARK 2.0 GAS FIRED LOW NOx BOILER
Operating & Maintenance Instructions
FOREWORD A
Chapter 1 – SAFETY PRECAUTIONS 1-1
Para. Subject Page
1-1 Safety Warnings 1-1
1-2 Emergency Shutdown 1-2
Chapter 2 – INSTALLATION PROCEDURES 2-1
Para. Subject Page
2.1 Receiving the Unit 2-1
2.2 Unpacking 2-1
2.3 Installation 2-2
2.4 Gas Supply Piping 2-3
2.5 Electrical Supply 2-5
2.6 Mode of Operation and Field
Control Wiring
2-5
Para. Subject Page
1-3 Prolonged Shutdown 1-2
Para. Subject Page
2.7 I/O Box Connections 2-7
2.8 Auxiliary Relay Contacts 2-9
2.9 Flue Gas Vent Installation 2-9
2.10 Combustion Air 2-9
Chapter 3 – CONTROL PANEL COMPONENTS AND OPERATING PROCEDURES 3-1
Para. Subject Page
3.1 Introduction 3-1
3.2 Control Panel Description 3-1
3.3 Control Panel Menus 3-3
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 Start Sequence 3-7
3.9 Start/Stop Levels 3-9
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 Unit Reassembly 4-5
4.5 Over-Temperature Limit Switch 4-5
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 Low Gas Pressure Fault Test 6-1
6.3 High Gas Pressure Test 6-1
6.4 Low Water Level Fault Test 6-2
6.5 Water Temperature Fault Test 6-2
6.6 Interlock Tests 6-2
6.7 Flame Fault Test 6-3
Para. Subject Page
6.8 Air Flow Fault Test 6-4
6.9 SSOV Proof of Closure Switch 6-4
6.10 Purge Switch Open During
Purge
6.11 Ignition Switch Open During
Ignition
6.12 Safety Pressure Relief Valve
Test
6-5
6-5
6-5
Chapter 7 – MAINTENANCE REQUIREMENTS 7-1
Para. Subject Page
7.1 Maintenance Schedule 7-1
7.2 Spark Igniter 7-1
7.3 Flame Detector 7-2
7.4 Combustion Calibration 7-2
7.5 Safety Device Testing 7-3
7.6 Burner 7-3
Para. Subject Page
7.7 Condensate Drain Trap 7-4
7.8 Shutting the Boiler Down For An
Extended Period of Time
7.9 Placing The Boiler Back In
Service After A Prolonged
Shutdown
7-4
7-4
Chapter 8 – TROUBLESHOOTING GUIDE 8-1
Para. Subject Page
8.1 Introduction 8-1
Para.
Subject Page
ii
CONTENTS
APPENDICES
App Subject Page
A Boiler Menu Item Descriptions A-1
B Startup, Status and Fault
Messages
C Temperature Sensor Resistance
Chart
D Indoor/Outdoor Reset Ratio
Charts
B-1
C-1
D-1
WARRANTIES W-1
App Subject Page
E Boiler Default Settings E-1
F Dimensional and Part Drawings F-1
G Piping Drawings G-1
H Wiring Schematics H-1
I Recommended Periodic Testing
Checklist
J Benchmark Control Panel Views J-1
I-1
iii
FOREWORD
Foreword
The AERCO Benchmark 2.0 LN Boiler is a true industry advance that meets the needs of
today's energy and environmental concerns. Designed for application in any closed loop
hydronic system, the Benchmark's modulating capability relates energy input directly to
fluctuating system loads. The Benchmark’s 20:1 turn down ratio and condensing capability,
provides extremely high efficiencies and makes it ideally suited for modern low temperature, as
well as, conventional heating systems.
When installed and operated in accordance with this Instruction Manual, the Benchmark 2.0 LN
Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
• Texas Commission on Environmental Quality (TCEQ), Title 30, Chaptr 117, Rule117.465
Whether used in singular or modular arrangements the Benchmark 2.0 LN offers 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 management system integration.
For service or parts, contact your local sales representative or AERCO INTERNATIONAL.
NAME:
ORGANIZATION:
ADDRESS:
TELEPHONE:
INSTALLATION DATE: _____________________________________________
A
SAFETY PRECAUTIONS
CHAPTER 1 SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all
times, observe all safety regulations. The
following warnings and cautions are general and
must be given the same attention as specific
precautions included in these instructions. In
addition to all the requirements included in this
AERCO Instruction Manual, the installation of
units MUST conform with local building codes,
or, in the absence of local codes, ANSI Z223.1
(National Fuel Gas Code Publication 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 regulations for the class; which should
be carefully followed in all cases. Authorities
having jurisdiction should be consulted before
installations are made.
See pages 1-2 and 1-3 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.
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!
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.
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
460 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.
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
be rinsed thoroughly with
clean water after leak checks have
been completed.
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 procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of
this manual be performed, to verify all systemoperating 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.
Figure 1-1
Manual Gas Shutoff Valve
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS
Boiler Installations within the Commonwealth of Massachusetts must conform to the following
requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
Massachusetts.
• Prior to unit operation, the complete gas train and all connections must be leak tested using a
non-corrosive soap.
• If a glycol solution is used as anti-freeze protection, a backflow preventer must be installed
upstream of the Fill/Makeup Valve.
• 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 all side wall horizontally vented gas fueled equipment installed in every dwelling, 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
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 monoxide detector with an
alarm is installed on each additional level of the dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professionals for the installation of hard wired carbon
monoxide detectors.
. At the time of installation of the
1-2
Extracted Information From 248 CMR 5.08 (2) – Continued
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
the above requirements; provided, however, that during said thirty (30) day period, a
battery operated carbon monoxide detector with an alarm shall be installed.
SAFETY PRECAUTIONS
2. APPROVED CARBON MONOXIDE DETECTORS.
required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
3. SIGNAGE
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 VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS
1. The equipment listed in Chapter 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.
the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting
system design or venting system components with the equipment, the instructions 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.
. A metal or plastic identification plate shall be permanently mounted to the exterior
. The state or local gas inspector of the side wall horizontally vented gas fueled
: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
Each carbon monoxide detector as
When
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally vented gas fueled 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 identification of each "special venting system" shall include the listing of either the
website, phone number or manufacturer’s addres where the venting system installation
instructions can be obtained; and
2. The "special venting systems" shall be Product Approved by the Board, and the instructions
provided with the system shall include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for the Product Approved side wall horizontally vented gas fueled
equipment and all the venting instructions, parts lists and/or design instructions for the venting system
shall remain with the appliance or equipment at the completion of the installation.
_______________________________ [End of Extracted Information From 248 CMR 5.08 (2)]
1-3
INSTALLATION
Chapter 2 - INSTALLATION
2.1 RECEIVING THE UNIT
Each Benchmark is shipped as a single crated
unit. The shipping weight is approximately 1850
pounds, and must be moved with the proper
rigging equipment for safety and to avoid damages. The unit should be completely inspected
for shipping damage and completeness at the
time of receipt from the carrier and before the bill
of lading is signed.
NOTE:
AERCO is not responsible for lost or
damaged freight.
Each unit has a Tip-N-Tell indicator on the
outside of the crate. This indicates if the unit has
been turned on its side. If the Tip-N-Tell
indicator is tripped, do not sign 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
should also be made clear to the delivering
carrier.
2.2 UNPACKING
Carefully unpack the unit taking care not to
damage the unit jacket when cutting away
packaging materials. A close inspection of the
unit should be made to determine if there has
been any damage not indicated by the Tip-NTell. The freight carrier should be notified
immediately if any damage is detected. The
following accessories come standard with each
unit and are packed separately within the unit’s’
packing container or are factory installed on the
boiler.
• Pressure/Temperature Gauge
• Spare Spark Ignitor
• Spare Flame Detector
• ASME Pressure Relief Valve
• Regulator Adjustment Tool (One per
Site)
• Condensate Drain Trap
• 2” Gas Supply Shutoff Ball Valve
When ordered, optional accessories may be
packed separately or within the boiler shipping
container, or may be installed on the boiler. Any
standard or optional accessories shipped loose
should be identified and put in a safe place until
ready for installation or use.
.
Figure 2.1
Boiler Clearances
2-1
INSTALLATION
2.3 INSTALLATION
The unit must be installed by qualified personnel
(i.e. licensed plumber, gas fitter, etc.) in compliance with local and state regulations. The
prescribed clearances for service are shown in
Figure 2.1. The minimum
required by AERCO, are listed below. Local
building codes may require more clearance and
take precedence
Minimum clearances required:
Sides 24"
Rear 36”
Front 24"
Top 18”
All gas piping, water piping and electrical conduit
or cable must be arranged so that they do not
interfere with the removal of any cover, or inhibit
service or maintenance of the unit.
WARNING!
KEEP UNIT AREA CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS AND FLAMMA-
BLE VAPORS AND LIQUIDS
CAUTION!
While packaged on the shipping skid the boiler
must be moved by pallet jack or forklift from the
rear only.
IMPORTANT
The boiler installation must be
installed by a plumber or gas fitter
who is licensed within the Commonwealth of Massachusetts. In addition,
the installation must comply with all
requirements specified in Chapter 1
(Safety Precautions), pages 1-2 & 1-3.
2.3.1. SETTING THE UNIT
The unit must be installed on a 4 to 6 inch
housekeeping pad for proper condensate
drainage. If anchoring the unit, see the
dimensional drawings in Appendix F for anchor
location. Lifting lugs are provided for moving the
unit when it has been removed from the shipping
skid (See Fig. 2.2). USE ONLY THE LIFTING
LUGS TO MOVE THE UNIT. Remove the rear
top panel from the unit to provide access to the
lifting lugs. Remove the four (4) lag screws
securing the boiler to the shipping skid. Lift the
unit off the shipping skid and position it on to the
4 to 6 inch housekeeping concrete pad
(required) in the desired location.
clearance dimensions,
.
In multiple unit installations, it is important to
plan the position of each unit. Sufficient space
for piping connections and future maintenance
requirements must be given. All piping must
include ample provision for expansion.
If installing a Combination Control (CCP)
system, it is important to identify and place the
Combination Mode units in the proper physical
location. If these boilers are not properly located,
it will be necessary to reprogram them.
Figure 2.2
Lifting Lug Location
2.3.2 SUPPLY AND RETURN PIPING
The Benchmark 2.0 utilizes 4" 150# flanges for
the water system supply and return piping
connections. See Appendix F for dimensional
data. The physical location of the supply and
return piping connections is on the rear of the
unit (See Fig 2.3 for details).
2-2
INSTALLATION
BOILER SUPPLY
(4"-150# FLG'D CONN.)
BOILER RETURN
(4"-150# FLG'D CONN.)
Figure 2.3
Supply and Return Location
2.3.3 CONDENSATE DRAIN & PIPING
The Benchmark Boiler is designed to condense
water vapor from the flue products. Therefore,
the installation must have provisions for suitable
drainage or collection. A 1/2” NPT drain
connection is provided on the exhaust manifold
(see Fig 2.4). A separate condensate drain trap
(part no. 24060) is shipped loose and must be
installed on the floor behind the unit. Connect
the trap to the exhaust manifold as follows:
1. First, install a 1/2” NPT nipple in the
condensate drain port (Fig. 2.4). Next,
connect a 3/4-to 1/2” reducer to the 1/2”
nipple.
2. On the condensate drain trap, install 3/4”
NPT nipples in the tapped inlet and outlet of
the trap.
3. Attach a length of 1” I.D. polypropylene hose
between the exhaust manifold drain and the
inlet side of the condensate trap (Fig 2.5).
Secure both ends of the hose with clamps.
Drainage from the condensate drain trap
outlet must be by gravity to a nearby floor
drain via a polypropylene hose or suitable
piping.
If a floor drain is not available, a condensate
pump can be used to remove the condensate to
drain. The maximum condensate flow rate is 11
GPH. The condensate drain trap, associated
fittings and drain line must be removable for
routine maintenance. Do Not
hard pipe.
Figure 2.4
Condensate Drain Connection Location
Figure 2.5
Condensate Trap Installation
2.4. GAS SUPPLY PIPING
The AERCO Gas Fired Equipment Gas Components and Supply Design Guide (GF-2030LN-M)
must be consulted before any gas piping is
designed or started.
WARNING!
DO NOT USE MATCHES, CANDLES,
FLAMES OR OTHER SOURCES OF
IGNITION TO CHECK FOR GAS LEAKS
.
2-3
INSTALLATION
CAUTION!
Many soaps used for gas pipe leak testing
are corrosive to metals. Therefore, AERCO
recommends the use of non-corrosive
soaps for leak tests. The piping must be
rinsed thoroughly with clean water after leak
checks have been completed.
NOTE:
All gas piping must be arranged so that it
does not interfere with removal of any
cover, inhibit service or maintenance, or
prevent access between the Unit and walls,
or another unit.
The location of the 2" inlet gas connection is
located on the rear of the unit as shown in
Figure 2.5.
All pipes should be de-burred and internally
cleared of any scale or iron chips before
installation. No flexible connectors or nonapproved gas fittings should be installed. Piping
should be supported from floor, ceiling or walls
only and must not be secured to the unit.
A suitable piping compound, approved for use
with natural gas or propane, should be used.
Any excess must be wiped off to prevent
clogging of components.
To avoid damage to the unit, when pressure
testing gas piping, isolate the unit from the gas
supply piping. At no time should there be more
than 14” W.C. to the unit. Leak test all external
piping thoroughly for leaks using a non-corrosive
soap and water solution or suitable equivalent.
The gas piping must meet all applicable codes.
When installing the gas supply regulator(s),
union connections should be placed in the
proper locations to allow for maintenance.
The gas supply regulator must be properly
vented to outdoors. Consult the local gas utility
for exact
supply gas regulators.
The regulator must be capable or regulating
2,000,000 BTU/HR of natural gas while
maintaining 5.3” W.C. to the boiler.
requirements concerning venting of
NOTE:
CAUTION!
A lockup style regulator must be used when
gas supply pressure exceeds 14” W.C.
2.4.2 MANUAL GAS SHUTOFF VALVE
A 2” manual gas shut-off valve is furnished with
each unit. The valve should be positioned on the
inlet to the unit, as shown in Figure 2.5,
upstream of the supply regulator in a readily
accessible location.
2.4.3 IRI GAS TRAIN KIT
The IRI gas train is an optional gas train
required in some areas by code or for insurance
purposes. The IRI gas train is factory pre-piped
and wired.
2.4.1 GAS SUPPLY SPECIFICATONS
− Natural Gas:
The maximum static pressure to the unit
must be no more than 2 psi. Minimum
natural gas operating pressure is 5.3“ W.C.
for FM gas trains & 5.5“ W.C. for IRI gas
trains when the unit is firing at maximum
input (2000 cfh). For Benchmark 2.0 Low
NOx boilers configured for De-Rated
capacity, the required minimum natural gas
operating pressure is 4.0” W.C. for FM gas
trains (4.2” W.C. for IRI gas trains) at maximum input of 1,750,000 BTU/hr (1750 cfh).
A gas supply regulator must be positioned as
shown in Figure 2.5. If the gas supply pressure
will exceed 14" W.C., a lock -up style regulator is
required.
2-4
Figure 2.5
Manual Shut-Off Valve Location
INSTALLATION
2.5 ELECTRICAL SUPPLY
The AERCO Gas Fired Equipment Electrical
Power Wiring Guide, (GF-2060), must be
consulted in addition to the following material
before wiring to the unit is started. External AC
power connections are made to the unit inside
the power box on the front panel of the unit,
behind the removable front door (Figure 2.6).
NOTE:
All electrical conduit and hardware should
be installed so that it does not interfere with
the removal of any cover, inhibit service or
maintenance, or prevent access between
the unit and walls or another unit.
Each Benchmark Boiler must be connec ted to a
dedicated electrical circuit. No other devices
should be on the same electrical circuit as the
Benchmark Boiler. A means for disconnecting
AC power from 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 acc ordance with
the National Electrical Code and/or with any
applicable local codes.
For electrical power wiring diagrams, see the
Benchmark Electrical, Power Wiring Guide, GF2060
220 VAC, 1 PHASE
GND
NEU
208 VAC, 3 PHASE
GND
NEU
L3
Figure 2.6
AC Input Terminal Location
2.5.1 ELECTRICAL REQUIREMENTS
The Benchmark Boiler is available in one three
different AC power configurations:
220 Vac/1 Phase/60 Hz @ 20 amps
208 Vac/3-Phase/60 @15 amps
460 Vac/3-Phase/60 Hz @ 15 amps
Each of the above power configurations contain
a Power Box with a terminal block which
matches the configuration ordered. The three
different terminal block configurations are shown
in Figure 2.7. A wiring diagram showing the
required AC power connections is provided on
the front panel of each Power Box.
L2
L1
220 VAC, 1 Phase
460 VAC, 3 PHASE
GND
L3
L2
L1
460 VAC, 3 Phase
L2
L1
208 VAC, 3 Phase
Figure 2.7
AC Terminal Block Configurations
2.6 MODE OF OPERATION and FIELD
CONTROL WIRING
The Benchmark Boiler is available in several
different modes of operation. While each unit is
factory configured and wired for a particular
mode, some field wiring may be required to
complete the installation. This wiring is typically
run to the Input/Output (I/O) Box located on the
front of the unit behind the removable front door
2-5
INSTALLATION
(see Fig. 2.8). A brief description of each mode
of operation, and their requirements, is
described in the following paragraphs. Additional
information concerning field wiring is provided in
paragraphs 2.7.1 through 2.7.9. For additional
information on modes of operation, refer to
Chapter 5.
Figure 2.8
I/O Box Terminal Location
OUTDOOR SENSOR IN
SENSOR COMMON
AUX SENSOR IN
NOT USED
SHIELD
+
+
-
ANALOG IN
B.M.S. (PWM) IN
2.6.1 CONSTANT SETPOINT MODE
The Constant Setpoint Mode is used when it is
desired to have a fixed setpoint that does not
deviate. No wiring connections other than
electrical supply connections are required for
this mode. However, if desired, fault monitoring
or enable/disable interlock wiring can be utilized
(see paragraphs 2.7.9.1 and 2.7.10).
2.6.2 INDOOR/OUTDOOR RESET MODE
This mode of operation increases supply water
temperature as outdoor temperatures decrease.
An outside air temperature sensor (AERCO PN
122790) is required. The sensor MUST BE
wired to the I/O Box wiring terminals (see Fig.
2.9). For more information concerning the
outside air sensor installation, refer to paragraph
2.7.1
REMOTE INTL'K IN
EXHAUST SWITCH IN
DELAYED INTL'K IN
NOT USED
NC
FAULT RELAY
COM
120 VAC, 5A, RES
NO
NC
AUX RELAY
COM
NO
120 VAC, 5A, RES
NOT USED
2-6
mA OUT
RS-485
COMM.
NOT USED
+
+
G
-
Figure 2.9 I/O Box Terminal Strip
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
2.6.3 BOILER MANAGEMENT SYSTEM
(BMS) 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 2-9). Twisted shielded
pair wire from 18 to 22 AWG must be utilized for
the connections. The BMS Mode can utilize
either pulse width modulation (PWM) signaling,
or RS485 Modbus signaling. For 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 Modbus signaling, connections are made
from the BMS to the RS485 COMM terminals on
the I/O Box terminal strip. Polarity must be
maintained and the shield 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
Model 168) and GF-124 (BMS II Model 5R5-
384), BMS -Operations Guides.
2.6.4 REMOTE SETPOINT and DIRECT
DRIVE MODES
The Benchmark Boiler can accept several types
of signal formats from an Energy Management
System or other source to control either the
setpoint (Remote Setpoint Mode) or firing rate
(Direct Drive Mode) of the Boiler. These formats
are:
4 to 20 mA/1 to 5 Vdc
0 to 20 mA/0 to 5 Vdc
PWM – (Pulse Width Modulated signal. See
paragraph 2.7.4)
Network – (RS485 Modbus. See para. 2.7.7)
While it is possible to control a boiler or boilers
using one of the previously described modes of
operation, it may not be the method best suited
for the application. Prior to selecting one of
these modes of operation, it is recommended
that you consult with your local AERCO
representative or the factory for the mode of
INSTALLATION
operation that will work best with your
application. For more information on wiring the
4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5
VDC, see paragraph 2.7.3.
2.6.5 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
connected between the unit’s I/O Box wiring
terminals, the CCP (Combination Control Panel),
and the BMS Model 168 (Boiler Management
System). The wiring must be done using a
shielded twisted pair of 18- 22 AWG wire and
polarity must be maintained. For further
instructions and wiring diagrams, refer to the
GF-108 Boiler Management System Operations
Guide and the CCP-1 data sheet.
2.7 I/O BOX CONNECTIONS
The types of input and output signals and
devices to be connected to the I/O Box terminals
shown in Figure 2.9 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.
2.7.1 OUTDOOR SENSOR IN
An outdoor air temperature sensor (AERCO Part
No. 122790) will be required mainly for the
Indoor/Outdoor reset mode of operation. It can
also be used with another mode 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 choose
an enable/disable outdoor temperature, see the
Configuration menu in Chapter 3.
The outdoor sensor may be wired up to 200 feet
from the boiler and is connected to the
OUTDOOR SENSOR IN and SENSOR
COMMON terminals in the I/O box (see Figs. 2.8
and 2.9). Wire the sensor using a twisted
shielded pair cable of 18-22 AWG wire. There is
no polarity when terminating the wires. The
2-7
shield is to be connected only to the terminals
labeled SHEILD in the I/O box. The sensor end
of the shield must be left free and ungrounded.
When mounting the sensor, it must be located
on the North side of the building where an
average outside air temperature is expected.
The sensor must be shielded from direct sunlight
as well as impingement by the elements. If a
shield is used, it must allow for free air
circulation.
2.7.2 AUX SENSOR IN
The AUX SENSOR IN terminals can be 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 SENSOR IN and SENSOR
COMMON and must be similar to AERCO
BALCO wire sensor P/N 12449. A resistance
chart for this sensor can be found in APPENDIX
C.
2.7.3 ANALOG IN
The ANALOG IN + and – terminals are used
when an external signal is used to drive the
firing rate (Direct Drive Mode) or change the
setpoint (Remote 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 firing rate. The factory default setting
is for 4 to 20 mA / 1 to 5 VDC, however this may
be changed to 0 to 20 mA / 0 to 5 VDC using the
Configuration Menu described in Chapter 3. If
voltage rather than current is selected as the
drive signal, a DIP switch must be set on the
PMC Board located inside the Control Box.
Contact the AERCO factory for information on
setting DIP switches.
All supplied signals must be floating
(ungrounded) signals. Connections between the
source and the Boiler’s I/O Box must be made
using twisted shielded pair of 18 –22 AWG wire
such as Belden 9841(see Fig. 2.9). Polarity
must be maintained and the shield must be
connected only at the source end and must be
left floating (not connected) at the Boiler’s I/O
Box.
Whether using voltage or current for the drive
signal, they are linearly mapped to a 40° to
240°F setpoint or a 0% to 100% firing rate. No
scaling for these signals is provided
2.7.4 B.M.S. (PWM) IN
NOTE
Only BMS Model 168 can utilize Pulse
Width Modulation (PWM), not the BMS II
(Model 5R5-384).
These terminals are used to connect the
AERCO Boiler Management System (BMS)
Model 168 to the unit. The BMS Model 168
utilizes a 12 millisecond, ON/OFF duty cycle.
This duty cycle is Pulse Width Modulated (PWM)
to control firing rate. A 0% firing rate = a 5% ON
pulse and a 100% firing rate = a 95% ON pulse.
2.7.5 SHIELD
The SHIELD terminals are used to terminate any
shields used on sensor wires connected to the
unit. Shields must only be connected to these
terminals.
2.7.6 mA OUT
These terminals provide a 4 to 20 mA output
that can be used to monitor setpoint ( 40
o
F), outlet temperature (30o to 240oF), or fire
240
rate (0% to 100%). This function is enabled in
the Configuration Menu (Chapter 3, Table 3.4).
o
to
2.7.7 RS-485 COMM
These terminals are used for RS-485 MODBUS
serial communication between the unit and an
external “Master” such as a Boiler Management
System or other suitable device.
2.7.8 EXHAUST SWITCH IN
These terminals permit an external exhaust
switch to be connected to the exhaust manifold
of the boiler. The exhaust sensor should be a
normally open type switch (such as AERCO Part
No. 123463) that closes (trips) at 500
o
F.
2.7.9 INTERLOCKS
The unit offers two interlock circuits for
interfacing with Energy Management Systems
and auxiliary equipment such as pumps or
louvers. These interlocks are called the Remote
Interlock and Delayed Interlock (Fig. 2.9). The
wiring terminals for thes e interlocks are located
inside the I/O Box on the unit front panel. The
I/O Box cover contains a wiring diagram which
shows the terminal strip locations for these
interlocks labeled REMOTE INTL’K IN and
DELAYED INTL’K IN. Both interlocks, described
below, are factory wired in the closed position.
2-8
INSTALLATION
NOTE:
Both the Delayed Interlock and Remote
Interlock must be in the closed position to
allow the unit to fire.
2.7.9.1 REMOTE INTERLOCK IN
The remote interlock circuit (REMOTE INTL’K
IN) is provided to remotely start (enable) and
stop (disable) the Boiler if desired. The circuit is
24 VAC and comes factory pre-wired closed
(jumped).
2.7.9.2 DELAYED INTERLOCK IN
The delayed interlock circuit (DELAYED INTL’K
IN) is typically used in conjunction with the
auxiliary relay described in paragraph 2.8. 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 by the
Boiler’s auxiliary relay. The delayed interlock
must be closed for the boiler to fire. If the
delayed interlock is connected to a proving
device that requires time to close (make), a time
delay (Aux Start On Dly) that holds the start
sequence of the boiler long enough for a proving
switch to make can be programmed. Should the
proving switch not prove within the programmed
time frame, the boiler will shut down. The Aux
Start On Dly can be programmed from 0 to 120
seconds. This option is locate in the Configuration Menu (Chapter 3).
2.7.10 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 120 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 2.9
2.8 AUXILIARY 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 demand for heat is satisfied.
The relay is provided for the control of auxiliary
equipment, such as pumps and louvers, or can
be used as a Boiler status indictor (firing or not
firing). Its contacts are rated for 120 VAC @ 5
amps. Refer to Figure 2.9 to locate the AUX
RELAY terminals for wiring connections.
2.9 FLUE GAS VENT INSTALLATION
The AERCO Venting and Combustion Air Guide,
GF-2050, must be consulted before any flue gas
vent or inlet air venting is designed or installed.
U/L listed, positive pressure, watertight vent
materials as specified in AERCO’s GF-2050,
must be used for safety and code compliance.
Because the unit is capable of discharging low
temperature exhaust gases, the flue must be
pitched back to the unit a minimum of 1/4" per
foot to avoid any condensate pooling and to
allow for proper drainage.
The combined pressure drop of vent and
combustion air systems must not exceed 140
equivalent feet of 8 inch ducting. Fittings as well
as pipe lengths must be calculated as part of the
equivalent length.
For a natural draft installation the draft must not
exceed -0.25”/+0.25" W.C. These factors must
be planned into the vent installation. If the
maximum allowable equivalent lengths of piping
are exceeded, the unit will not operate properly
or reliably.
The Heatfab Division of the Selkirk Corporation
provides vent systems which conform to all
applicable requirements for installations within
the Commonwealth of Massachusetts. Contact
information for this supplier are as follows:
Selkirk Corporation
Heatfab Division
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
2.10 COMBUSTION AIR
The AERCO Venting and Combustion Air Guide,
GF-2050, MUST be consulted before any flue or
combustion supply air venting is designed or
started. Combustion air supply is a direct
requirement 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 hazardous when us ed in gasfired equipment. Common sources of these
compounds are swimming pools, degreasing
compounds, plastic processing and refrigerants.
Whenever the environment contains these types
of chemicals, combustion air must be supplied
from a clean area outdoors for the protection
and longevity of the equipment.
2-9
The Benchmark is UL listed for 100% sealed
combustion and can be ordered with a sealed
combustion option, or can be installed using
room air as long as there is an adequate supply.
(See paragraph 2.10.3 for more information
concerning sealed combustion air.)
If the sealed combustion air option is not being
used, an inlet screen will be attached at the
blower suction and the knockout at the top of the
unit will be and should remain in place.
The more common methods of supplying
combustion air are outlined below. For more
information concerning combustion air, consult
the AERCO GF-2050, Venting and Combustion
Air Guide.
2.10.1 COMBUSTION AIR FROM
OUTSIDE THE BUILDING
Air supplied from outside the building must be
provided through two permanent openings. Each
opening must have a free area of not less than
one square inch for each 4000 BTU boiler input.
The free area must take into account restrictions
such as louvers and bird screens.
2.10.2 COMBUSTION AIR FROM INSIDE
THE BUILDING
When combustion air is provided from 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 BTUH of total boiler
input. The free area must take into account any
restrictions such as louvers.
2.10.3 SEALED COMBUSTION
The BENCHMARK boiler is UL listed for 100%sealed combustion and can be ordered with a
sealed combustion option or without. Units
ordered in the sealed combustion configuration
will come with an air inlet assembly installed on
the blower. The knockout at the top of the boiler
must be removed and the combustion air
ductwork must be attached to the 6" x 8" adapter
that is provided just below the knockout.
Remove and discard the screen attached to the
adapter.
In a sealed combustion air application, the
combustion air ducting pressure los ses must be
taken into account when calculating the total
maximum allowable venting run. See the
AERCO Venting and Combustion Air Guide, GF-
2050. When using the boiler in a sealed
combustion air configuration, each unit must
have a minimum 8" diameter connection at the
unit.
2-10
CONTROL PANEL OPERATING PROCEDURES
Chapter 3 - CONTROL PANEL OPERATING PROCEDURES
3.1. INTRODUCTION
The information in this Chapter provides a guide
to the operation of the Benchmark Boiler using
the Control Panel mounted on the front of the
unit. It is imperative that the initial startup of this
unit be performed by factory trained personnel.
Operation prior to initial startup by factory
trained personnel will void the equipment
warranty. In addition, the following WARNINGS
and CAUTIONS must be observed at all times.
CAUTION:
All initial installation procedures must be
satisfied before attempting to start the unit.
WARNING:
THE ELECTRICAL VOLTAGES IN THIS
SYSTEM MAY INCLUDE 460, 220, 120
AND 24 VOLTS AC. IT MUST NOT BE
SERVICED OR ACCESSED BY OTHER
THAN FACTORY CERTIFIED SERVICE
TECHNICIANS.
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
PERSONNEL INJURY OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID
ANY WARRANTY.
3.2. CONTROL PANEL DESCRIPTION
The Benchmark Control Panel shown in Figure
3-1 contains all of the controls, indicators and
displays necessary to operate, adjust and
troubleshoot the Benchmark 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.
2
1
3
4
12
11
10
9
5
6
7
8
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
2
OUTLET
TEMPERATURE
Display
3 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines, each
4 RS-232 Port Port permits a Laptop Computer or External Modem to be
5 FAULT Indicator Red FAULT LED indicator lights when a boiler alarm
6 CLEAR Key Turns off the FAULT indicator and clears the alarm message
7 READY Indicator
8 ON/OFF Switch
9
LOW WATER LEVEL
TEST/RESET Switches
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.
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
Startup Messages
Fault Messages
Operating Status Messages
Menu Selection
connected to the boiler 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 when 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 CLEAR resets the display.
FUNCTION
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
ENTER
11 AUTO/MAN Switch This switch toggles the boiler between the Automatic and
12 FIRE RATE Bargraph 20 segment red LED bargraph continuously shows the Fire
Saves the modified menu settings in memory. The display
will stop flashing.
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.
Rate in 5% increments from 0 to 100%
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 four major menu categories as
shown in Figure 3-2. Each of the menus shown,
contain options which permit operating parameters to be viewed or changed. The menus are
protected by a password to prevent unauthorized use.
Prior to entering the correct password, the
options contained in the Operating, 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 password (159) is entered, the
options listed in the Setup, Configuration and
Tuning Menus can be viewed and changed, if
desired.
3.3.1. Menu Processing Procedure
Accessing 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.
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.
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
available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will
Figure 3-2. Menu Structure
NOTE:
The following paragraphs provide brief
descriptions of the options contained in
each menu. Refer to Appendix A for
detailed descriptions of each menu option.
Factory Default settings for all menu options
are listed in Appendix E. Refer to Appendix
B for listings and descriptions of displayed
startup, status and error messages.
3-4
CONTROL PANEL OPERATING PROCEDURES
3.4. OPERATING MENU
The Operating Menu displays a number of key
operating parameters for the unit as listed in
Table 3-2. This menu is “Read-Only” and does
not allow personnel to change or adjust any
other displayed items. Since this menu is “ReadOnly”, it can be viewed at any time without
entering a password. Press the ▲ arrow key to
display the menu items in the order listed (TopDown). Pressing the ▼ arrow key will display
the menu items in reverse order (Bottom-Up).
3.5. 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
Table 3-2. Operating Menu
Available Choices or Limits
Menu Item Display Minimum Maximum Default
Status Message
Active Setpoint 40°F 240°F
Aux Temp 30°F 245°F
Outdoor Temp* -70°F 130°F
Fire Rate In 0% Max Fire Rate
Flame Strength 0% 100%
Run Cycles 0 999,999
Run Hours 0 999,999
Fault Log 0 9 0
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
Comm Address 0 127 0
Baud Rate 2400, 4800
9600, 19.2K
Software Ver 0.00 Ver 9.99
Setup Menu is also used to enter date and time,
language to be used for display messages, 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).
Fahrenheit
Celsius
9600
3-5
CONTROL PANEL OPERATING PROCEDURES
3.6. CONFIGURATION MENU
The Configuration Menu shown in Table 3-4
permits adjustment of the Internal Setpoint
(Setpt) temperature regardless of whether the
valid password has been entered. Setpt is
required for operation in the Constant Setpoint
mode. The remaining options in this menu
require the valid password to be entered, prior to
changing existing entries. 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 Boiler
Water Heater
Unit Size 0.5 MBTU, 1.0 MBTU
1.5 MBTU, 2.0 MBTU
2.5 MBTU, 3.0 MBTU
Boiler Mode Constant Setpoint
Remote Setpoint
Combination
Outdoor Reset
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
Bldg Ref Temp
(If Boiler Mode =
Outdoor Reset)
Reset Ratio
(If Boiler 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 240°F 200°F
Temp Hi Limit 40°F 240°F 215°F
Max Fire Rate 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
mA Output Setpoint, Outlet Temp,
Lo Fire Timer 2 sec 120 sec 2 sec
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 5°F
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
BMS (PWM Input
40°F 240°F 70°F
0.1 9.9 1.2
30°F 100°F 60°F
Fire Rate Out, Off
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
Boiler
1.0 MBTU
Constant
Setpoint
Direct Drive
4 – 20 mA,
1-5V
Network
Off
3-6
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
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 2.0 min 0.0 min
Reset Defaults? Yes
3.8. START SEQUENCE
When the Control Box ON/OFF switch is set to
the ON position, it checks all pre-purge safety
switches to ensure they are closed. These
switches include:
• Safety Shut-Off Valve Proof of Closure
(POC) switch
• Low Water Level switch
• High Water Temperature switch
• High Gas Pressure switch
• Low Gas Pressure switch
If all of the above switches are closed, the
READY light above the ON/OFF switch will light
and the unit will be in the Standby mode.
When there is a demand for heat, the following
events will occur:
NOTE:
menu entries unless specifically requested to do
so by Factory-Trained personnel.
No
No
Are You Sure?
If any of the Pre-Purge safety device switches
are open, the appropriate fault message will be
displayed. Also, the appropriate fault messages
will be displayed throughout the start sequence,
if the required conditions are not observed.
1. The DEMAND LED status indicator will light.
2. The unit checks to ensure that the proof of
closure switch in the Safety Shut-Off Valve
(SSOV) is closed (Figure 3-3).
Figure 3-3.
Safety Shut-Off Valve
3. With all required safety switches closed, a
purge cycle will be initiated and the following
events will occur:
3-7
CONTROL PANEL OPERATING PROCEDURES
(a) Blower relay energizes and turns on
blower.
(b) Air/Fuel Valve rotates to full-open purge
position and closes purge position
switch. The dial on the Air/Fuel Valve
(Figure 3-4) will read 100 to indicate that
it is full-open (100%).
(c) The FIRE RATE bargraph will show
100%.
5. Upon completion of the purge cycle, the
Control Box initiates an ignition cycle and the
following events occur:
(a) The Air/Fuel Valve rotates to the low-fire
ignition position and closes the ignition
switch. The dial on the Air/Fuel Valve
(Figure 3-6) will read between 25 and 35
to indicate that the valve is in the lowfire position.
Figure 3-5.
Blower Proof Switch
Figure 3-4.
Air/Fuel Valve In Purge Position
4. Next, the blower proof switch (Figure 3-5)
closes. The display will show Purging and
indicate the elapsed time of the purge cycle
in seconds. The normal (default) time for the
purge cycle is 7 seconds.
(b) Simultaneously, the ignition transformer
and the staged ignition solenoid valve
will be activated. The ignition transformer provides ignition spark. The
activated (open) solenoid valve allows a
small volume of gas to flow directly to
the burner assembly (Appendix F).
(c) The gas Safety Shut-Off Valve (SSOV)
is energized (opened) allowing gas to
flow into the Air/Fuel Valve.
6. Up to 7 seconds will be allowed for ignition to
be detected. The igniter relay will be turned
off one second after flame is detected.
7. After 2 seconds of continuous flame, Flame
Proven will be displayed and the flame
strength will be indicated. After 5 seconds,
the current date and time will be displayed in
place of the flame strength.
3-8
Loading...