AERCO BMK 3.0 LN Nat. Gas Jan 2011 User Manual Gas Jan 2011
Instruction
GF-116
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Benchmark 3.0LN
Series
Gas Fired
Low NOx
Boiler System
Condensing, Modulating
Forced Draft, Hot Wa t e r Boiler
3,000,000 BTU/H Input
Applicable for Serial Numbers G-10-1473 and above
Printed in U.S.A. REVISED JANUARY 27, 2011
Telephone Support
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through Friday):
1-800-526-0288
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco,com
© AERCO International, Inc., 2011
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-116 - AERCO BENCHMARK 3.0LN GAS FIRED LOW NOx 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 Drains 2-3
2.7 Gas Supply Piping 2-5
2.8 AC Electrical Power Wiring 2-6
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 2-9
2.11 Auxiliary Relay Contacts 2-11
2.12 Flue Gas Vent Installation 2-11
2.13 Combustion Air 2-11
2-7
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 3-8
3.8 Combustion Cal Menu 3-8
3.9 Start Sequence 3-8
3.10 Start/Stop Levels 3-10
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 4-6
4.5 Over-Temperature Limit Switch 4-6
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 6-2
6.4 Low Water Level Fault Test 6-2
6.5 Water Temperature Fault Test 6-2
6.6 Interlock Tests 6-3
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
6-6
Chapter 7 – MAINTENANCE REQUIREMENTS 7-1
Para. Subject Page
7.1 Maintenance Schedule 7-1
7.2 Ignitor-Injector 7-1
7.3 Flame Detector 7-2
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 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
7-6
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
Chart
D Indoor/Outdoor Reset Ratio
Charts
E Boiler Default Settings E-1
F Dimensional and Part Drawings F-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
G Piping Drawings G-1
H Wiring Schematics H-1
I Recommended Periodic Testing
Checklist
J Benchmark Control Panel Views J-1
K Recommended Spare Parts K-1
9-1
I-1
WARRANTIES W-1
iii
FOREWORD
Foreword
The AERCO Benchmark 3.0LN Boiler is a modulating unit. It represents a true industry advance
that meets the needs of today's energy and env ironmental concer ns. Desig ned for application
in any closed loop hydronic system, the Benchmark's modulating capability relates energy input
directly t o f luctuating sy stem loads. T he Benchm ark 3. 0, w ith it s 15: 1 t urn down ratio and
condensing capabilit y, pr ovides ex tremely hig h ef ficiencies and makes it ideally suited for
modern low temperature, as well as, conventional heating systems.
The Benchmark 3.0 operates at inputs ranging from 200,000 BTU/hr. to 3,000,000 BTU/hr. The
output of t he boiler is a f unction of the unit ’s f iring r ate and r eturn w ater t emperature. O utput
ranges from 198,000 BTU/hr. to 2,900,000 BTU/hr., depending on operating conditions.
When installed and oper ated in accor dance w ith t his I nstruction M anual, t he Benchm ark 3. 0
Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.1
Whether used in sing ular or modular ar rangements, t he Benchmark 3. 0 of fers the maximum
flexibility in v enting with m inimum inst allation space requirements. The Benchmark's advanced
electronics are available in sev eral select able m odes of oper ation of fering t he m ost ef ficient
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 o perating p ersonnel M UST, at all
times, obs erve al l s afety r egulations. T he
following warnings and cautions are general and
must be gi ven th e s ame attention as s pecific
precautions i ncluded in t hese ins tructions. In
addition to all t he r equirements inc luded in th is
AERCO Ins truction Man ual, th e ins tallation of
units MUST conform with loc al bu ilding codes,
or, in th e absence of local c odes, ANSI Z223.1
(National Fuel Gas Code P ublication No. NF PA-
54). Where ASM E CS D-1 is r equired b y local
jurisdiction, the i nstallation m ust c onform to
CSD-1.
Where appl icable, th e equipment s hall be
installed in a ccordance w ith t he cu rrent
Installation Co de f or G as Bur ning Appliances
and Equipment, CG A B149, an d a pplicable
Provincial regulations for the class; which should
be ca refully f ollowed in all ca ses. Authorities
having j urisdiction s hould be c onsulted before
installations are made.
IMPORTANT
This I nstruction M anual is an int egral
part o f the pr oduct a nd m ust be
maintained in legible condition. It must
be g iven t o t he user b y t he inst aller
and k ept in a sa fe pla ce for future
reference.
WARNINGS!
MUST BE OBSERVED TO PREVENT
SERIOUS INJURY.
WARNING!
BEFORE ATT EMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHU T OFF AL L G AS AND
ELECTRICAL INPUTS TO THE UNIT.
WARNING!
DO NOT USE MATCHES, CANDLES,
FLAMES, OR OTHER SOURCES O F
IGNITION TO CHECK FO R G AS
LEAKS.
WARNING!
FLUIDS UNDER PRE SSURE MAY
CAUSE I NJURY T O PERSO NNEL
OR DAM AGE TO EQUIPMENT
WHEN RELEASED. BE SURE T O
SHUT O FF ALL I NCOMING AND
OUTGOING W ATER SHUTOFF
VALVES. CAREFULLY DECREASE
ALL T RAPPED PRE SSURES T O
ZERO BEFO RE P ERFORMING
MAINTENANCE.
WARNING!
ELECTRICAL VO LTAGES UP T O
120 VAC MAY BE US ED I N T HIS
EQUIPMENT. T HEREFORE T HE
COVER O N THE UNIT ’S PO WER
BOX ( LOCATED BEHI ND T HE
FRONT PANEL DOO R) M UST BE
INSTALLED AT ALL TIMES, EXCEPT
DURING M AINTENANCE AND
SERVICING.
CAUTIONS!
Must be obser ved t o pr event
equipment da mage or loss o f
operating effectiveness.
CAUTION!
Many soaps used f or gas pipe leak
testing a re co rrosive to me tals. The
piping must
clean water a fter leak checks hav e
been completed.
be r insed t horoughly with
WARNING!
THE EX HAUST VENT PIPE OF THE
UNIT OPERATES UNDER A
POSITIVE PRESSURE AND T HEREFORE MUST BE C OMPLETELY
SEALED T O PREVENT LEAKAG E
OF COMBUSTION PRODUCTS INTO
LIVING SPACES.
CAUTION!
DO NOT use this boiler if any part has
been under w ater. Cal l a q ualified
service t echnician t o inspect and
replace any par t that ha s been under
water.
1-1
SAFETY PRECAUTIONS
1.2 EMERGENCY SHUTDOWN
If over heating occurs or th e gas s upply f ails to
shut of f, c lose the m anual g as s hutoff val ve
(Figure 1-1) located external to the unit.
IMPORTANT
The Ins taller m ust identif y and indicate
the loc ation of the e mergency s hutdown
manual gas valve to operating personnel.
MANUAL GAS SHUTOFF VALVE
VALVE OPEN
VALVE CLOSED
1.3 PROLONGED SHUTDOWN
After pr olonged s hutdown, it is r ecommended
that the startup procedures in Chapter 4 and the
safety device test pr ocedures in C hapter 6 of
this m anual be performed, to ver ify a ll s ystemoperating parameters. If there is an emergency,
turn of f the elec trical p ower s upply to th e
AERCO b oiler a nd c lose t he m anual g as v alve
located ups tream the unit . T he ins taller m ust
identify the emergency shut-off device.
Figure 1-1
Manual Gas Shutoff Valve
IMPORTANT – FOR MASSACHUSETTS INSTALLATIONS ONLY
Boiler Ins tallations within t he Com monwealth of Ma ssachusetts must c onform to the f ollowing
requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of
Massachusetts.
• Prior to u nit operation, the c omplete gas train and a ll connections must be lea k tested using a
non-corrosive soap.
• If a gl ycol s olution is us ed as anti- freeze protection, a b ackflow pr eventer must be ins talled
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:
1-2
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
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 address 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
for that 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 INTRODUCTION
This Chapt er pr ovides t he d escriptions a nd
procedures nec essary t o unpack, ins pect an d
install th e AERCO Benchmark 3.0 Boi ler. Br ief
descriptions are also provided for each available
mode of oper ation. Det ailed procedures f or
implementing th ese m odes ar e pr ovided in
Chapter 5.
2.2 RECEIVING THE UNIT
Each Benchmark 3.0 S ystem is s hipped as a
single c rated unit. T he s hipping weight is
approximately 2,170 pounds. T he un it m ust be
moved w ith the pr oper rigging equ ipment for
safety and to avoid equipment damage. The unit
should b e c ompletely inspected f or e vidence of
shipping damage and shipment completeness at
the t ime of r eceipt f rom the c arrier a nd before
the bill of lading is signed.
NOTE
AERCO is no t r esponsible f or los t or
damaged freight.
Each u nit has a T ip-N-Tell indicator on th e
outside of the crate. This indicates if the unit has
been t urned on its s ide d uring s hipment. If the
Tip-N-Tell indicator is tripped, do not sign for the
shipment. Not e th e information o n t he c arrier’s
paperwork and r equest a f reight c laim and
inspection b y a c laims adj uster bef ore
proceeding. A ny other v isual d amage to t he
packaging m aterials s hould als o be m ade c lear
to the delivering carrier.
2.3 UNPACKING
Carefully unpack the unit tak ing c are not to
damage the un it enclosure when c utting away
packaging materials
• Pr essure/Temperature Gauge
• Spar e Ignitor-Injector
• Spare Flame Detector
• ASME Pressure Relief Valve
• Condensate Drain Trap & Adapter `
• 2” Gas Supply Shutoff Valve
When or dered, o ptional accessories may be
packed separately, pac ked with in the boiler
shipping c ontainer, or m ay be i nstalled on th e
boiler. A ny s tandard or opti onal ac cessories
shipped loose should be identified and stored in
a safe place until ready for installation or use.
2.4 SITE PREPARATION.
Ensure t hat t he s ite s elected f or ins tallation of
the Benchmark 3.0 Boiler includes:
• Access to AC Inp ut Po wer corresponding to
the or dered po wer c onfiguration. T he
available power configurations are:
• 208 VAC, 3-Phase, 60 Hz @ 20 A
• 460 VAC, 3-Phase, 60 Hz @ 15 A
• Access to Natur al G as line at a m inimum
static pressure of 3.5” W.C.(FM) or 4.0” W.C.
(IRI). M aximum static p ressure must n ot
exceed 2 psi.
2.4.1 Installation Clearances
The unit m ust be i nstalled with t he prescribed
clearances f or s ervice as shown in F igure 2-1.
The minimum
AERCO, ar e l isted below. Ho wever, if Loc al
Building Cod es r equire a dditional c learances,
these c odes s hall s upersede A ERCO’s
requirements. Mi nimum ac ceptable c learances
required are:
clearance dimensions, required by
A close inspection of the unit should be m ade to
ensure that there is no e vidence of damage not
indicated by the Tip-N-Tell indicator. The freight
carrier s hould b e not ified im mediately if an y
damage is detected.
The f ollowing accessories c ome s tandard with
each un it and ar e eit her pack ed s eparately
within the unit’s packing container or are factory
installed on the boiler:
• Sid es: 24 inches
• Front : 24 inches
• Rear : 43 inches
• T op: 18 inches
All gas piping, water piping and electrical conduit
or c able m ust be ar ranged s o th at t hey d o not
interfere with the r emoval of an y panels, or
inhibit service or maintenance of the unit.
2-1
INSTALLATION
Figure 2-1 Benchmark 3.0 Boiler Clearances
WARNING
KEEP T HE UNIT AREA CLEAR AND
FREE FRO M ALL C OMBUSTIBLE
MATERIALS AND FLAMMABLE
VAPORS OR LIQUIDS
.
CAUTION
While pac kaged in the shipping
container, the boiler m ust be m oved
by p allet ja ck o r forklift from th e
FRONT ONLY.
FOR MASSACHUSETTS ONLY
For M assachusetts i nstallations, th e
boiler m ust be ins talled by a plum ber
or gas fitter who is licensed within the
Commonwealth of M assachusetts. I n
addition, t he inst allation m ust comply
with all r equirements specif ied in
Chapter 1 (Safety Precautions), pages
1-2 & 1-3.
2.4.2 Setting the Unit
The unit m ust be ins talled on a 4 inc h to 6 inc h
housekeeping pad to ensure proper condensate
drainage. If anc horing th e unit, r efer to the
dimensional dr awings in A ppendix F for anchor
locations. A total of 3 lifting tabs are provided at
the top of the primary heat exchanger as shown
in F igure 2- 2. Ho wever, USE O NLY T ABS 1
AND 2 SHOWN IN FIGURE 2-2 TO MOVE THE
ENTIRE UNIT . T abs 1 and 3 ar e us ed o nly
when r emoving or r eplacing the unit’s pr imary
heat exchanger. Rem ove the f ront t op p anel
from the unit to provide access to the lifting tabs.
2-2
Remove the four (4) lag screws securing the unit
to the s hipping skid. Lift the unit off the s hipping
skid and pos ition it on t he 4 inc h t o 6 inc h
housekeeping c oncrete p ad ( required) in t he
desired location.
BURNER
ASSEMBLY
LIFTING
TAB 1
PRIMARY HEAT
EXCHANGER
LIFTING
TAB 2
LIFTING
TAB 3
Figure 2-2
Lifting Lug Locations
In m ultiple unit installations, it is important to
plan the pos ition of eac h unit i n ad vance.
Sufficient s pace f or pi ping c onnections a nd
future s ervice/maintenance r equirements must
also be taken into consideration. All piping must
include ample provisions for expansion.
If ins talling a Com bination Control Pa nel ( CCP)
system, it is important to identify th e
Combination Mode Boilers in advance and place
them in the pr oper ph ysical loc ation. Ref er to
Chapter 5 f or information o n Combination Mode
Boilers.
INSTALLATION
5
Y
2.4.3 Removal of Support Rod
Prior to ins tallation of w ater supply a nd return
piping, the 24” threaded rod shown in Figure 2-3
must be r emoved. T his r od is installed pr ior to
shipment from the f actory to prevent damage t o
the ins ulated m etal f lex h ose on the hot water
supply outlet of the b oiler. In order to install t he
water s upply piping, th is r od m ust be r emoved
as follows:
1. Refer to Figure 2-3 and back off the hex nut
on the outlet side of the flex hose.
2. Next, disconnect the coupling nut from the
flange stud.
3. Completely remove the threaded rod, hex
nut and coupling nut from the boiler.
5/8-11 x 24" LONG
THREADED ROD
OUTLET
FLANGE
5/8-11
HEX NUT
/8-11
COUPLING NUT
INSULATED
FLEX HOSE
(SEE IMPORTANT
NOTE BELOW)
This c an be eas ily accomplished b y r emoving
the top
panel nearest to the front of the unit.
2.5 SUPPLY AND RETURN PIPING
The Benc hmark 3.0 B oiler uti lizes 4” 1 50#
flanges f or the water s ystem s upply a nd r eturn
piping connections. The ph ysical location of the
supply and return piping connections are on the
rear of the unit as shown in Figure 2-4. Refer to
Appendix F, Dr awing A P-A-811 f or ad ditional
dimensional data.
BOILER SUPPL
4" – 150# FLANGED
CONNECTION
BOILER RETURN
EXHAUST
MANIFOLD
SHELL DRAIN
VALVE
4" – 150# FLANGED
CONNECTION
2" GAS INLET
CONNECTION
EXHAUST
MANIFOLD
PARTIAL TOP VIEW - REAR
Figure 2-3
Location of Threaded Support Rod
IMPORTANT
THE IN SULATED F LEX H OSE
SHOWN IN FIG URE 2- 3 M UST
LEVEL O R SLO PING UPWARD AS
IT EXITS THE BOILER. FAILURE TO
PROPERLY PO SITION T HIS HO SE
MAY CAUSE I NEFFECTIVE AI R
ELIMINATION R ESULTING IN E LEVATED T EMPERATURES THAT
COULD CO MPROMISE T HE TOP
HEAD GASKET.
2.4.4 Removal of Strap and Packing
Material From Heat Exchanger
Prior to c onnecting th e ex ternal g as s upply or
electrical po wer to t he unit. the s trap and
packing material m ust be r emoved f rom the top
of the primary he at exchanger. T his m aterial is
located i n the area of the ig nitor-injector an d
staged ignition solenoid on the b urner assembly
BE
REAR VIEW
Figure 2-4
Supply and Return Locations
2.6 CONDENSATE DRAINS
The Benc hmark 3.0 Boi ler is d esigned t o
condense water vapor f rom the f lue pr oducts.
Therefore, the ins tallation must have pr ovisions
for suitable condensate drainage or collection.
Two condensate drain connections are provided
on th e r ear of the u nit as shown i n F igure 2- 5.
One dr ain connection is located o n the ex haust
manifold and th e oth er is loc ated on th e
connecting manifold.
The drain at th e bottom of the ex haust manifold
also i ncludes a c ondensate tr ap c ontaining a
float assembly. When condensate collects in the
exhaust m anifold, th e f loat r ises, ther eby
allowing i t to dis charge thr ough t he dr ain
opening. T he dr ain p ipe loc ated on t he
connecting m anifold m ust be c onnected to a
second c ondensate tr ap whic h is pac ked
separately within the unit’s shipping container.
2-3
INSTALLATION
The pr ocedures to install and c onnect b oth of
the c ondensate drains ar e pr ovided i n
paragraphs 2.6.1 and 2.6.2.
EXHAUST
MANIFOLD
CONDENSATE
TRAP
DRAIN
SHELL DRAIN
VALVE
A
A
B
CONNECTING
MANIFOLD
EXHAUST
MANIFOLD
DRAIN
FRAME
REAR VIEW
UNIT
UNIT
FRAME
SHELL
B
2.6.2 Connecting Manifold Condensate
Drain
The c onnecting m anifold drain pi pe s hown i n
Figure 2-5, View B – B m ust be c onnected to a
separate c ondensate drain tr ap ex ternal t o th e
unit. T his c ondensate tr ap ( part n o. 24060) is
supplied w ith the un it along w ith a trap adapter
and a 3/4” NPT x 5” long n ipple. Refer to Figure
2-6 and install the trap as follows:
NOTE
The c ondensate tr ap d escribed in the
following s teps c an be installed o n t he
floor behind the unit as shown in Figure 2-
6. Ensure that the condensate trap inlet is
level with or be low t he c onnecting
manifold drain pipe. Ensure that the outlet
hose f rom the tr ap s lopes awa y ( down)
from the trap.
1. Apply Teflon tape to the threads of the 3/4” x
5” long nipple provided with the boiler.
2. Attach t he 3/4” N PT nip ple b etween th e
condensate trap inl et and the tr ap ada ptor
(Figure 2-6).
3. Attach another 3/4” NPT nipple (not supplied) to the condensate trap outlet on the
lower part of the trap.
CONDENSATE
TRAP
DRAIN
HOSE
CLAMP
1" I.D.
HOSE
VIEW “A - A”
TO FLOOR
DRAIN
DRAIN
VALVE
CONNECTING
MANIFOLD
TO
CONDENSATE
TRAP
CONDENSATE
DRAIN PIPE
VIEW “B - B”
Figure 2-5
Condensate Drain Connection Location
2.6.1 Exhaust Manifold Condensate
Drain
Refer to F igure 2- 5, V iew A – A a nd install as
follows:
1. Connect a length of 1 inch I.D. hose (part no.
91030) to the drain on the exhaust manifold
and secure it in place with a hose clamp.
2. Route the hose to a nearby floor drain.
4. Connect the condensate trap and adaptor to
the connecting manifold drain pipe. Position
the trap so it is level and then tighten the
thumb screw on the adaptor.
5. Place a suitable support under the
condensate trap to maintain the trap in the
level position.
6. Connect a length of 1” I.D. polypropylene hose
to the outlet side of the condensate trap and
route it to a nearby floor drain.
If desired, a Tee fitting may be used to connect the
two drain ho ses from the exhaust m anifold and the
outlet side
of the of the condensate trap attached to
the connecting manifold.
If a floor drain is n ot available, a condensate pump
can be u sed to r emove the condensate to drain.
The m aximum co ndensate flow r ate i s 20 GPH.
The condensate dr ain t rap, a ssociated fittings a nd
drain lines m ust be removable fo r routine
maintenance.
2-4
INSTALLATION
CONNECTING
CONDENSATE
TRAP
CLAMP
TO
FLOOR
DRAIN
1" I.D.
HOSE
MANIFOLD
3/4" NPT
NIPPLES
ADAPTOR
DRAIN
PIPE
Figure 2-6
Condensate Trap Installation
2.7 GAS SUPPLY PIPING
The AERCO Benchmark 3.0 Gas Components
and S upply Des ign G uide, G F-3030 m ust be
consulted prior to designing or installing any gas
supply piping.
WARNING
NEVER US E MATCHES, CANDLES,
FLAMES O R OT HER S OURCES O F
IGNITION TO CHECK FO R G AS
LEAKS
Many soaps used f or gas pipe leak
testing are corrosive to metals. There-
fore, piping must be rinsed thoroughly
with clean water af ter leak chec ks
have been completed.
All gas piping must be ar ranged so that it
does not i nterfere with r emoval of an y
covers, in hibit s ervice/maintenance, or
restrict ac cess bet ween the unit a nd
walls, or another unit.
A 2 inch gas inlet c onnection is l ocated o n th e
rear of the unit as shown in Figure 2-4.
Prior to i nstallation, al l p ipes s hould be d eburred and internally cleared of any scale, metal
chips or oth er f oreign particles. Do Not install
any f lexible c onnectors or unap proved gas
fittings. Piping must be supported from the f loor,
ceiling or walls only and m ust not be s upported
by the unit.
.
CAUTION
NOTE
A s uitable p iping c ompound, appr oved f or us e
with natur al gas , should b e used. An y excess
must be wipe d of f to prevent c logging of
components.
To avoid unit damage when pressure testing gas
piping, is olate the unit f rom the gas s upply
piping. At no t ime s hould the g as pr essure
applied to th e un it ex ceed 2 ps i. Leak tes t al l
external p iping th oroughly us ing a s oap a nd
water s olution or s uitable equivalent. T he g as
piping used must meet all applicable codes.
2.7.1 Gas Supply Specification
The gas s upply input s pecifications to the unit
for Natural Gas are as follows:
The m aximum static pr essure to th e unit m ust
not exceed 2 psi. The gas supply pressure to the
unit m ust be of s ufficient c apacity to provide
3000 c fh whi le m aintaining the gas pr essure at
3.5” W.C. for FM or 4.0” for IRI gas trains.
2.7.2 Manual Gas Shutoff Valve
A manual shut-off valve must be ins talled in the
gas supply line upstream of the Boiler as shown
in Figure 2-7. Maximum allowable gas pressure
to the Boiler is 2 psi
NOTE
Paragraph 2.7. 3 applies onl y to bo lier
installations with in t he Co mmonwealth of
Massachusetts.
2.7.3 External Gas Supply Regulator
For Mas sachusetts installations, a m andatory
external gas supply regulator must be positioned
as s hown i n F igure 2- 7. T he gas s upply
regulator m ust be pr operly ve nted to out doors.
Consult th e l ocal gas uti lity f or det ailed
requirements c oncerning ve nting of the th e
supply gas regulator.
NOTE
The external regulator must be capable of
regulating 3, 00,000 BTU/HR of natur al
gas while m aintaining a g as pr essure to
the boiler of 3.5” W.C. for FM or 4.0” W.C.
for IRI gas trains.
CAUTION
A lock -up st yle r egulator M UST be
used w hen g as supply pr essure w ill
exceed 14” W.C.
2-5
INSTALLATION
2" MANUAL
SHUTOFF
VALVE
NATURAL
GAS
SUPPLY
TERMINAL BLOCK
MANDATORY
REGULATOR FOR
MASSACHUSSETTS
INSTALLATIONS ONLY
DIRT
TRAP
Figure 2-7
Manual Gas Shut-Off Valve Location
2.7.4 IRI Gas Train Kit
The IRI gas tr ain is a n opti onal g as tr ain
configuration which is required in some areas for
code c ompliance or f or ins urance purposes.
The IRI gas train is factory pr e-piped and wired.
See Appendix F, Drawing AP-A-803 for details.
2.8 AC ELECTRICAL POWER WIRING
The AERCO Be nchmark 3.0 E lectrical Po wer
Wiring Guide, GF-3060, must be c onsulted prior
to c onnecting a ny AC po wer wiring t o th e u nit.
External AC po wer connections are made to the
unit inside the Power Box on the f ront pa nel of
the u nit. Remove the f ront door of the unit to
access the P ower Box m ounted directly above
the Co ntrol Box . Loosen the f our Po wer B ox
cover scre ws a nd re move co ver t o a ccess t he
AC t erminal c onnections i nside the P ower Box
(Figure 2-8).
NOTE
All elec trical c onduit a nd hardware m ust
be ins talled s o that it do es not inter fere
with the removal of any unit covers, inhibit
service/maintenance, or pr event ac cess
between the unit and w alls or ano ther
unit.
UPPER RIGHT CORNER OF FRONT PANEL
Figure 2-8
AC Input Terminal Block Location
2.8.1 Electrical Power Requirements
The AERCO Be nchmark 3 .0 Bo iler is ava ilable
in two different AC power configurations:
• 208 VAC/3-Phase/60 @20 amps
• 460 VAC/3-Phase/60 Hz @ 15 amps
Each of the power configurations utilize a Power
Box with a t erminal b lock that m atches the
configuration ordered. The two different terminal
block configurations are shown in F igure 2-9. A
wiring d iagram s howing t he r equired AC po wer
connections is provided on the front cover of the
Power Box.
Each B enchmark 3.0 Boil er must be c onnected
to a d edicated el ectrical circuit. NO O THER
DEVICES SHO ULD B E O N THE SAM E
ELECTRICAL CIRCU IT AS T HE BENCHMARK
BOILER. A m eans f or dis connecting AC p ower
from the unit ( such as a s ervice switch) must be
installed n ear th e un it f or normal oper ation and
maintenance. All e lectrical c onnections s hould
be m ade i n ac cordance with th e Nat ional
Electrical Co de and/or with an y a pplicable local
codes.
For elec trical p ower wiring diagr ams, s ee the
AERCO Benchmark 3.0 El ectrical Power Wiring
Guide, (GF-3060).
2-6
208 VAC, 3 PHASE
GND
NEU
460 VAC, 3 PHASE
GND
INSTALLATION
TERMINAL
STRIPS
L3
L2
L1
208 VAC, 3 Phase
L3
L2
L1
460 VAC, 3 Phase
Figure 2-9
AC Terminal Block Configurations
2.9 MODES OF OPERATION AND FIELD
CONTROL WIRING
The Benchmark 3.0 Boiler is available in several
different modes of operation. While each unit is
factory c onfigured an d wired f or its intend ed
mode, s ome addit ional f ield wir ing m ay be
required to c omplete the in stallation. This wiring
is t ypically c onnected t o t he I nput/Output ( I/O)
Box located on the lower portion of the unit front
panel ( Figure 2- 10) beh ind the r emovable f ront
door.
To a ccess t he I /O B ox t erminal st rips shown in
Figure 2-10, loosen t he f our c over s crews an d
remove the c over. A ll f ield wiring is ins talled
from the r ear of the pa nel b y r outing th e wires
through one of the four bushings provided.
LOWER RIGHT CORNER
OF FRONT PANEL
Figure 2-10.
Input/Output (I/O) Box Location
Refer to the wiring d iagram pr ovided on t he
cover of the I/O Box (Figure 2-11) when making
all wiring connections.
Brief des criptions of eac h mode of oper ation,
and the ir wiring r equirements, ar e pr ovided in
the f ollowing par agraphs. Additional information
concerning field wiring is provided in paragraphs
2.9.1 thr ough 2.9. 9. Ref er to Chapt er 5 f or
detailed i nformation on t he av ailable m odes of
operation
2-7
INSTALLATION
OUTDOOR SENSOR IN
SENSOR COMMON
(AIR) AUX SENSOR IN
NOT USED
SHIELD
0 – 10V
AGND
+
+
-
+
-
+
G
-
ANALOG IN
B.M.S. (PWM) IN
mA OUT
RS-485
COMM.
NOT USED
Figure 2-11. I/O Box Terminal Strip
2.9.1 Constant Setpoint Mode
The Cons tant S etpoint M ode is us ed when it is
desired t o ha ve a f ixed s etpoint t hat d oes not
deviate. No w iring connections, oth er than AC
electrical po wer c onnections, ar e r equired f or
this mode. Ho wever, if desired, fault monitoring
or enable/disable interlock wiring can be utilized
(see paragraphs 2.9.9.1 and 2.9.10).
2.9.2 Indoor/Outdoor Reset Mode
This mode of oper ation i ncreases s upply water
temperature as outdoor temperatures decrease.
An outside air temperature sensor (AERCO Part
No. 122790) is required. T he sensor MUST BE
wired to the I/O Box wiring terminals (see Figure
2-11). Ref er to par agraph 2.10.1 f or add itional
information on ou tside air tem perature s ensor
installation.
2.9.3 Boiler Management System Mode
NOTE
BMS Mo del 16 8 c an utilize eit her p ulse
width m odulation ( PWM) or R S485
Modbus s ignaling to t he Boiler. BMS II
Model 5R 5-384 c an u tilize onl y RS 485
signaling to the Boiler.
When us ing an AERCO Boi ler M anagement
System ( BMS), th e f ield wir ing is c onnected
between th e BM S P anel and e ach Bo iler’s I/O
Box ter minal s trip ( Figure 2- 11). T wisted
shielded pair wire f rom 18 to 22 A WG must be
utilized for the connections. The BMS Mode can
2-8
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
RELAY CONTACTS:
120 VAC, 30 VDC
5 AMPS RESISTIVE
DANGER
120 VAC USED
IN THIS BOX
utilize e ither pu lse width modulation ( PWM)
signaling, or RS485 Modbus signaling. For PWM
signaling, c onnections a re m ade f rom the
AERCO B oiler M anagement System to th e
B.M.S. ( PWM) IN ter minals on t he I/O Box
terminal s trip. F or RS 485 Mo dus s ignaling,
connections ar e m ade f rom the BMS t o th e
RS485 COMM terminals on the I/O Box terminal
strip. Polarity must be m aintained and the shield
must be c onnected o nly at th e AERCO BMS.
The boiler end of the shield must be left floating.
For ad ditional i nstructions, r efer to C hapter 5,
paragraph 5.6 in this m anual. Also, refer t o GF108M ( BMS Mod el 1 68) and G F-124 ( BMS I I
Model 5R5-384), BMS -Operations Guides.
2.9.4 Remote Setpoint and Direct Drive
Modes
The Benc hmark 3.0 Boi ler c an ac cept s everal
types of s ignal f ormats f rom an E nergy
Management S ystem ( EMS), Building
Automation S ystem ( BAS) or oth er s ource, to
control e ither the s etpoint ( Remote Setpo int
Mode) or f iring r ate ( Direct Dr ive Mo de) 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. Se e
para. 2.10.4)
• Network (RS485 Modbus. See para. 2.10.8)
INSTALLATION
While it is pos sible to c ontrol a bo iler or boi lers
using one of the previously described modes of
operation, it m ay not be the m ethod best suited
for the appl ication. Prior to s electing o ne of
these m odes of oper ation, it is r ecommended
that y ou consult w ith y our local AER CO
representative or the f actory f or the m ode of
operation th at will work bes t with your
application. F or more inf ormation on wiring th e
4 to 20 mA / 1to 5VDC or the 0 to 20 mA / 0 to 5
VDC, see paragraph 2.9.3.
2.9.5 Combination Mode
NOTE
Only BMS M odel 16 8 c an be ut ilized f or
the Com bination Mode, n ot the B MS II
(Model 5R5-384).
With a Com bination Mode un it, f ield wiring is
between the unit’s I/O Box wiring t erminals, the
CCP (Combination Control Panel), and the BMS
Model 1 68 ( Boiler Ma nagement S ystem). The
wiring m ust be ac complished us ing t wistedshielded pair wire from 18 to 22 A WG. Polar ity
must be m aintained. For further instructions and
wiring di agrams, r efer to the G F-108 Bo iler
Management System O perations Guide and the
CCP-1 data sheet.
2.10 I/O BOX CONNECTIONS
The t ypes of input and output s ignals and
devices to be connected to the I/O Box terminals
shown in F igure 2- 11 a re des cribed i n t he
following paragraphs.
CAUTION
DO NOT make any connections to the
I/O Box t erminals labeled “ NOT
USED”. A ttempting to d o so ma y
cause equipment damage.
2.10.1 OUTDOOR SENSOR IN
An outdoor air temperature sensor (AERCO Part
No. 12 2790) will be r equired pr imarily f or th e
Indoor/Outdoor reset mode of oper ation. It c an
also be used with another mode if it is desired to
use th e o utdoor s ensor e nable/disable f eature.
This f eature a llows the b oiler to be enabled or
disabled based on the outdoor air temperature.
The f actory def ault f or th e out door s ensor is
DISABLED. T o enable the sensor and/or select
an en able/disable o utdoor temperature, s ee the
Configuration menu in Chapter 3.
The outdoor sensor may be wired up to 200 feet
from the boiler. It is connected to the OUTDOOR
SENSOR IN and SENSOR COMMON terminals
in the I/O Box (see Figures 2-10 and 2-11). Wire
the s ensor us ing a t wisted s hielded pair wire
from 18 to 22 A WG. There is no po larity t o
observe when ter minating th ese wires. T he
shield is to be c onnected only t o t he terminals
labeled SHIELD in t he I/O Box. The sensor end
of the shield must be left free and ungrounded.
When mounting th e s ensor, it m ust be loc ated
on t he N orth s ide of th e bu ilding where an
average outs ide air tem perature is ex pected.
The sensor must be shielded from direct sunlight
as wel l as impingement b y the e lements. If a
shield is us ed, it m ust allo w f or f ree air
circulation.
2.10.2 AIR SENSOR IN
The AIR S ENSOR IN is c onnected t o the AUX
SENSOR IN and SENSOR COMMON terminals
on the I /O boar d. T he AI R SEN SOR m easures
the tem perature of the air inp ut to t he Air/Fuel
Valve. T his te mperature r eading is one of the
components us ed t o c alculate t he r otational
speed of the bl ower us ed in the c ombustion
Calibration process (Chapter 4).
The AUX SENSOR IN terminals can be used to
add a n ad ditional temperature s ensor f or
monitoring pur poses. T his in put is always
enabled a nd is a view-only input th at c an be
seen i n th e O perating M enu. T he s ensor m ust
be wired to the AUX SENSOR IN and SENSOR
COMMON t erminals a nd m ust be s imilar to
AERCO BALCO wire sensor Part No. 12449. A
resistance c hart f or this s ensor is pr ovided in
Appendix C.
2.10.3 ANALOG IN
The ANALO G IN + and – ter minals ar e us ed
when an ex ternal s ignal i s us ed t o dr ive t he
firing r ate ( Direct Dr ive Mode) or c hange th e
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 s ignal m ay be us ed to vary t he
setpoint or firing rate. The factory default setting
is for 4 to 20 mA / 1 to 5 V DC, however this may
be changed to 0 to 20 mA / 0 to 5 VDC using the
Configuration Me nu des cribed i n Cha pter 3. If
voltage r ather t han c urrent is s elected as t he
drive s ignal, a DI P s witch must be s et on t he
PMC Board l ocated i nside th e Co ntrol B ox.
Contact the A ERCO f actory f or inf ormation o n
setting DIP switches.
All of the s upplied s ignals must be floating
(ungrounded) signals. Connections between the
signal s ource and the B oiler’s I/O Box must be
made using twisted shielded pair wire from 18 to
2-9
INSTALLATION
22 AWG, s uch as Bel den 9 841 ( see
Figure 2-11). Polarity must be m aintained. T he
shield must be connected only at the source end
and m ust be left f loating ( not c onnected) at the
Boiler’s I/O Box.
Regardless of whether voltage or current is used
for the dr ive signal, they are linearly m apped to
a 40°F to 240°F setpoint or a 0% to 100% f iring
rate. No scaling for these signals is provided
2.10.4 B.M.S. (PWM) IN
NOTE
Only BMS Mod el 1 68 c an uti lize P ulse
Width Modulation (PWM), not th e B MS II
(Model 5R5-384).
These ter minals ar e used t o c onnect t he
AERCO Boi ler Ma nagement S ystem ( BMS)
Model 16 8 to the un it. T he BMS Mod el 1 68
utilizes a 12 m illisecond, ON/OFF dut y c ycle.
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.
2.10.5 SHIELD
The SHIELD terminals are used to terminate any
shields us ed on s ensor wires c onnected to t he
unit. O nly s hields m ust be c onnected t o th ese
terminals.
IMPORTANT
DO NO T USE the m A OUT output to
remotely monitor Setpoint, Outlet Temp or
Fire Rate Out.
2.10.9 EXHAUST SWITCH IN
These ter minals per mit an ex ternal ex haust
switch to be c onnected to the ex haust m anifold
of the bo iler. T he ex haust s witch s hould be a
normally open type switch (such as AERCO Part
No. 123463) that closes (trips) at 500°F.
2.10.10 INTERLOCKS
The unit offers tw o i nterlock c ircuits f or
interfacing with En ergy M anagement Systems
and a uxiliary eq uipment s uch as pum ps or
louvers. These interlocks are called the Remote
Interlock and Dela yed I nterlock ( Figure 2- 11).
The w iring ter minals f or these int erlocks ar e
located i nside th e I/O Box on t he u nit f ront
panel. T he I/O Box c over c ontains a wiring
diagram which shows the terminal strip locations
for thes e inter locks ( REMOTE IN TL’K IN and
DELAYED INT L’K IN). Both interlocks,
described below, are factory wired in the c losed
position.
IMPORTANT
Both th e Rem ote In terlock and Del ayed
Interlock MUST be in the c losed pos ition
to allow the unit to fire.
2.10.10.1 REMOTE INTERLOCK IN
The r emote inter lock c ircuit is pr ovided to
remotely s tart ( enable) an d s top ( disable) th e
Boiler, if des ired. T he c ircuit is labe led
REMOTE INTL’K IN and is located inside the I/O
Box on t he f ront pan el. T he c ircuit is 24 V AC
and is factory pre-wired in the closed (jumpered)
position.
2.10.6 mA OUT
These terminals provide a 4 to 20 m A output to
the VFD (if so equipped) to control the rotational
speed of the blower. This function is enabled in
the Configuration Menu (Chapter 3, Table 3-4).
2.10.7 0 – 10V OUT
These ter minals pr ovide a 0 to 10V o utput to
control t he r otational s peed of the b lower. T his
function is e nabled i n t he Conf iguration Me nu
(Chapter 3, Table 3-4).
2.10.8 RS-485 COMM
These terminals are used for RS-485 MODBUS
serial c ommunication be tween the u nit a nd an
external “Master” such as a Boiler Management
System ( BMS), En ergy Management S ystem
(EMS), Building Automation S ystem ( BAS) or
other suitable device.
2-10
2.10.10.2 DELAYED INT ER LOCK IN
The del ayed interlock is t ypically used i n
conjunction with t he aux iliary r elay described in
paragraph 2. 10. T his inter lock c ircuit is loc ated
in the purge section of the start string. It c an be
connected to t he proving dev ice ( end s witch,
flow s witch etc .) of an aux iliary p iece of
equipment started by the Boiler’s auxiliary relay.
The dela yed i nterlock must be c losed f or 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 O n D ly) that ho lds t he s tart
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 fr ame, the bo iler wi ll shut do wn. T he Aux
Start On Dly c an be programmed from 0 to 120
seconds. T his option is l ocate i n t he
Configuration Menu (Chapter 3, Table 3-4).
INSTALLATION
2.10.11 FAULT RELAY
The f ault r elay is a s ingle pol e do uble thr ow
(SPDT) relay ha ving a normally op en and
normally c losed s et of r elay c ontacts that ar e
rated for 5 am ps at 12 0 VAC and 5 amps at 30
VDC. T he r elay e nergizes whe n an y f ault
condition occurs and remains energized until the
fault is c leared an d th e CLE AR button is
depressed. T he f ault r elay c onnections ar e
shown in Figure 2-11.
2.11 AUXILIARY RELAY CONTACTS
Each Bo iler is equ ipped w ith a s ingle po le
double t hrow ( SPDT) r elay th at is ener gized
when th ere is a dem and f or heat and deenergized after the d emand for heat is satisfied.
The relay is provided for t he control of auxiliary
equipment, such as p umps and l ouvers, or c an
be us ed as a Boiler status indictor (firing or not
firing). Its contacts ar e rated for 120 VAC @ 5
amps. Ref er to F igure 2- 11 t o l ocate the AUX
RELAY terminals for wiring connections.
2.12 FLUE GAS VENT INSTAL LATION
The minimum allo wable vent diam eter f or a
single Benchmark 3.0 Boiler is 8 inches.
The AERCO Benchmark Ventin g a nd
Combustion Air G uide, GF-2050, m ust be
consulted bef ore an y f lue gas ven t or in let air
venting is des igned or i nstalled. U/ L l isted,
positive pr essure, watertight v ent m aterials as
specified in AERCO’s G F-2050, m ust be us ed
for safety and code compliance. Since the unit is
capable of discharging low temperature exhaust
gases, h orizontal s ections of the f lue vent
system must be pitc hed bac k to the unit a
minimum of 1/4 inc h per f oot to avoid
condensate po oling a nd allo w f or pr oper
drainage.
The c ombined pr essure dr op of ve nt a nd
combustion air s ystems must not ex ceed 1 40
equivalent feet of 8 inch ducting. Fittings as well
as pipe lengths must be calculated as part of the
equivalent length.
For a n atural draft installation the draft must not
exceed ± 0.25 inch W.C. These factors must be
planned i nto t he vent ins tallation. If the
maximum allowable e quivalent lengths of piping
are ex ceeded, the unit will not oper ate pr operly
or reliably.
For Mas sachusetts boiler ins tallations, t he
Heatfab D ivision of the Se lkirk Cor poration
provides vent s ystems whic h c onform to all
applicable r equirements for ins tallations within
the C ommonwealth of Ma ssachusetts. Con tact
information for this supplier is as follows:
Selkirk Corporation
Heatfab Division
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
2.13 COMBUSTION AIR
The AERCO Be nchmark Venting and C ombustion Air G uide, G F-2050 MUST be c onsulted
before any flue or combustion supply air venting
is des igned or im plemented. C ombustion a ir
supply is a d irect r equirement of ANSI 22 3.1,
NFPA-54, and local codes. These codes should
be c onsulted bef ore a p ermanent des ign is
determined.
The c ombustion a ir m ust be f ree of c hlorine,
halogenated h ydrocarbons, or other c hemicals
that c an become hazardous when used in gasfired eq uipment. Com mon s ources of t hese
compounds ar e s wimming poo ls, de greasing
compounds, plastic processing an d refrigerants.
Whenever the environment contains these types
of c hemicals, c ombustion air m ust be s upplied
from a c lean area out doors f or the pr otection
and longevity of the equipment.
The AER CO Benchmark 3.0 Boiler is U L listed
for 100% s ealed c ombustion. It c an als o be
installed us ing r oom air , provided ther e is an
adequate s upply. ( See p aragraph 2.1 3.3 f or
more information concerning sealed combustion
air). If the s ealed c ombustion air op tion is no t
being used, an in let s creen will b e at tached at
the air inlet on the top of the unit
The more c ommon methods of s upplying
combustion air are o utlined b elow. F or m ore
information c oncerning c ombustion air , c onsult
the AERCO B enchmark Ventin g an d
Combustion Air Guide, GF-2050.
2.13.1 Combustion Air From Outside the
Building
Air s upplied f rom outs ide the building m ust be
provided through two permanent openings. Each
opening m ust have a free area of not l ess than
one s quare i nch f or eac h 4000 BTU/H bo iler
input. T he f ree ar ea m ust tak e into ac count
restrictions such as louvers and bird screens.
2-11
INSTALLATION
2.13.2 Combustion Air From Inside the
Building
When combustion air is provided from within the
building, it m ust be s upplied thr ough t wo
permanent op enings i n a n int erior wall. Each
opening m ust have a free area of not l ess than
one s quare inc h per 10 00 BTU/H of tota l b oiler
input. The free area must tak e into ac count any
restrictions such as louvers.
2.13.3 Sealed Combustion
The AER CO Benchmark 3.0 Boiler is U L listed
for 100%- sealed c ombustion. F or s ealed
combustion ins tallations, t he s creen on the a ir
inlet duct of the u nit must be removed. The inlet
air duc twork must then be attac hed dir ectly t o
the unit’s air inlet.
In a s ealed c ombustion air app lication, the
combustion air ducting pressure losses must be
taken into ac count when c alculating th e tota l
maximum allo wable v enting r un. See t he
AERCO Be nchmark Venti ng an d Com bustion
Air Guide, GF-2050. When using the boiler in a
sealed c ombustion a ir c onfiguration, each unit
must have a m inimum 8- inch diam eter
connection at the unit.
2.13.4 Temporary Combustion Air
Filtering During Construction
When the AERCO Benchmark 3.0 Boiler is used
to pr ovide he at tem porarily dur ing ongoing
building construction, accumulated drywall dust,
sawdust and similar particles can accumulate in
the un it’s c ombustion a ir i ntake f ilter and b lock
combustion air flow. In th ese situations, AERCO
recommends that a disposable air intake filter be
installed, temporarily, abo ve the bo iler
combustion air inlet.
AERCO recommends that the temporary air filter
be cut from a McMaster-Carr part no. 2 122K315
Polyester Air Filter Rol l Tackfield, 1/2” thick, 16”
wide, or e quivalent. C over the Benchmark 3.0
air in let with the b lue s ide of the f ilter m aterial
facing out ward to hold th e dus t on t he o utside
surface. Max imize th e s urface ar ea of the f ilter
covering the 8 " diameter opening b y c reating a
dome out of the filter material.
During c onstruction, c heck the f ilter f or dus t
accumulation a nd r eplace it when t he
accumulation becomes noticeable.
2-12
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 3.0 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.
2
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
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.
12
11
10
9
1
3
4
5
6
7
8
3.2 CONTROL PANEL DESCRIPTION
The Benchmark 3.0 Control Panel shown in
Figure 3-1 contains all of the controls, indicators
and displays necessary to operate, adjust and
troubleshoot the Benchmark 3.0 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.
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%
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% Max Valve
Position
Flame Strength 0% 100%
Run Cycles 0 999,999,999
Run Hours 0 999,999,999
Fault Log 0 9 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 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 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
1.0 MBTU
6.0 MBTU
Constant
Setpoint
Direct Drive
3-6
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