AERCO BMK 3.0 LN Nat. Gas Jan 2011 User Manual Gas Jan 2011

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Page 1

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

Page 2

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

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.

Page 3

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

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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

6-6

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

Chapter 8 – TROUBLESHOOTING GUIDE 8-1

Para. Subject Page

8.1 Introduction 8-1

Para. Subject Page

Page 5

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

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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: _____________________________________________

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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

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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

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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

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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

Page 14

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.

Page 15

INSTALLATION

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

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

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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

CONNECTING

MANIFOLD

EXHAUST

MANIFOLD

DRAIN

FRAME

REAR VIEW

UNIT

FRAME

SHELL

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

VALVE

CONNECTING

MANIFOLD

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

Page 17

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

Page 18

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

Page 19

208 VAC, 3 PHASE

GND

NEU

460 VAC, 3 PHASE

GND

INSTALLATION

TERMINAL

STRIPS

208 VAC, 3 Phase

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

Page 20

INSTALLATION

OUTDOOR SENSOR IN

SENSOR COMMON

(AIR) AUX SENSOR IN

NOT USED

SHIELD

0 – 10V

AGND

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

FAULT RELAY

COM

120 VAC, 5A, RES

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)

Page 21

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

Page 22

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).

Page 23

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

Page 24

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

Page 25

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.

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.

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

Page 26

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

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

FAULT Indicator Red FAULT LED indicator lights when a boiler alarm

CLEAR Key Turns off the FAULT indicator and clears the alarm message

READY Indicator

ON/OFF Switch

LOW WATER LEVEL

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

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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:

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

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

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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

Page 29

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

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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

1.0 MBTU

6.0 MBTU

Constant

Setpoint

Direct Drive

3-6

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CONTROL PANEL OPERATING PROCEDURES

Table 3-4. Configuration Menu - Continued

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination)

Bldg Ref Temp (If Mode = Outdoor Reset)

Reset Ratio (If Mode = Outdoor Reset)

Outdoor Sensor Enabled or Disabled Disabled

System Start Tmp (If Outdoor Sensor = Enabled)

Setpt Lo Limit 40°F Setpt Hi Limit 60°F

Setpt Hi Limit Setpt Lo Limit 220°F 200°F

Temp Hi Limit 40°F 240°F 210°F

Max 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

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (BMS)

Network

40°F 230°F 70°F

0.1 9.9 1.2

30°F 100°F 60°F

4 – 20 mA,

1-5V

*Analog Output

(See CAUTION at end of Table 3-4 )

Low Fire Timer 2 sec. 600 sec. 2 sec.

Setpt Limiting Enabled or Disabled Disabled

Setpt Limit Band 0°F 10°F 5°F

Network Timeout 5 Sec 999 Sec 30 Sec

HI DB Setpt EN 0% 100% 30%

Demand Offsert 0 25 10

Deadband High 0 25 2

Deadband Low 0 25 2

*CAUTION:

1. DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V).

Off, Setpoint, Outlet Temp,

Valve Position 4-20 mA,

Valve Position 0-10V

*Valve

Position

0-10V

3-7

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CONTROL PANEL OPERATING PROCEDURES

3.7 TUNING MENU

The Tuning Menu items in Table 3-5 are Factory set for each individual unit. Do not change these menu entries unless specifically requested to do so by Factory-Trained personnel.

3.8 COMBUSTION CAL MENU

The Combustion Cal (Calibration) Menu items in Table 3-6 are used to vary the speed of the unit’s blower motor based on air temperature and air density at prescribed Air/Fuel Valve

Table 3-5. Tuning Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Prop Band 1°F 120°F 70°F

Integral Gain 0.00 2.00 1.00

Derivative Time 0.0 min 2.00 min 0.00 min

Reset Defaults? Yes, No, Are You Sure? No

Table 3-6. Combustion Cal Menu

positions (% open). This is accomplished by providing a DC drive voltage to the motor which adjusts the rotational speed of the blower to maximize combustion efficiency and ensure the unit conforms to the Nitrogen Oxide (NOx) and Carbon Monoxide (CO) emissions specified in Chapter 4. The firing rates (%) and default drive voltages are listed in Table 3-6.

Available Choices or Limits

Menu Item Display Minimum Maximum Default

CAL Voltage 16% .25 8.20 1.80v

CAL Voltage 30% .25 8.20 3.20v

CAL Voltage 45% .25 8.20 3.70v

CAL Voltage 60% .25 8.20 3.80

CAL Voltage 80% .25 8.20 4.60

CAL Voltage 100% .25 8.20 6.00

SET Valve Position 0% 100% 0%

Blower Output Monitor Blower Output Voltage .00

3.9 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

• Blower Proof 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

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.

3-8

Page 33

CONTROL PANEL OPERATING PROCEDURES

1. The DEMAND LED status indicator will light.

2. The unit checks to ensure that the Proof of

Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location.

Valve (Figure 3-6) will read between 25 and 35 to indicate that the valve is in the low-fire position.

(b) The igniter relay is activated and

provides ignition spark.

is energized (opened) allowing gas to flow into the Air/Fuel Valve.

Figure 3-3.

SSOV Location

3. With all required safety device switches

closed, a purge cycle will be initiated and the following events will occur:

(a) The Blower relay energizes and turns

on blower.

(b) The Air/Fuel Valve rotates to the 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%).

show 100%.

4. Next, the blower proof switch on the Air/Fuel

Valve (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.

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

Figure 3-4.

Air/Fuel Valve In Purge Position

Figure 3-5.

Blower Proof Switch

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CONTROL PANEL OPERATING PROCEDURES

8. With the unit firing properly, it will be controlled by the temperature controller

circuitry. The boiler’s VALVE POSITION will

be continuously displayed on the front panel bargraph.

Once the demand for heat has been satisfied, the Control Box will turn off the dual SSOV gas valves. The blower relay will be deactivated and

the Air/Fuel Valve will be closed. Standby will

be displayed.

3.10 START/STOP LEVELS

The start and stop levels are the Air/Fuel Valve positions (% open) that start and stop the unit, based on load. These levels are Factory preset as follows:

Figure 3-6.

Air/Fuel Valve In Ignition Position

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.

Table 3-7

Relationship Between Air/Fuel Valve Position and Energy Input

Air/Fuel Valve

Position (% Open)

0% 0 0 10% 0 0 14%

(Stop Level) 200,000

20% 287,000 10% 30% 486,000 16% 40% 802,000 27% 50% 1,180,000 39% 60% 1,720,000 57% 70% 2,300,000 77% 80% 2,550,000 85% 90% 2,720,000 91%

100% 3,000,000 100%

Energy Input

(BTU/HR)

Start Level: 20%

Stop Level: 14%

Normally, these settings should not require adjustment. 6. Up to 7 seconds will be allowed for ignition

Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. Refer to Table 3-7 for the relationship between the boiler energy input and the Air/Fuel Valve position (% open) for a unit running on Natural Gas.

Boiler Energy Input

(% Of Full Capacity)

6.67%

3-10

Page 35

INITIAL START-UP

CHAPTER 4 INITIAL START-UP

4.1 INITIAL START-UP REQUIREMENTS

The requirements for the initial start-up of the Benchmark 3.0 Boiler consists of the following:

• Complete installation

• Perform combustion calibration

• Set proper controls and limits

• Set up mode of operation (see Chapter 5)

• Test safety devices (see Chapter 6)

Installation should be fully completed before performing initial start-up; and the start-up must be complete prior to putting the unit into service. Starting a unit without the proper piping, venting, or electrical systems can be dangerous and may void the product warranty. The following start-up instructions should be followed precisely in order to operate the unit safely and at a high thermal efficiency, with low flue gas emissions.

Initial unit start-up is to be performed ONLY by AERCO factory trained start-up and service personnel. After following the steps in this chapter, it will be necessary to perform the Mode of Operation settings in Chapter 5, and the Safety Device Testing procedures in Chapter 6 to complete the initial unit start-up.

An AERCO Gas Fired Startup Sheet, included with each Benchmark Boiler, must be completed for each unit for warranty validation and a copy must be returned promptly to AERCO at:

AERCO International, Inc.

159 Paris Ave. Northvale, NJ 07647

CAUTION

All applicable installation procedures in Chapter 2 must be completed before attempting to start the unit.

4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION

To properly perform combustion calibration, the proper instruments and tools must be used and correctly attached to the unit. The following paragraphs outline the necessary tools and instrumentation as well as their installation.

4.2.1 Required Tools & Instrumentation

The following tools and instrumentation are necessary to perform combustion calibration of the unit:

• Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1PPM.

• 16 inch W.C. manometer or equivalent gauge and plastic tubing.

• 1/8 inch NPT-to-barbed fittings for use with gas supply manometer or gauge.

• Small and large flat blade screwdrivers.

• Tube of silicone adhesive

4.2.2 Installing Gas Supply Manometer

The gas supply manometer is installed in the gas train as follows:

1. Close the main manual gas supply shut-off valve upstream of the unit.

WARNING

2. Remove the front door and left side panels from the boiler to access the gas train components.

3. Remove the 1/8 inch NPT pipe plug from the leak detection ball valve on the downstream side of the Safety Shut Off Valve (SSOV) as shown in Figure 4-1.

4-1

Page 36

INITIAL START-UP

4. Install a NPT-to-barbed fitting into the tapped plug port.

5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16 inch W.C. manometer.

1/8" NPT PLUG

(INSTALL MANOMETER HERE)

LEAK DETECTION

HIGH GAS

PRESSURE

SWITCH

SSOV

BALL VALVE

AIR/FUEL

VALVE

LOW GAS

PRESSURE

SWITCH

GAS

INLET

Figure 4-1.

1/8 Inch Gas Plug Location

Prepare the port for the combustion analyzer probe as follows:

1. Remove the plug from the probe port on the right side of the exhaust manifold.

left or

2. If necessary, adjust the stop on the

combustion analyzer probe so that it will extend mid-way into the flue gas flow. DO NOT install the probe at this time.

4.3 NATURAL GAS COMBUSTION

CALIBRATION

The Benchmark 3.0LN Boiler is combustion calibrated at the factory prior to shipping. However, recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation.

It is important to perform the following procedure as outlined. This will keep readjustments to a minimum and provide optimum performance.

1. Open the water supply and return valves to

the unit and ensure that the system pumps are running.

2. Open the natural gas supply valve(s) to the

unit.

4.2.3 Accessing the Vent Probe Port

The unit contains NPT plugs on both the left and right side of the exhaust manifold at the rear of the unit as shown in Figure 4-2.

Figure 4-2

Analyzer Probe Hole Location

3. Set the control panel ON/OFF switch to the

OFF position.

4. Turn on external AC power to the unit. The

display will show LOSS OF POWER and the

time and date.

5. Set the unit to the Manual Mode by pressing

the AUTO/MAN key. A flashing Manual Valve Position message will be displayed

showing the present air/fuel valve % open

position. Also, the MANUAL LED will light.

6. Adjust the air/fuel valve position to 0% by

pressing the ▼ arrow key.

7. Ensure that the leak detection ball valve

downstream of the SSOV is open.

8. Set the ON/OFF switch to the ON position.

9. Change the valve position to 29% using the

▲ arrow key. The unit should begin its start sequence and fire.

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INITIAL START-UP

10. Next, verify that the gas pressure downstream of the SSOV is 1.8” W.C. for both FM and IRI gas trains. If gas pressure adjustment is required, remove the brass hex nut covering the SSOV gas pressure adjustment screw (Figure 4-3). Make gas pressure adjustments using a flat-tip screwdriver to obtain 1.8” W.C.

Table 4-1

Combustion Oxygen Levels for a 100%

Open Air/Fuel Valve Position

Inlet Air

Temp

>100°F 4.8 % <100 ppm <30 ppm

90°F 5.0 % <100 ppm <30 ppm 80°F 5.2 % <100 ppm <30 ppm

<70°F 5.3 % <100 ppm <30 ppm

14. If necessary, adjust the iris air damper shown in Figure 4-4 until the oxygen level is within the range specified in Table 4-1.

15. Once the oxygen level is within the specified range at 100%, decrease the valve position to 70%.

Oxygen %

± 0.2

Carbon

Monoxide NOx

Figure 4-3

Regulator Adjustment Screw Location

11. Increase the valve open position to 100% and verify that the gas pressure downstream of the SSOV remains at 1.8” W.C. Readjust pressure if necessary. -

12. With the valve position at 100%, insert the combustion analyzer probe into the flue probe opening and allow enough time for the combustion analyzer to settle.

13. Compare the measured oxygen level to the oxygen range for the inlet air temperature shown in Table 4-1. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Figure 4-4

Iris Air Damper Location/Adjustment

4-3

Page 38

INITIAL START-UP

NOTE

The remaining combustion calibration steps are

performed using the Combustion Cal Menu

included in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at air/fuel valve positions of 80%, 60%, 45%, 30% and 16% as described in the following steps. These steps assume that the inlet air temperature is within the range of 50°F to 100°F.

16. Press the MENU Key on the front panel of the C-MORE and access the Setup menu.

Enter password 6817 and then press the

ENTER key.

17. Press the MENU Key on the front panel of the C-MORE until Combustion Cal Menu

appears on the C-More display.

18. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display.

19. Press the CHANGE key. SET Valve Position

will begin to flash.

20. Press the ▲ arrow key until the SET Valve Position reads 70%. Press the ENTER key.

21. Next, press the

CAL Voltage 70% is displayed.

down (▼) arrow key until

22. Press the CHANGE key and observe that CAL Voltage 70% is flashing.

23. The oxygen level at the 70% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Combustion Oxygen Level at

70% Valve Position

Oxygen %

± 0.2

6.0 % <100 ppm <30 ppm

24. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the down ▼ arrow key decreases the oxygen level.

25. Once the oxygen level is within the specified

range at 70%, press the ENTER key to store

the selected blower output voltage for the 70% valve position.

4-4

Carbon

Monoxide

NOx

NOTE

The remaining steps basically repeat the procedures in steps 18 through 25 for air/fuel valve positions of 50%, 40%, 30% and 14% open. However, since oxygen levels vary, these steps are repeated in their entirety. When performing these steps, also ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown for each valve position.

26. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display.

27. Press the CHANGE key. SET Valve Position

will begin to flash.

28. Press the ▼ arrow key until the SET Valve Position reads 50% and then press the ENTER key.

29. Press the

Voltage 50% is displayed.

down ▼ arrow key until CAL

30. Press the CHANGE key. CAL Voltage 50%

will begin to flash.

31. The oxygen level at the 50% Valve Position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Combustion Oxygen Level at

50% Valve Position

Oxygen %

± 0.2

7.0 % <50 ppm <20 ppm

32. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level.

33. Once the oxygen level is within the specified

range at 50%, press the ENTER key to store

the selected blower output voltage for the

50% Valve Position.

34. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display.

35. Press the CHANGE key. SET Valve Position

will begin to flash.

36. Press the ▼ arrow key until the SET Valve Position reads 40%, then press the ENTER

key.

Carbon

Monoxide

NOx

Page 39

INITIAL START-UP

37. Press the

40% is displayed.

▼ arrow key until CAL Voltage

38. Press the CHANGE key. CAL Voltage 40%

will begin to flash.

39. The oxygen level at the 40% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Combustion Oxygen Level at

40% Valve Position

Oxygen %

± 0.2

7.8 % <50 ppm <20 ppm

40. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level.

41. Once the oxygen level is within the specified

range at 40%, press the ENTER key to store

the selected blower output voltage for the 40% valve position.

42. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display.

43. Press the CHANGE key. SET Valve Position

will begin to flash.

44. Press the ▼ arrow key until the SET Valve Position reads 30%, then press the ENTER

key.

45. Press the

▼ arrow key until CAL Voltage

30% is displayed.

46. Press the CHANGE key. CAL Voltage 30%

will begin to flash.

47. The oxygen level at the 30% Valve Position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Carbon

Monoxide

NOx

Combustion Oxygen Level at

30% Valve Position

Oxygen %

± 0.2

8.0 % <50 ppm <20 ppm

48. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼

Carbon

Monoxide

NOx

arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level.

49. Once the oxygen level is within the specified

range at 30%, press the ENTER key to store

the selected blower output voltage for the 30% valve position.

50. Press the ▲ arrow key until SET Valve Position appears on the C-MORE display.

51. Press the CHANGE key. SET Valve Position

will begin to flash.

52. Press the ▼ arrow key until the SET Valve Position reads 14%, then press the ENTER

key.

53. Press the

14% is displayed.

▼ arrow key until CAL Voltage

54. Press the CHANGE key. CAL Voltage 14%

will begin to flash.

55. The oxygen level at the 14% Valve Position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown.

Combustion Oxygen Level at

14% Valve Position

Oxygen %

± 0.2

8.5 % <50 ppm <30 ppm

56. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key increases the oxygen level and pressing the ▼ arrow key decreases the oxygen level.

57. Once the oxygen level is within the specified

range at 14%, press the ENTER key to store

the selected blower output voltage for 14% Valve Position.

Carbon

Monoxide

NOx

IMPORTANT

Repeat steps 18 through 57 until the blower output voltage does not require adjustment when sequencing from 70% to 14%.

58. This completes the natural gas combustion calibration procedure.

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INITIAL START-UP

4.4 UNIT REASSEMBLY

Once the combustion calibration adjustments are properly set, the unit can be reassembled for service operation.

1. Set the ON/OFF switch in the OFF position.

2. Disconnect AC power from the unit.

3. Shut off the gas supply to the unit.

4. Remove the manometer and barbed fittings and reinstall the NPT plug using a suitable pipe thread compound.

5. Remove the combustion analyzer probe from the vent hole. Replace the NPT plug in the vent hole using a suitable pipe joint compound.

6. Replace the unit’s side panels and front door.

RESET button before the boiler can be restarted. The automatic reset over-temperature switch is adjustable and allows the boiler to restart, once the temperature drops below its temperature setting. Set the automatic overtemperature switch to the desired setting.

4.5 OVER-TEMPER ATURE LIMIT

SWITCHES

The unit contains both automatic and manual reset over-temperature limit switches. These switches are mounted on a plate attached to the boiler shell as shown in Figure 4-6. The switches can be accessed by removing the left side panels of the unit. The manual reset switch is not adjustable and is permanently fixed at 210°F. This switch will shut down and lock out the boiler if the water temperature exceeds 210°F. Following an over-temperature condition, it must be manually reset by pressing the

Over Temperature Limit Switch

Figure 4-6 Locations

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MODE OF OPERATION

CHAPTER 5 MODE OF OPERATION

5.1 INTRODUCTION

The boiler is capable of being operated in any one of six different modes. The following paragraphs in this Chapter provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation. All temperature related parameters are at their factory default values which work well in most applications. However, it may be necessary to change certain parameters to customize the unit to the system environment. A complete listing and descriptions of the temperature related parameters are included in Appendix A. Factory defaults are listed in Appendix E. After reading this chapter, parameters can be customized to suit the needs of the specific application.

5.2 INDOOR/OUTDOOR RESET MODE

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

5.2.3 Outdoor Air Temperature Sensor Installation

The outdoor air temperature sensor must be mounted on the North side of the building in an area where the average outside air temperature is expected. The sensor must be shielded from the sun's direct rays, as well as direct impingement by the elements. If a cover or shield is used, it must allow free air circulation. The sensor may be mounted up to two hundred feet from the unit. Sensor connections are made at the Input/Output (I/O) Box on the front of the boiler. Connections are made at the terminals labeled OUTDOOR SENSOR IN and SENSOR COMMON inside the I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is provided on the cover of the I/O Box. Refer to Chapter 2, paragraph 2.9.1 for additional wiring information.

5.2.4 Indoor/ Outdoor Startup

Startup in the Indoor/Outdoor Reset Mode is accomplished as follows:

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

5.2.1 Reset Ratio

Reset ratio is an adjustable number from 0.1 to

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

5.2.2 Building Reference Temperature

This is a temperature from 40°F to 230°F. Once selected, it is the temperature that the system references to begin increasing its temperature. For instance, if a reset ratio of 1.6 is used, and we select a building reference temperature of 70°F, then at an outside temperature of 69°F, the supply header temperature will increase by

1.6° to 71.6°F.

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

3. Go down the left column of the chart to the coldest design outdoor air temperature expected in your area.

NOTE

A design engineer typically provides design outdoor air temperature and

header temperature data

supply

4. Once the design outdoor air temperature is chosen, go across the chart to the desired supply header temperature for the design temperature chosen in step 3.

5. Next, go up that column to the Reset Ratio row to find the corresponding reset ratio.

6. Access the Configuration Menu and scroll

through it until the display shows Bldg Ref Temp. (Building Reference Temperature).

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MODE OF OPERATION

7. Press the CHANGE key. The display will begin to flash.

8. Use the ▲ and ▼ arrow keys to select the desired Building Reference Temperature.

9. Press ENTER to save any changes.

10. Next, scroll through the Configuration Menu

until the display shows Reset Ratio.

11. Press the CHANGE key. The display will begin to flash.

12. Use the ▲ and ▼ arrow keys to select the Reset Ratio determined in step 5.

13. Press ENTER to save the change.

Refer to paragraph 3.3 for detailed instructions on menu changing.

5.3 CONSTANT SETPOINT MODE

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

5.4 REMOTE SETPOINT MODES

The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges:

4-20 mA/1-5 Vdc

0-20 mA/0-5 Vdc

The factory default setting for the Remote Setpoint mode is 4 - 20 mA/1 - 5 Vdc. With this setting, a 4 to 20 mA/1 to 5 Vdc signal, sent by an EMS or BAS, is used to change the unit's setpoint. The 4 mA/1V signal is equal to a 40°F setpoint while a 20 mA /5V signal is equal to a 240°F setpoint. When a 0 to 20 mA/0 to 5 Vdc signal is used, 0 mA is equal to a 40°F setpoint.

In addition to the current and voltage signals described above, the Remote Setpoint mode can also driven by a RS485 Modbus Network signal from an EMS or BAS.

The Remote Setpoint modes of operation can be used to drive single as well as multiple units.

No external sensors are required to operate in this mode. While it is necessary to set the desired setpoint temperature, it is not necessary to change any other temperature-related functions. The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. For descriptions of temperature-related functions and their factory defaults, see Appendices A and E.

5.3.1 Setting the Setpoint

The setpoint temperature of the unit is adjustable from 40°F to 240°F. To set the unit for operation in the Constant Setpoint Mode, the following menu settings must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Constant Setpoint

Internal Setpt Select desired setpoint

using ▲ and ▼ arrow keys (40°F to 240°F)

NOTE

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

In order to enable the Remote Setpoint Mode, the following menu setting must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Remote Setpoint

Remote Signal 4-20mA/1-5V,

0-20mA/0-5V, or

Network

Refer to paragraph 3.3 for detailed instructions on changing menu options.

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MODE OF OPERATION

If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information.

While it is possible to change the settings of temperature related functions, the unit is factory preset with settings that work well in most applications. It is suggested that an AERCO representative be contacted, prior to changing any temperature related function settings. For descriptions of temperature-related functions and their factory defaults, refer to Appendices A and E.

5.4.1 Remote Setpoint Field Wiring

The only wiring connections necessary for the Remote Setpoint mode are connection of the remote signal leads from the source to the unit’s I/O Box. The I/O Box is located on the front panel of the boiler. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.4.2 Remote Setpoint Startup

Since this mode of operation is factory preset and the setpoint is being externally controlled,

no startup instructions are necessary. In this

mode, the REMOTE LED will light when the external signal is present.

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

To change back to the Remote Setpoint mode, simply press the AUTO/M AN switch. The REMOTE LED will again light and the MANUAL LED will go off.

5.5 DIRECT DRIVE MODES

The unit’s air/fuel valve position (% open) can be changed by a remote signal which is typically sent from an Energy Management System (EMS) or from a Building Automation System (BAS). The Direct Drive mode can be driven by a current or voltage signal within the following ranges:

4-20 mA/1-5 Vdc

0-20 mA/0-5 Vdc

The factory default setting for the Direct Drive mode is 4-20 mA/1-5 Vdc. With this setting, a 4 to 20 mA signal, sent by an EMS or BAS is used to change the unit’s valve position from 0% to 100%. A 4 mA/1V signal is equal to a 0% valve position, while a 20 mA /5V signal is equal to a 100% valve position. When a 0-20 mA/0-5 Vdc signal is used, zero is equal to a 0% valve position.

In addition to the current and voltage signals described above, the Direct Drive mode can also driven by a RS485 Modbus Network signal from an EMS or BAS.

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

NOTE

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

To enable the Direct Drive Mode, the following menu setting must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Direct Drive

Remote Signal 4-20mA/1-5V,

0-20mA/0-5V, or

Network

Refer to paragraph 3.3 for instructions on changing menu options.

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MODE OF OPERATION

If the Network setting is selected for RS485 Modbus operation, a valid Comm Address must be entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional information.

5.5.1 Direct Drive Field Wiring

The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box. For a Network setting, the connections are made at the RS-485 COMM terminals in the I/O Box. The signal must be floating, (ungrounded) at the I/O Box and the wire used must be a two wire shielded pair from 18 to 22 AWG. Polarity must be observed. The source end of the shield must be connected at the source. When driving multiple units, each unit’s wiring must conform to the above.

5.5.2 Direct Drive Startup

Since this mode of operation is factory preset and the valve position is being externally

controlled, no startup instructions are necessary.

In this mode, the REMOTE LED will light when the signal is present.

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

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

5.6 BOILER MANAGEMENT SYSTEM

(BMS)

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.

The BMS mode of operation is used in conjunction with an AERCO Boiler Management System. The BMS mode is used when it is desired to operate multiple units in the most efficient manner possible. For this mode of operation, a BMS Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant's supply water

header. The BMS can control up to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS485) network communication. For BMS programming, operation, and Header Sensor installation details, see GF-108M (BMS Model 168) and GF-124 (BMS II Model 5R5-

384), BMS Operations Guides. For operation via an RS485 Modbus network, refer to Modbus Communication Manual GF-114.

To enable the BMS Mode, the following menu settings must be made in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Direct Drive

Remote Signal BMS (PWM Input)

or Network (RS485)

Refer to paragraph 3.3 for instructions on changing menu options.

5.6.1 BMS External Field Wiring

Wiring connections for BMS control using PWM signaling are made between connector JP2 on the BMS panel (boilers 1 through 8), and the B.M.S. (PWM) IN terminals in the I/O Box on the front of the boilers. Refer to the wiring diagram provided on the cover of the I/O Box.

Wiring connections for RS485 Modbus control are made between connector JP11 on the BMS (boilers 9 through 40) and the RS485 COMM terminals in the I/O Box on the front of the boilers.

Wire the units using shielded twisted pair wire between 18 and 22 AWG. Observe the proper polarity for the B.M.S. (PWM) IN and/or RS485 COMM wiring connections. Shields should be terminated only at the BMS and the boiler end must be left floating. Each unit’s wiring must conform to the above.

5.6.2 BMS Setup and Startup

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

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

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MODE OF OPERATION

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

5.7 COMBINATION CONTROL SYSTEM

(CCS)

NOTE

Only BMS Model 168 can be utilized for the Combination Mode, not the BMS II (Model 5R5-384).

A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. An AERCO Boiler Management System (BMS) Model 168 and a Combination Control Panel (CCP) are necessary to configure this system. Typically, an adequate number of boilers are installed to cover the space-heating load on the design day, however one or more units are used for the domestic hot water load.

The theory behind this type of system is that the maximum space-heating load and the maximum domestic hot water load do not occur simultaneously.+ Therefore, boilers used for the domestic hot water are capable of switching between constant setpoint and BMS modes of operation. These boilers are the combination units and are referred to as the combo boilers. The combo boilers heat water to a constant setpoint temperature. That water is then circulated through a heat exchanger in a domestic hot water storage tank.

When the space-heating load is such that all the space-heating boilers are at the 100% valve position, the BMS will then ask the Combination Control Panel for the domestic boilers to become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot water) boilers will then become spaceheating boilers. If the domestic hot water load is not satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch over to space heating, but there is a call for domestic hot water, the CCP switches the combo units back to the domestic load.

When the combo units are satisfying the domestic load they are in constant setpoint mode of operation. When the combo units switch over to space heating, their mode of operation changes to the BMS mode. For more information concerning the operation of the

Combination Control Panel see the AERCO CCP-1 literature.

5.7.1 Combination Control System Field Wiring

Wiring for this system is between the BMS Model 168 panel, the CCP and the B.M.S. (PWM) IN terminals in the I/O Box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above. For a complete CCP system-wiring diagram see the AERCO CCP-1 literature.

5.7.2 Combination Control System Setup and Startup

Setup for the Combination Mode requires entries to be made in the Configuration Menu for boiler mode, remote signal type and setpoint. The setpoint is adjustable from 40°F to 240°F.

Enter the following settings in the Configuration Menu:

MENU OPTION SETTING

Boiler Mode Combination

Remote Signal BMS (PWM Input)

Internal Setpt 40°F to 240°F

Refer to paragraph 3.3 for instructions on changing menu options.

While it is possible to change other temperaturerelated functions for combination mode, thes functions are preset to their factory default values. These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Appendix E.

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

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

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

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SAFETY DEVICE TESTING

1/8

CHAPTER 6 SAFETY DEVICE TESTING

6.1 TESTING OF SAFETY DEVICES

Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The Benchmark

3.0LN control system comprehensively monitors

all combustion-related safety devices before, during and after the start sequence. The following tests check to ensure that the system is operating as designed.

Operating controls and safety devices should be tested on a regular basis or following service or replacement. All testing must conform to local codes such as ASME CSD-1.

NOTE

MANUAL and AUTO modes of operation are required to perform the following tests. For a complete explanation of these modes, see Chapter 3.

NOTE

It will be necessary to remove the front door and side panels from the unit to perform the following tests.

WARNING

ELECTRICAL VOLTAGES IN THIS SYSTEM MAY INCLUDE 460, 220, 120 AND 24 VOLTS AC. POWER MUST BE REMOVED PRIOR TO PERFORMING WIRE REMOVAL OR OTHER TEST PROCEDURES THAT CAN RESULT IN ELECTRICAL SHOCK.

6.2 LOW GAS PRESSURE FAULT TEST

Refer to Figure 6-1 and ensure that the leak detection ball valve located at the high gas pressure switch is closed.

1. Remove the 1/8 “ plug from the ball valve at

the low gas pressure switch shown in the lower portion of Figure 6-1.

2. Install a 0 – 16 “ W.C. manometer or a W.C.

gauge where the 1/8" plug was removed.

3. Slowly open the ball valve near the low gas

pressure switch.

4. Place the unit in Manual Mode and adjust the air/fuel valve position (% open) between 25 and 30%.

5. While the unit is firing, slowly

close the

external manual gas shut-off valve.

6. The unit should shut down and display a

LOW GAS PRESSURE fault message at approximately 2.6” W.C. The FAULT indi-

cator should also start flashing.

(INSTALL MANOMETER HERE

FOR HIGH GAS PRESSURE

HIGH GAS

PRESSURE

SWITCH

SSOV

1/8" NPT PLUG

(INSTALL MANOMETER HERE

FOR LOW GAS PRESSURE

FAULT TEST)

" NPT PLU

FAULT TEST)

LEAK DETECTION

BALL VALVE

AIR/FUEL

VALVE

LOW GAS

PRESSURE

SWITCH

GAS

INLET

Figure 6-1

Low & High Gas Pressure Testing

7. Fully open the external manual gas shut-off

valve and press the CLEAR button on the

Control Box.

8. The fault message should clear and the

FAULT indicator should go off. The unit

should restart.

9. Upon test completion, close the ball valve and remove the manometer. Replace the 1/8 “ plug removed in step 1.

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SAFETY DEVICE TESTING

6.3 HIGH GAS PRESSURE TEST

To simulate a high gas pressure fault, refer to Figure 6-1 and proceed as follows:

1. Remove the 1/8 “ plug from the leak detection ball valve shown in the upper portion of Figure 6-1.

2. Install a 0 – 16” W.C. manometer (or W.C. gauge) where the 1/8” plug was removed.

3. Slowly open the leak detection ball valve

4. Start the unit in Manual mode at a valve position (firing rate) between 25 and 30%.

5. Slowly increase the gas pressure using the adjustment screw on the SSOV Actuator (see Figure 4-3).

6. The unit should shut down and display a

HIGH GAS PRESSURE fault message

when the gas pressure exceeds 2.6” W.C.

The FAULT indicator should also start

flashing.

7. Reduce the gas pressure back to 1.8” W.C.

8. Press the CLEAR button on the Control Box

to clear the fault.

9. The fault message should clear and the

FAULT indicator should go off. The unit

should restart.

10. Upon test completion, close the ball valve and remove the manometer. Replace the 1/8“ plug removed in step 1.

6.4 LOW WATER LEVEL FAUL T TEST

To simulate a low water level fault:

1. Set the ON/OFF switch to the OFF position

2. Close the water shut-off valves in the supply

and return piping to the unit.

3. Slowly open the drain valve on the rear of the

unit. If necessary the unit’s relief valve may be opened to aid in draining.

4. Continue draining the unit until a LOW

WATER LEVEL fault message is displayed and the FAULT indicator flashes.

6. Set the ON/OFF switch to the ON position. The READY light should remain off and the

unit should not start. If the unit does start, shut the unit off immediately and refer fault to qualified service personnel.

7. Close the drain and pressure relief valve used in draining the unit.

8. Open the water shut-off valve in the return piping to the unit.

9. Open the water supply shut-off valve to the unit to refill.

10. After the shell is full, press the LOW WATER LEVEL RESET button to reset the low water

cutoff.

11. Press the CLEAR button to reset the FAULT

LED and clear the displayed error message.

12. Set the ON/OFF switch to the ON position.

The unit is now ready for operation.

6.5 WATER TEMPERATURE FAULT

TEST

A high water temperature fault is simulated by adjusting the automatic over-temperature switch. This switch is accessible from the left side of the unit as shown in Figure 6-2.

1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint.

Lower the adjustable over-temperature switch

setting to match the displayed OUTLET TEMPERATURE.

Once the adjustable over-temperature switch

setting is approximately at, or just below, the actual outlet water temperature, the unit

should shut down. The FAULT indicator should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should

be displayed. It should not be possible to restart the unit.

Reset the adjustable over-temperature switch to

its original setting.

The unit should start once the adjustable

temperature limit switch setting is above the actual outlet water temperature.

5. Place the unit in the Manual Mode and raise the valve position above 30%.

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SAFETY DEVICE TESTING

RESET BUTTON FOR MANUAL

RESET TEMPERATURE LIMIT

SWITCH

HIGH LIMIT

ADJUSTABLE TEMPERATURE LIMIT SWITCH

MOUNTING PLATE ON SHELL

Figure 6-2

Temperature Limit Switch Setting

Once the adjustable over-temperature switch

setting is approximately at, or just below, the actual outlet water temperature, the unit

should shut down. The FAULT indicator should start flashing and a HIGH WATER TEMP SWITCH OPEN fault message should

be displayed. It should not be possible to restart the unit.

Reset the adjustable over-temperature switch to

its original setting.

The unit should start once the adjustable

temperature limit switch setting is above the actual outlet water temperature.

6.6 INTERLOCK TESTS

The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock. Terminal connections for these circuits are located in the I/O Box (Figure 2-9) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN. These circuits can shut down the unit in the event that an interlock is opened. These interlocks are shipped from the factory jumpered (closed). However, each of these interlocks may be utilized in the field as a remote stop and start, an emergency cut-off, or to prove

that a device such as a pump, gas booster, or louver is operational.

6.6.1 REMOTE INTERLOCK

1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals.

2. Start the unit in the Manual Mode and set the valve position between 25% and 30%.

3. If there is a jumper across the REMOTE INTL’K IN terminals, remove one side of the jumper. If the interlock is being controlled by an external device, either open the interlock via the external device or disconnect one of the wires leading to the external device.

4. The unit should shut down and display

INTERLOCK OPEN.

5. Once the interlock connection is

reconnected, the INTERLOCK OPEN

message should automatically clear and the unit should restart.

6.6.2 DELAYED INTERLOCK

Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals.

Start the unit in the Manual Mode at a valve position between 25% and 30%.

If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the jumper. If the interlock is connected to a proving switch of an external device, disconnect one of the wires leading to the proving switch.

The unit should shut down and display a

DELAYED INTERLOCK OPEN fault message. The FAULT LED should be flashing.

Reconnect the wire or jumper removed in step 3 to restore the interlock.

Press the CLEAR button to reset the fault

The unit should start.

6.7 FLAME FAULT TESTS

Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows:

1. Set the ON/OFF switch to the OFF position.

2. Place the unit in the Manual Mode and set the valve position between 25% and 30%.

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SAFETY DEVICE TESTING

3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV) and the Air/Fuel Valve (see Figure 6-3).

AIR

INLET

BLOCKED

P/O FRAME

AIR/FUEL

VALVE

MANUAL GAS

SHUTOFF VALVE

GAS

INLET

HANDLE

PARTIAL LEFT SIDE VIEW

INLET

SWITCH

BLOWER PROOF

SWITCH

BLOWER

SSOV

Figure 6-3

Manual Gas Shut-Off Valve Location

4. Set the ON/OFF switch to the ON position to

start the unit.

5. The unit should shut down after reaching the

Ignition cycle and display FLAME LOSS

DURING IGN.

6. Open the valve previously closed in step 3

and press the CLEAR button.

7. Restart the unit and allow it to prove flame.

8. Once flame is proven, close the manual gas valve located between the SSOV and the Air/Fuel Valve.

The unit should shut down and execute an

IGNITION RETRY cycle by performing the

following steps:

(a) The unit will execute a shutdown purge

cycle for a period of 15 seconds and

display WAIT FAULT PURGE.

(b) The unit will execute a 30 second re-

ignition delay and display WAIT RETRY PAUSE.

ignition sequence and display WAIT IGNITION RETRY.

9. Open the valve previously closed in step 8.

10. Press the CLEAR button. The unit should

restart and fire.

6.8 AIR FLOW FAULT TESTS

These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3.

1. Disable the blower output drive voltage as follows:

(a) Press the MENU key until CONFIGUR-

ATION MENU is displayed.

(b) Press the ▲ arrow key until the ANA-

LOG OUTPUT function is displayed, then press the CHANGE key.

displayed, then press the ENTER key.

2. Start the unit in the Manual Mode at a valve position between 25% and 30%.

3. The unit should shut down and execute an

IGNITION RETRY cycle by performing the

following steps:

(a) The unit will execute a 30 second re-

ignition delay and display WAIT RETRY PAUSE.

(b) The unit will then execute a standard

ignition sequence and display WAIT IGNITION RETRY.

4. The unit should perform two IGNITION RETRY cycles and then shut down on the

third successive ignition attempt. The unit will

display AIRFLOW FAULT DURING PURGE.

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SAFETY DEVICE TESTING

5. Re-enable the blower output drive voltage by performing the following steps:

(a) Press the MENU key until CONFIGUR-

ATION MENU is displayed.

(b) Press the ▲ arrow key until the ANA-

LOG OUTPUT function is displayed, then press the CHANGE key.

POSITION 0-10V is displayed, then press the ENTER key.

6. Once the unit has proved flame, turn off the blower by going to the Configuration Menu,

Analog Output menu item and select OFF.

7. The Blower Proof Switch will open and the blower should stop. The unit should shut

down and display AIRFLOW FAULT DURING RUN.

8. Go to the Configuration Menu, Analog Output item and select Valv e Posit i on 0-1 0v .

9. Press the CLEAR button. The unit should

restart.

5. Disconnect wire #148 from the SSOV to “open” the proof of closure switch circuit.

6. The unit should fault and display SSOV SWITCH OPEN.

7. Replace wire #148 and press the CLEAR

button.

8. Set the ON/OFF switch to ON to start the

unit.

9. Remove the wire again when the unit

reaches the purge cycle and PURGING is

displayed.

10. The unit should shut down and display SSOV FAULT DURING PURGE.

11. Replace the wire on the SSOV and press the

CLEAR button. The unit should restart.

10. Next, check the Blocked Inlet Switch by first noting the current position of the Iris Air Damper and then closing the Damper to position 8.

11. The unit should shut down and again display

AIRFLOW FAULT DURING RUN.

12. Return the Iris Air Damper to its previous setting.

13. Press the CLEAR button. The unit should

restart.

6.9 SSOV PROOF OF CLOSURE SWITCH

The SSOV shown in Figure 6-1 contains a proof of closure switch. The proof of closure switch circuit is checked as follows:

1. Set the unit’s ON/OFF switch to the OFF

position.

2. Place the unit in Manual Mode and set the valve position between 25% and 30%

3. Refer to Figure 6-1 and locate the SSOV.

4. Remove the cover from the SSOV by loosening the screw shown in Figure 6-4. Lift off the cover to access the terminal wiring connections.

SSOV

ACTUATOR

COVER

ACTUATOR

COVER SCREW

Figure 6-4

SSOV Actuator Cover Location

6.10 PURGE SWITCH OPEN DURING PURGE

The Purge Switch (and Ignition Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:

1. Set the unit’s ON/OFF switch to the OFF

position. Place the unit in manual mode and set the valve position between 25% and 30%.

2. Remove the Air/Fuel Valve cover by rotating the cover counterclockwise to unlock it and then lift up (see Figure 6-5).

3. Remove one of the two wires (#171 or #172) from the Purge Switch (Figure 6-6).

6-5

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SAFETY DEVICE TESTING

4. Initiate a unit start sequence.

5. The unit should begin it’s start sequence,

then shut down and display PRG SWITCH OPEN DURING PURGE.

6. Replace the wire on the Purge Switch and

depress the CLEAR button. The unit should

restart.

6.11 IGNITION SWITCH OPEN DURING IGNITION

The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows:

1. Set the unit’s ON/OFF switch to the OFF

position.

2. Place the unit in Manual Mode and set the valve position between 25% and 30%.

3. Remove the Air/Fuel Valve cover (Figure 6-5) by rotating the cover counterclockwise to unlock and lift up to remove.

4. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 6-6).

5. Initiate a unit start sequence.

STEPPER

BLOWER

MOTOR

169

IGNITION

POSITION

SWITCH

DIAL

172

PURGE

POSITION

SWITCH

AIR

Figure 6-6

Air/Fuel Valve Purge and Ignition Switch

Locations

6. The unit should begin its start sequence and

then shut down and display IGN SWITCH OPEN DURING IGNITION.

7. Replace the wire on the Ignition Switch and

press the CLEAR button. The unit should

restart.

AIR/FUEL VALVE COVER (ROTATE CCW TO REMOVE)

Figure 6-5

Air/Fuel Valve Cover Location

6.12 SAFETY PRESSURE RELIEF VALVE TEST

Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.

6-6

Page 53

CHAPTER 7 MAINTENANCE

MAINTENANCE

7.1 MAINTENANCE SCHEDULE

The unit requires regular routine maintenance to keep up efficiency a nd r eliability. F or bes t operation and l ife of the unit, th e f ollowing routine m aintenance procedures s hould be carried out in the time periods specified in Table 7-1. S ee A ppendix I f or a c omplete CSD- 1 inspection check list.

In or der to perform the m aintenance tas ks specified i n T able 7 -1, the f ollowing maintenance k its ar e av ailable thr ough your local AERCO Sales Representative:

• Annual Maintenance Kit, Part No. 58025-01

• 24- Month Waterside/Fireside Inspection Kit,

Part No. 58025-04 (See NOTE below)

NOTE

The 24-Month Waterside/Fireside Ins pection Kit a lso includes the items contained in the A nnual Maintenance Kit. T herefore, only Kit Par t No. 5 8025-04 is r equired when per forming the w aterside/fireside inspections.

Appendix K c ontains r ecommended s pare parts lists for maintenance of the boiler.

WARNING

TO A VOID P ERSONAL IN JURY, PRIOR TO SERVICING:

• DISCONNECT THE AC SUPPLY BY TURNING O FF THE SERVI CE SWITCH AND AC SUP PLY CIRCUIT BREAKER.

• SHUT O FF THE G AS SUPPLY AT THE M ANUAL SHUT -OFF VALVE PROVIDED WITH THE UNIT

• ALLOW THE UNIT TO C OOL T O A SAFE WATER T EMPERATURE T O PREVENT BURNING OR SCALDING

7.2 IGNITOR-INJECTOR

The ignitor-injector (part no. 58023) is located in the bo dy of the b urner (see F igure 7- 1). In addition t o pr oviding t he ignition s park r equired to light the bur ner, this component also contains a gas injector tube which connects to the staged ignition as sembly. T he ig nitor-injector m ay be hot, therefore, care should be exercised to avoid burns. It is eas ier t o r emove the i gnitor-injector from the uni t af ter th e u nit has c ooled to r oom temperature.

BURNER

HOUSING

STAGED

IGNITION

ASSY

IGNITOR-

INJECTOR

FLAME DETECTOR & GASKET (SECURED WITH 2 SCREWS)

Figure 7-1.

Burner Assembly – Top View

To ins pect/replace th e Ign itor-injector, pr oceed as follows:

1. Set the ON/OFF switch on the c ontrol panel, to the OFF pos ition. Dis connect AC p ower

from the unit

2. Remove th e t op and s ide pan els f rom the unit.

3. Disconnect the cable from the ignitor-injector.

4. Using a 7/ 16” ope n-end wr ench, dis connect the compression nut securing the gas injector tube of the ig nitor-injector to the el bow of the staged i gnition as sembly. Dis connect the staged ig nition as sembly f rom the ig nitorinjector.

7-1

Page 54

MAINTENANCE

5. Next, lo osen an d r emove the i gnitor-injector from the burner housing using a 1" open-end wrench.

6. Check the ign itor-injector f or evide nce of erosion or c arbon b uild-up. If ther e is evidence of s ubstantial erosion or c arbon build-up, the ignitor-injector s hould b e replaced. If carbon build-up is pr esent, c lean the c omponent us ing f ine em ery c loth. Repeated c arbon bui ld-up is an indic ation that the c ombustion s ettings of the unit should be c hecked. Ref er to Ch apter 4 f or combustion calibration procedures.

7. Prior t o reinstalling the ignitor-injector, a high temperature, c onductive, ant i-seize c ompound must

If a r eplacement ignitor -injector ( part no.

58023) is bei ng i nstalled, a c ompression nut c ontaining a b uilt-in f errule wil l be included with t he r eplacement par t. If needed, 3 i ndexing washers ar e als o included. T hese washers m ay be ne eded to pr operly position the gas inj ector tube of the ignitor-injector within the 120° angle shown in Figure 7-2.

be applied to the threads.

NOTE

IGNITOR-

INJECTOR

120

DEG.

BURNER

HOUSING

120

HOUSING CENTERLINE

GAS INJECTOR TUBE

MUST BE WITHIN

THIS RANGE

Fgurei 7-2

Burner Assembly – Top View

8. Reinstall the ignitor-injector in th e bur ner housing and t orque t o 80 to 90 i n-lbs. However, if the burner housing was replaced just pr ior to r eplacing t he ig nitor-injector, torque to 1 80 in-lbs, then lo osen a nd r etighten to 80 to 90 in-lbs.

9. Connect the s taged ig nition as sembly to t he gas inj ector t ube of the ignitor-injector b y securing the compression nut to t he elbow of the staged ignition assembly.

10. Reconnect the ignitor-injector cable.

11. Reinstall the side and top panels on the unit.

Table 7-1 - Maintenance Schedule

PARAGRAPH ITEM 6 Mos. 12 Mos. 24 Mos.

7.2

7.3

7.4

7.5

Ignitor-Injector

(58023)

Flame Detector

(66006)

Combustion

Calibration

Testing of

Safety Devices

*Inspect Inspect Replace 15 mins.

*Check Check 1 hr.

See CSD-1

Chart in

20 mins.

Appendix I

7.6 Burner Inspect 2 hrs.

7.7

* Only performed after initial 6 month period after initial startup.

Condensate Drain Traps

*Inspect

Inspect &

Clean

1 hr.

Labor

Time

7-2

Page 55

7.3 FLAME DETECTOR

The flame detector, part no. 66006, is located in the body of the b urner ( see F igure 7- 1). T he flame detec tor m ay b e H OT. Allo w th e un it to cool s ufficiently bef ore r emoving th e f lame detector.

To inspect or replace the flame detector:

MAINTENANCE

7.6 BURNER ASSEMBLY INSPECTION

The bur ner assembly is located at t he top f ront of the unit. T he burner as sembly m ay be hot. Allow th e un it to c ool s ufficiently bef ore removing the burner assembly.

The f ollowing r eplacement p arts wil l b e necessary for reassembly following inspection:

1. Set the ON/OFF switch on the c ontrol panel, to the O FF pos ition. Dis connect AC po wer from the unit.

2. Remove the top panels from the unit.

3. Disconnect the le ad wire f rom the f lame detector.

4. Remove t he t wo (2 ) screw s se curing t he flame detector to t he burner housing (Figure 7-1). T he f lame detec tor i s s ecured t o t he burner ho using with on e ( 1) #10- 32 s crew and one (1) #8-32 screw.

5. Remove the f lame detec tor and gas ket f rom the burner housing.

6. Inspect th e d etector t horoughly. If er oded, the det ector s hould b e r eplaced. O therwise clean the detector with a fine emery cloth.

7. Reinstall th e f lame det ector an d f lame detector gasket.

8. Reconnect the flame detector lead wire.

9. Reinstall the top and side panels on the unit.

7.4 COMBUSTION CALIBRATION

Combustion s ettings m ust be c hecked at the intervals s hown i n T able 7- 1 as par t of the maintenance requirements. Ref er to Chapt er 4 for combustion calibration instructions.

7.5 SAFETY DEVICE TESTING

Systematic an d thor ough tests of the oper ating and safety de vices should be per formed to ensure t hat t hey ar e op erating as designed. Certain c ode r equirements, s uch as A SME CSD-1, require that these tests be performed on a s cheduled bas is. T est s chedules m ust conform t o local ju risdictions. T he results of t he tests s hould be r ecorded in a lo g bo ok. See Chapter 6-Safety Device Testing Procedures.

Part No. Description

81030 Burner Gaskets (Qty=2) 81048 Flame Detector Gasket

To inspect or replace the burner assembly:

1. Set the ON/OFF switch on the c ontrol panel, to the OFF pos ition. Dis connect AC po wer

from the unit and turn off the gas supply.

2. Remove th e s ide and to p pan els f rom the unit.

3. Disconnect the le ad wire f rom the f lame detector (see Figure 7-1).

4. Remove t he t wo (2 ) screw s se curing t he flame detec tor to the b urner h ousing. T he flame detec tor is s ecured to th e b urner housing with on e ( 1) #10- 32 s crew a nd o ne (1) #8-32 screw.

5. Remove the f lame detec tor and gas ket f rom the burner housing.

6. Disconnect the cable from the ignitor-injector.

7. Using a 7/ 16” ope n-end wr ench, dis connect the compression nut securing the gas injector tube of the ig nitor-injector to the el bow of the staged i gnition as sembly. Dis connect the staged ig nition as sembly f rom the ig nitorinjector.

8. Loosen and r emove th e ig nitor-injector f rom the burner plate using a 1" wrench.

9. Disconnect the bur ner h ousing f rom the blower by removing the six (6) 1/4-20 screws using a 3/8” wrench.

10. Remove the eight ( 8) 3/8-16 n uts f rom the burner f lange ( Figure 7- 3) us ing a 9/ 16” wrench.

7-3

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MAINTENANCE

3/8-16

NUTS (8)

STAGED IGNITION ASSEMBLY

GROUNDING SCREW

BURNER

HOUSING

STAGED IGNITION

ASSEMBLY

FLAME

DETECTOR

IGNITORINJECTOR

BURNER

HOUSING

1/4-20

SCREWS

(6)

Figure 7-3

Burner Disassembly Diagram - Top View

NOTE

The bur ner hous ing is h eavy, weighing approximately 25 pounds.

11. Refer to the ex ploded v iew in F igure 7- 4. Remove the bur ner hou sing f rom bur ner flange by pulling straight up.

12. Remove the grounding screw.

13. Remove the burner by pulling straight up.

14. Remove and replace the burner gaskets.

BURNER GASKET

BURNER

BURNER GASKET

Figure 7-4

Burner Assembly - Exploded View

7.7 CONDENSATE DRAIN TRAPS

The Benc hmark 3.0 B oiler c ontains t wo condensate traps as shown in Chapter 2, F igure 2-5. One trap is located external to t he unit and attached to the drain p ipe f rom the c onnecting manifold. The other trap is an integral part of the exhaust m anifold. T hese tr aps s hould b e inspected an d, if nec essary, c leaned t o ens ure proper o peration. F ollow the pr ocedures i n paragraphs 7.7.1 and 7.7.2.

15. Beginning with th e bur ner r emoved in s tep 13, reinstall all the components in the reverse order that they were removed.

16. Make s ure to ali gn th e bu rner hous ing with the blower and the heat exchanger top head.

17. Check to ens ure that t he grounding screw is reinstalled. Also, ens ure that c onductive, high-temperature, a nti-seize c ompound is applied to th e thr eads of the gr ound s crew and th e ig nitor-injector. T orque th e ig nitorinjector t o 8 0 t o 9 0 in-lbs. H owever, if t he burner housing w as r eplaced during inspection, tor que to 18 0 i n-lbs, then l oosen and re-tighten to 80 to 90 in-lbs.

7-4

7.7.1 Connecting Manifold Condensate Trap

To ins pect an d c lean t he condensate tr ap ( part no. 24060) attached to the connecting manifold, proceed as follows:

1. Loosen th e t humbscrew securing the tr ap adaptor (Figure 2-6) to th e condensate drain pipe on the connecting manifold.

2. Remove the n ipples a nd c onnections o n the inlet an d out let sides of the c ondensate tr ap shown in Figure 7-5.

Page 57

3. Loosen t he f our ( 4) thum bscrews s ecuring the c over on the c ondensate tr ap. Rem ove the cover.

4. Remove the float from the condensate trap.

5. Remove the orifice gasket from the trap.

6. Thoroughly c lean t he tr ap, f loat an d gas ket. Also i nspect the dr ain p iping f or blockage. If the tr ap c annot b e tho roughly c leaned, replace the trap.

MAINTENANCE

1. Loosen t he c lamp s ecuring the h ose to th e condensate dr ain ( Figure 7- 6). Dis connect the hose.

2. Remove the f our bol ts s ecuring th e f lue to the top of the exhaust manifold. Separate the flue from the exhaust manifold.

3. From the top of the e xhaust m anifold, remove the f loat a nd or ifice gas ket f rom the condensate trap.

7. After the ab ove it ems have bee n ins pected and t horoughly c leaned, r eplace the or ifice gasket and f loat in t he c ondensate tr ap a nd replace the trap cover.

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

9. Reconnect the c ondensate tr ap ad aptor to connecting m anifold dr ain pip e, Ens ure th at the trap is level and then tighten the adaptor thumbscrew. Pl ace a s uitable s upport u nder the trap to maintain it in the level position.

THUMB

SCREWS

(4)

INLET

3/4 NPT

PORT

O-RING

FLOAT

ORIFICE GASKET

3/4 NPT

PORT

OUTLET

COVER

4. Thoroughly c lean t he tr ap, f loat an d gas ket. Also, inspect the drain hose for blockage.

5. After the ab ove it ems have bee n ins pected and c leaned, replace the g asket and f loat in the condensate trap.

6. Replace the four bolts securing the flue to the exhaust m anifold a nd c onnect the hos e t o the manifold condensate drain.

FLUE

BOLTS

(4)

EXHAUST

MANIFOLD

CONDENSATE

CLAMP

HOSE

1" I.D. HOSE

TRAP

DRAIN

UNIT FRAME

Figure 7-5

External Condensate Trap

7.7.2 Exhaust Manifold Condensate Trap

The ex haust m anifold c ondensate tr ap a lso contains a f loat and or ifice gas ket s imilar to those shown in Figure 7-5. The only difference is that the or ifice gasket in t he ex haust m anifold trap has a 0.7 5" I.D. o pening and th e gas ket shown in Figure 7-5 has a 0.25" I.D. To ins pect and c lean th e tr ap, r efer to F igure 7- 6 an d proceed as follows:

TO FLOOR

DRAIN

Figure 7-6

Exhaust Manifold Condensate Trap &

Drain

7-5

Page 58

MAINTENANCE

7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME

If the boiler is to be tak en out of s ervice f or an extended period of time (one year or more), the following instructions must be followed.

1. Set ON/OFF switch on the front panel to the OFF pos ition to s hut d own th e bo iler’s

operating controls.

2. Disconnect AC power from the unit.

3. Close th e water s upply a nd r eturn v alves to isolate boiler.

4. Close external gas supply valve.

5. Open relief valve to vent water pressure.

7.9 PLACING THE BOILER BACK IN

SERVICE AFTER A PROLONGED SHUTDOWN

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

1. Review installation requirements included in

Chapter 2.

2. Inspect a ll piping an d c onnections to the

unit.

3. Inspect exhaust vent, air duct (if applicable).

4. Perform initial startup per Chapter 4.

5. Perform s afety de vice t esting and the

scheduled m aintenance pr ocedures per Chapters 6 and 7 of this manual.

7-6

Page 59

Chapter 8- TROUBLESHOOTING GUIDE

8.1 INTRODUCTION

This tr oubleshooting guide is intended to aid service/maintenance per sonnel in is olating the cause of a f ault in a Benc hmark 3.0 Boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages. These tables are c omprised of thr ee c olumns labeled: F ault Indic ation, Pr obable Caus e and Corrective Ac tion. T he num bered item s in the Probable Cause and Cor rective Ac tion c olumns correspond to eac h other . F or ex ample, Probable Cause No. 1 corresponds to Corrective Action No. 1, etc.

NOTE:

The front panel of the C- More Contr ol Box contains an RS232 por t which can be interfaced to a laptop c omputer or other s uitable devic e. This RS232 c ommunication f eature permits service personnel to view m enu item s and data logs which can be useful in isolating faults. Refer to Chapter 9 of this m anual f or detailed RS232 communication set-up and procedures.

TROUBLESHOOTING

When a f ault oc curs in the Benc hmark Boiler , proceed as f ollows to is olate and c orrect the fault:

1. Observe the fault messages displayed in the Control Box display.

2. Refer to the F ault Indic ation c olumn in Troubleshooting Table 8-1 which follows and locate the F ault that bes t describes the existing conditions.

3. Proceed to the Pr obable Caus e column and start with the first item (1) listed for the Fault Indication.

4. Perform the checks and procedures listed in the Cor rective Ac tion c olumn f or the first Probable Cause candidate.

5. Continue checking eac h additional Probable Cause f or the ex isting f ault until the fault is corrected.

6. Paragraph 8.2 and T able 8- 2 c ontain additional tr oubleshooting inf ormation w hich may apply w hen no f ault message is displayed.

7. If the f ault c annot be c orrected us ing the information pr ovided in the Troubleshooting Tables, contact y our loc al AERCO Representative.

8-1

Page 60

TROUBLESHOOTING

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

AIRFLOW FAULT

DURING IGNITION

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked Blower proof switch

4. Blocked blocked-air inlet switch

5. Defective Blower proof switch

6. Defective blocked-air inlet switch

7. Loose temperature to AUX connection in I/O Box

8. Defective temperature sensor

9. Loose wire connection between the

0-10V signal from I/O box to the Blower Motor input

10. Defective I/O box

11. Wrong 0-10V output selection on the

control box

12. Defective Air-Fuel Valve

potentiometer

TABLE 8-1. BOILER TROUBLESHOOTING

1. Check combustion blower for signs of excessive heat or high current drain that may trip thermal or current overload devices.

2. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

3. Remove the Blower proof switch and inspect for signs of blockage, clean or replace as necessary.

4. Remove the blocked-air inlet switch and inspect for signs of blockage, clean or replace as necessary.

5. Measure the Blower proof switch for continuity with the combustion blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

6. Measure the blocked-air inlet switch for continuity with the combustion blower running. If there is an erratic resistance reading or the resistance reading is greater than zero ohms, replace the switch.

7. Check the actual inlet air temperature and measure voltage at AUX input in the I/O Box. Verify that the voltage conforms to the values shown in the tabular listing provided in Appendix C.

8. Refer to CORRECTIVE ACTION 7 and verify that the voltage conforms to the values shown in Appendix C.

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

10. Measure voltage at the I/O box 0-10V output. A voltage of 8.2V equates to a 100% open air/fuel valve position.

11. Check the Analog Out option on the C-More Configuration Menu. Valve Position 0-10V should be selected.

12. Check Air/Fuel Valve position at 0%, 50% and 100% open positions. The position on the VALVE POSITION bar graph should match the reading on the Air/Fuel Valve dial.

8-2

Page 61

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PRO BABLE CAUSES CORRECTIVE ACTION

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING RUN

1. Blower not running or running too slow

2. Defective Air Flow Switch

3. Blocked Air flow Switch

4. Blocked Blower inlet or inlet ductwork.

5. No voltage to switch from control box.

PROBABLE CAUSES from 3 to 12

for AIRFLOW FAULT DURING IGNITION also apply for this fault

1. Blower stopped running due to thermal or current overload

2. Blocked Blower inlet or inlet ductwork

3. Blocked airflow switch

4. Defective airflow switch

5. Combustion oscillations

PROBABLE CAUSES from 3 to 12

for AIRFLOW FAULT DURING IGNITION applies for this fault

1. Start the unit. If the blow er does not r un check the blow er solid state relay for input and output voltage. If the relay is okay, check the blower.

2. Start the unit. If the blow er r uns, c heck the airflow switch for continuity. Replace the switch if there is no continuity.

3. Remove the air flow s witch and ins pect f or s igns of bloc kage, clean or replace as necessary.

4. Inspect the inlet to the combustion blower including any ductwork leading up to the combustion blower for signs of blockage.

5. Measure for 24 VAC during start sequence from each side of the switch to gr ound. If 24VAC is not present refer to qualified service personnel.

6. See

1. Check combustion blower for s igns of ex cessive heat or high

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

3. Remove the air flow s witch and ins pect for signs of blockage,

4. Measure the air flow s witch f or c ontinuity with the combustion

5. Run unit to f ull f ire. If the unit r umbles or r uns r ough, per form

CORRECTIVE ACTION f rom 3 to 12 for AIRFLOW

FAULT DURING IGNITION

current draw that may trip thermal or current overload devices.

leading up to the c ombustion blow er f or s igns of blockage.

clean or replace as necessary.

blower running. If ther e is an er ratic r esistance r eading or the resistance reading is greater than zero ohms, replace the switch.

combustion calibration.

PROBABLE CAUSES f rom 3 to 12 for AIRFLOW FAULT

DURING IGNITION applies for this fault

8-3

Page 62

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

DELAYED

INTERLOCK OPEN

DIRECT DRIVE SIGNAL FAULT

FLAME LOSS

DURING IGN

1. Delayed Interlock Jumper not installed or removed.

2. Device proving switch hooked to interlocks is not closed

1. Direct drive signal is not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

2. Signal is not isolated (floating).

3. Control Box signal type selection switches not set for correct signal type (voltage or current).

1. Burner Ground Screw not installed or loose.

2. Worn flame detector

3. No spark from Spark Plug

4. Defective Ignition Transformer

5. Defective Ignition/Stepper (IGST) Board

6. Defective SSOV

1. Check for a jumper properly installed across the delayed interlock terminals in the I/O box.

2. If there are 2 external wires on these terminals, check to see if an end switch for a device such as a pump, louver, etc. is tied these interlocks. Ensure that the device and or its end switch are functional. (jumper may be temporarily installed to test interlock)

1. Check I/O Box to ensure signal is hooked up. Hook up if not installed. If installed, check polarity. Measure signal level. Check continuity of wiring between source and boiler.

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

3. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Check control signal type set in Configuration Menu.

1. Inspect and install/retighten Burner Ground Screw.

2. Remove and inspect the flame detector for signs of wear. Replace if necessary.

3. Close the internal gas valve in the boiler. Install and arc a spark igniter outside the unit.

4. If there is no spark, check for 120VAC at the primary side of the ignition transformer during the ignition cycle.

5. If 120VAC is not present, the IGST Board in the Control Box may be defective. Refer fault to qualified service personnel.

6. While externally arcing the spark igniter, observe the open/close indicator in the Safety Shut-Off Valve to ensure it is opening. If the valve does not open, check for 120VAC at the valve’s input terminals. If 120VAC is not present, the IGST board in the Control Box may be defective. Refer fault to qualified service personnel.

8-4

Page 63

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 7. Carbon or other debris on Burner

8. Staged ignition ball valve closed.

9. Staged ignition solenoid valve doesn’t open.

10. Clogged staged ignition piece.

FLAME LOSS

DURING RUN

HEAT DEMAND

FAILURE

HIGH EXHAUST TEMPERATURE

1. Worn Flame Detector or cracked ceramic.

2. Defective SSOV Regulator.

3. Poor combustion calibration.

4. Debris on burner.

5. Blocked condensate drain.

1. The Heat Demand Relays on the Ignition/Stepper board failed to activate when commanded

2. Relay is activated when not in Demand

1. Defective exhaust sensor.

2. Carboned heat exchanger due to incorrect combustion calibration

7. Remove the burner and inspect for any carbon or debris. Clean and reinstall.

8. Open 1/4” ball valve downstream of the SSOV (see Figure 8-1).

9. When boiler goes to ignition, lis ten to the s olenoid valve f or a

clicking sound to ensure it is opening.

10. Remove and inspect staged ignition piece for blockage.

1. Remove and inspect the Flame Detector for signs of wear or cracked ceramic. Replace if necessary.

2. Check gas pressure readings using a gauge or manometer into and out of the Air/Fuel Valve to ensure that the gas pressures into and out of the valve are correct.

3. Check combustion calibration. Adjust as necessary.

4. Remove the burner and inspect for any carbon or debris. Clean and reinstall.

5. Remove blockage in condensate drain.

1. Press CLEAR button and r estart the unit. If the f ault persists, replace Ignition/Stepper (IGST) Board.

2. Defective relay. Replace IGST Board.

1. Measure the actual exhaust temperature and continuity of the exhaust sensor. If the exhaust temperature is less than 475 and the exhaust sensor shows continuity replace the sensor.

2. If exhaust temperature is greater than 500

combustion calibration. Calibrate or repair as necessary.

F, check

8-5

Page 64

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

HIGH GAS

PRESSURE

HIGH WATER TEMP

SWITCH OPEN

1. Incorrect supply gas pressure.

2. Defective SSOV Actuator gas pressure adjustment regulator.

3. Defective High Gas Pressure Switch

4. Gas pressure snubber not installed.

1. Faulty Water temperature switch.

2. Incorrect PID settings.

3. Faulty shell temperature sensor.

4. Unit in Manual mode

5. Unit setpoint is greater than Over Temperature Switch setpoint.

6. Boiler Management System PID or other settings not correctly setup.

7. No interlock to boiler or BMS to disable boiler(s) in event that system pumps have failed.

8. System flow rate changes are occurring faster than boilers can respond.

1. Check to ensure gas pressure at inlet of SSOV is 2 psig maximum.

2. If gas supply pressure downstream of the SSOV cannot be lowered, to 1.8” W.C. (see para. 4.3, step 10), the SSOV Actuator gas pressure adjustment regulator may be defective.

3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity.

4. See Figure 8-1. Ensure that the gas pressure snubber is installed at the high gas pressure switch.

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

2. Check PID settings against Menu Default settings in the Appendix. If the settings have been changed, record the current readings then reset them to the default values.

3. Using the resistance charts in the Appendix C, Measure the resistance of Shell sensor and BTU sensor at a known water temperature.

4. If unit is in Manual Mode switch to Auto Mode.

5. Check setpoint of unit and setpoint of Temperature Switch; Ensure that the temperature switch is set higher than the unit’s setpoint.

6. Check the BMS for changes to PID default values, correct as necessary.

7. If system pump is controlled by Energy Management System other than BMS or pumps are individually controlled by boiler, check to see if there are flow switches interlocked to the BMS or boiler.

8. If the system is a variable flow system, monitor system flow changes to ensure that the rate of flow change is not faster than what the boilers can respond to.

8-6

Page 65

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

HIGH WATER

TEMPERATURE

IGN BOARD

COMM FAULT

IGN SWTCH CLOSED

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Temp HI Limit setting is too low.

1. Communication fault has occurred between the PMC board and Ignition/Stepper (IGST) board

1. Air/Fuel Valve not rotating

2. Defective or shorted switch

3. Switch wired incorrectly

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Air/Fuel Valve not rotating to ignition position.

2. Defective ignition switch

3. Defective Power Supply Board or fuse

4. Defective IGST Board

1. See HIGH WATER TEMPERATURE SWITCH OPEN.

2. Check Temp HI Limit setting.

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

1. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration. If calibration is okay, the problem may be in the Air-Fuel Valve or

the Control Box. Refer to qualified service personnel

2. . If the Air/Fuel Valve does rotate to purge, check the ignition switch for continuity between the N.O. and COM terminals. If the switch shows continuity when not in contact with the cam replace

the switch.

3. Check to ensure that the switch is wired correctly (correct wire numbers on the normally open terminals). If the switch is wired

correctly, replace the switch

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

steady ON, replace Power Supply Board.

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

every second. If not, replace IGST Board

1. Start the unit. T he Air /Fuel Valve s hould r otate to the pur ge (open) position, then back to ignition pos ition ( towards c losed) during the ignition c ycle. If the valve does not rotate back to the ignition position, c heck the Air /Fuel Valve c alibration. If calibration is ok ay, the pr oblem m ay be in the Air /Fuel Valve or the Control Box. Refer fault to qualified service personnel.

2. If the Air/Fuel Valve does rotate to the ignition position, check the ignition position switch for continuity between the N.O. and CO M terminals when in contact with the cam.

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

steady ON, replace Power Supply Board.

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

every second. If not, replace IGST Board.

8-7

Page 66

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

INTERLOCK

OPEN

LINE VOLTAGE

OUT OF PHASE

LOW GAS

PRESSURE

LOW WATER

LEVEL

MODBUS COMM

FAULT

PRG SWTCH CLOSED

DURING IGNITION

1. Interlock jumper not installed or removed

2. Energy Management System does not have boiler enabled.

3. Device proving switch hooked to interlocks is not closed.

1. Line and Neutral switched in AC Power Box.

2. Incorrect power supply transformer wiring.

1. Incorrect supply gas pressure.

2. Defective Low Pressure Gas Switch

1. Insufficient water level in system

2. Defective water level circuitry.

3. Defective water level probe.

1. Boiler not s eeing information from Modbus network

1. A/F Valve rotated open to purge and did not rotate to ignition position

1. Check for a jumper properly installed across the interlock terminals in the I/O box

2. If there are two external wires on these terminals check any Energy Management system to see if they have the units disabled (a jumper may be temporarily installed to see if the interlock circuit is functioning).

3. Check that proving switch for any device hooked to the interlock circuit is closing and that the device is operational.

1. Check Line (hot) and Neutral in AC Power Box to ensure they are not reversed

2. Check transformer wiring, in AC Power Box, against the power box transformer wiring diagram to ensure it is wired correctly

1. Measure gas pressure upstream of the supply gas regulator with the unit firing. Ensure it is at least 3.5” W.C. for FM gas train, or

4.0” W.C. for IRI gas train. Max. allowable pressure is 2 psig (see para. 2.7.1).

2. Measure gas pressure at the low gas pressure switch. If it is greater than 2.6” W.C., measure continuity across the switch and replace if necessary.

1. Check system for sufficient water level.

2. Test water level circuitry using the Control Box front panel LOW WATER TEST and RESET buttons. Replace water level circuitry if it does not respond.

3. Check continuity of probe end to the shell, change probe if there is no continuity.

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

8-8

Page 67

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 2. Defective or shorted switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

PRG SWTCH OPEN

DURING PURGE

OUTDOOR TEMP

SENSOR FAULT

REMOTE SETPT

SIGNAL FAULT

1. Defective purge switch.

2. No voltage present at switch.

3. Switch wired incorrectly.

4. Defective Power Supply Board or fuse

5. Defective IGST Board

1. Loose or broken wiring.

2. Defective Sensor.

3. Incorrect Sensor.

1. Remote setpoint signal not present: Not yet installed. Wrong polarity. Signal defective at source. Broken or loose wiring.

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

3. Control Box signal type selection switches not set for correct signal type (voltage or current).

2. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O. and COM terminals. If the switch shows continuity when not in c ontact w ith the c am, check to ens ure that the s witch is wired correctly (correct wire numbers on the normally open terminals).

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

4. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and ver ify it is blink ing ON & O FF every second. If not, replace IGST Board.

1. If the air -fuel valve does r otate, c heck the purge switch for continuity w hen c losing. Replac e s witch if c ontinuity does not exist.

2. Measure for 24 VAC f rom each s ide of the s witch to gr ound. If 24VAC is not present, refer fault to qualified service personnel.

3. Check to ens ure that the s witch is w ired c orrectly (correct wire numbers on the normally open terminals).

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

steady ON, replace Power Supply Board.

5. Check “Heartbeat” LED DS1 and ver ify it is blink ing ON & O FF every second. If not, replace IGST Board.

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

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

3. Ensure that the correct sensor is installed.

1. Check I/O Box to ensure signal is hooked up. Hook up if not installed. If installed, check polarity. Measure signal level. Check continuity of wiring between source and boiler.

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

3. Check DIP switch on PMC board to ensure it is set correctly for the type of signal being sent. Check control signal type set in Configuration Menu.

8- 9

Page 68

TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

RESIDUAL

FLAME

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING RUN

SSOV RELAY

FAILURE

SSOV

SWITCH OPEN

STEPPER MOTOR

FAILURE

1. SSOV not fully closed.

2. Defective Flame Detector

See SSOV SWITCH OPEN

1. SSOV switch c losed f or 15 s econds during run.

1. SSOV relay failed on board.

2. Floating Neutral.

3. Hot and Neutral reversed at SSOV.

1. Actuator not allowing for full closure of gas valve

2. SSOV powered when it should not be

3. Defective Switch or Actuator

4. Incorrectly wired switch.

1. Air/Fuel Valve out of calibration.

1. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.

Close gas shut-off valve downstream of SSOV. Install a manometer or gauge in a gas test port between the SSOV and the gas shut off valve. If a gas pressure reading is observed replace the SSOV valve and or actuator.

2. Replace Flame Detector.

1. Replace or adjust microswitch in SSOV actuator. If fault persists, replace actuator.

1. Press CLEAR button and restart unit. If fault persists, replace Ignition/Stepper (IGST) Board.

2. The Neutral and Earth Ground are not connected at the source and therefore there is a voltage measured between the two. Normally this measurement should be near zero or no more than a few millivolts.

3. Check SSOV power wiring.

1. Observe operation of the Safety Shut-Off Valve (SSOV) through indicator on the Valve actuator and ensure that the valve is fully and not partially closing.

2. If the SSOV never closes, it may be powered continuously. Close the gas supply and remove power from the unit. Refer fault to qualified service personnel.

3. Remove the electrical cover from the SSOV and check switch continuity. If the switch does not show continuity with the gas valve closed, either adjust or replace the switch or actuator.

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

1. Refer to GF-112 and perform Stepper Test (para. 6.3.5) to ensure stepper motor rotates properly between the 0% (fully closed) and 100% (fully open) positions. Verify that the VALVE POSITION bargraph and the dial on the Air/Fuel Valve track each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (GF-112, para. 6.2.1).

8- 10

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TROUBLESHOOTING

TABLE 8-1. BOILER TROUBLESHOOTING – Continued

FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION

(continued) 2. Air/Fuel Valve unplugged.

3. Loose w iring c onnection to the stepper motor.

4. Defective Air /Fuel Valve s tepper motor.

5. Defective Power Supply Board or fuse

6. Defective IGST Board

8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES

Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed.

TABLE 8-2. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED

2. Check that the Air/Fuel Valve is connected to the Control Box.

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

4. Replace stepper motor.

5. Check DS1 & DS2 LEDs on Power Supply Board. If they are not steady ON, replace Power Supply Board.

6. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board.

OBSERVED INCIDENT PROBABLE CAUSES CORRECTIVE ACTION

Hard Light-Off 1. Staged Ignition Ball Valve closed.

2. Clogged/damaged Ignitor- Injector (Figure 8-2).

3. Defective Staged Ignition Solenoid (Figure 8-2)

Fluctuating Gas Pressure 1. Gas pressure going into unit is

fluctuating.

2. Damping Orifice not installed.

Air/Fuel Valve “hunting” at 80%

valve position

8- 11

1. IGST and Power Supply Boards in Control Box are outdated.

1. Open the 1/4” Ball Valve downstream of the SSOV (Fig. 8-1).

2. Remove and inspect gas injector to ensure it is not clogged or damaged.

3. Close the 2” and the 1/4” Ball Valve downstream of the SSOV (Fig. 8-1). Start the unit and listen for a “clicking” sound that the Staged Ignition Solenoid makes during Ignition Trial. If “clicking” sound is not heard after 2 or 3 attempts, replace the Staged Ignition Solenoid.

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

2. Check to ensure that the Damping Orifice is installed in the SSOV Actuator (Figure 8-3). For IRI Gas Trains, the Damping Orifice is installed in the downstream SSOV Actuator.

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

Page 70

TROUBLESHOOTING

Figure 8-2

Staged Ignition Solenoid Location

Figure 8-1

High Pressure Gas Switch & Snubber Locat i ons

8-12

Figure 8-3

Damping Orifice Location

Page 71

CHAPTER 9 RS232 COMMUNICATION

9.1 INTRODUCTION

The RS232 port on the front panel of the C-More Control Box (Figure 3- 1) can be inter faced to a laptop computer or other suitable ter minal using a RS2 32 ad apter c able. R S232 c ommunication can be ac complished us ing any “ Dumb Terminal” e mulation, s uch as “ Hyper T erminal” which is inc luded with Mic rosoft Windows. T he RS232 c ommunication f eature per mits vie wing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays.

9.2 RS232 COMMUNICATION SETUP

Regardless of the ter minal em ulation uti lized, the f ollowing guidelines m ust be adh ered t o when setting up the RS232 communication link:

1. Baud Rate – T he baud r ates w hich c an be used with the C-More Control Panel are:

2400

4800

9600 (Default)

19.2 K

2. Data Format – The program must be set for:

8 data b its, 1 s top bit , no par ity a nd e ither Xon/Xoff or No flow control.

9.3 MENU PROCESSING UTILIZING

RS232 COMMUNICATION

Viewing dat a lo gs and viewing or c hanging Control Panel m enu op tions using R S232 communication is accomplished as follows:

RS232 COMMUNICATION

M = Display next Menu D = Display menu items N = Display next menu items Cxx = Change item xx F = Fault log display S = Sensor log display T = Time line display L = Log off

NOTE:

The Leve l 1 pas sword ( 159) m ust be entered to c hange op tions in the S etup, Configuration a nd T uning Me nus. T he Level 2 password (6817) must be entered to v iew or c hange o ptions in th e Calibration and Diagnostics Menus.

With the exception of the password entry, all other k eyboard entries c an be m ade

using either upper or lower case.

5. To view the available menus in the top-down

sequence s hown i n F igure 3- 2, enter M <Rtn>. T he Menu ti tle a nd f irst 10 options

will be displayed.

6. When vie wing m enus c ontaining m ore than

10 op tions, en ter N <Rtn> to display th e

remaining options.

7. Shortcut keys are also available to go directly to a specific menu. These shortcut keys are:

m0 Default (Operating) Menu m1 Setup Menu m2 Configuration Menu m3 Tuning Menu m4 Calibration Menu m5 Diagnostic Menu

1. Start th e em ulator s oftware pr ogram and ensure that the specified baud rate and data formats have been entered.

2. Press the Ent er k ey on the lap top. An asterisk (*) prompt should appear.

3. At the pr ompt, enter the va lid RS23 2 password (jaguar) in lower c ase l etters and press Enter.

4. “Welcome to Aer co” will appear in th e laptop or “ dumb ter minal” dis play with a listing of the following available entry choices:

8. To change a value or setting for a displayed menu option, proceed as follows:

(a) Enter C, fo llowed b y the number t o the

right of the dis played o ption to be

changed, and then press <Rtn>.

(b) Enter the desired value or setting for the

option and press <Rtn>. R efer to

Chapter 3, T ables 3- 2 t hrough 3-5 f or allowable entry r anges a nd s ettings f or the Operating, Setup, Configuration and Tuning Me nus. ( The Cal ibration a nd Diagnostic M enus s hould only be used by Factory-Trained service personnel).

9-1

Page 72

RS232 COMMUNICATION

volatile memory.

9. To r edisplay th e m enu and vie w t he opt ion which was j ust c hanged in s tep 5, enter D

and press <Rtn>.

10. To dis play the F ault (F) Log, Se nsor ( S) Lo g or T ime ( T) Line Lo g, pr ess F , S or T

followed by <Rtn>. Refer to paragraph 9.4 for

descriptions and samples of these data logs.

11. To log of f and ter minate the R S232 c om-

munication link, press L followed by <Rtn>.

9.4 DATA LOGGING

During oper ation, the C- More Con trol Panel continuously m onitors an d logs data as sociated with op erational e vents, f aults and s ensor readings as sociated with the b oiler or water heater s ystem. Des criptions of thes e d ata logs are pr ovided in t he f ollowing par agraphs. T he basic pr ocedure f or ac cessing each data log is described in paragraph 9.3, step 7.

9.4.1 Fault Log

9.4.2 Operation Time Log

The O peration T ime Log c onsists of a string of ASCII r ecords s tored i n non-volatile m emory within th e C- More C ontrol Panel. E vents s uch as po wer-up, i gnition a nd tur n-off ar e tim e stamped. Data logged while the unit is r unning are r un-length e ncoded. Data is lo gged or the run-length incremented every 30 seconds. For a new r un r ecord to be logged, t he f ire r ate or flame s trength m ust c hange b y m ore than 5%, or the r un mode must change. At steady-state, the run-length is allowed to reach a maximum of 30 m inutes bef ore th e r ecord is l ogged. T his means that no more than 30 minutes of data can be lost if the un it loses power. Table 9-2 shows a sample Operation Time Log for a boiler:

The O peration T ime Log c an only be ac cessed through th e RS 232 in terface us ing a l aptop or other t erminal d evice. Ten oper ation tim e records ar e d isplayed f or eac h T c ommand entry. T he op eration tim e lo g c an be c leared ONLY by factory authorized personnel using the Clear Log option in the Factory menu.

The C-More Control Panel logs the last 10 faults (0 – 9) s tarting with the m ost r ecent (#0). T hey can be v iewed i n the f ront pane l dis play or v ia the RS 232 por t. T he F ault L og c annot be cleared. If the F ault L og alr eady c ontains 10 faults, the earliest f ault is over written when a new f ault occurs. A s ample F ault L og display is shown in Table 9-1.

NOTE:

The O peration T ime ( T) Log c an s tore thousands of r ecords. T herefore, to vi ew the most recently logged record, enter “T” followed b y 0 ( zero) a nd pr ess Ent er (i.e. T 0 <En ter>). T o vi ew earlier r ecords in r everse c hronological or der, enter T and press Enter. To go ba ck 200 or 1000 records, ent er T 200 or T 1000, etc . an d press Enter.

NOTE:

The Sensor (S) Log can store up to 1200 records. T herefore, to view th e m ost recently logged record, enter “S” followed by 0 ( zero) and the n press Enter ( i.e. S0 <Enter>). T o v iew e arlier re cords i n reverse c hronological or der, enter S an d press Ent er. T o go bac k 200 or 7 00 records, enter S20 0 or S700, etc . an d

press Enter.

9.4.3 Sensor Log

The s ensor valu es c an be logg ed a t a d ifferent rate if needed by setting the Sensor Log Interval in t he Di agnostics Me nu. T he lo g interval c an vary from once every minute to onc e every day. Table 9- 3 shows a s ample Se nsor Lo g e very 5 minutes for a boiler running in Constant Setpoint mode.

9-2

Page 73

RS232 COMMUNICATION

Table 9-1. Sample Fault Log Display

No. Fault Message Cycle Date Time 0 Direct Drive Signal Fault 609 1/10/02 8:42am 1 Low Gas Pressure 366 7/04/01 5:29pm 2 Loss of Power 0 1/01/01 11:50am

Table 9-2. Sample Operation Time Log Display

Status Fire Rate Flame Run Length Date Time Off, Direct Drive 0 0 8 1/15/02 2:35pm Run, Direct Drive 38 100 34 1/15/02 2:27pm Run, Direct Drive 31 100 30 1/15/02 1:53am Run, Direct Drive 35 100 2 1/15/02 1:23pm Run, Direct Drive 29 100 0 1/15/02 1:21pm Ignition 0 0 0 1/15/02 1:20pm Off, Switch 0 0 35 1/15/02 12:30pm Run, Manual 40 100 0 1/15/02 11:55am Ignition 0 0 0 1/15/02 11:55am Power-up 0 0 0 1/15/02 11:50am

Table 9-3. Sample Sensor Log Display

Setpt Outlet Outdr FFWD Aux Inlet Exhst CO O2 Flow Date Time 130 181 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:51pm 130 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:41pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:36pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:31pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:26pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:21pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:16pm 130 179 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:11pm 130 180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:06pm

180 OPEN OPEN OPEN OPEN OPEN 0 .0 0 1/15/02 5:46pm

9-3

Page 74

Page 75

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS

MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the

control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode. When in the Constant Setpoint Mode, this value is equal to the Internal Setpoint setting in the Configuration Menu. When in the Remote Setpoint Mode, this value is the setpoint equivalent to the remote analog signal supplied to the unit. When in the Outdoor Reset Mode, this is the derived value from the charts in Appendix D.

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

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

Outdoor Temp Displayed only if outdoor sensor is installed and

enabled.

Valve Position In Desired input valve position. This would normally

be the same as the fire rate shown on the bargraph (valve position out) when the boiler is operating.

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

Run Cycles Displays the total number of run cycles from 0 to

999,999.

Run Hours Displays total run time of unit in hours from 0 to

9,999,999.

Fault Log Displays information on the last 20 faults.

A-1

Page 76

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED

MENU LEVEL & OPTION DESCRIPTION

SETUP MENU

Password Allows password to be entered.

Language Permits selection of English, Spanish or French for

Time Displays time from 12:00 am to 11:59 pm.

Date Displays dates from 01/01/00 to 12/31/99

Unit of Temp Permits selection of temperature displays in degrees

Comm Address For RS-485 communications (0 to 127). Default

Baud Rate Allows communications Baud Rate to be set (2400

Software Version Identifies the current software version of the control

Once the valid password (159) is entered, options in the Setup, Configuration and Tuning Menus can be modified.

displayed messages. Default is English.

Fahrenheit (°F) or degrees Celsius (°C). Default is °F.

address is 0. RS-232 should have its own (programmable) password.

to 19.2K). Default is 9600.

box (Ver 0.0 to Ver 9.9).

CONFIGURATION MENU

Internal Setpoint Allows internal setpoint to be set . Default is 130°F.

Unit Type Allows selection of KC Boiler, KC Boiler LN, BMK

Unit Size Sets unit size from 0.5 to 6.0 MBTUs. Default is 1.0

Fuel Type Allows selection of Natural Gas or Propane

Boiler Mode It allows selection of: Constant Setpoint, Remote

Remote Signal Used to set the type of external signal which will be

Bldg Ref Temp

Boiler, BMK Boiler LN, BMK Boiler Dual, KC Water Heater, KC Water Heater LN, Water Heater 2010

MBTU.

Setpoint, Direct Drive, Combination, or Outdoor Reset Mode. Default is Constant Setpoint Mode.

used when operating in the Remote Setpoint, Direct Drive or Combination Mode. The factory default is 4-20 mA/1-5V.

Allows the building reference temperature to be set when operating a boiler in the Outdoor Reset Mode. Default is 70°F.

A-2

Page 77

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU (Cont.)

Reset Ratio Permits setting of Reset Ratio when operating boiler

Outdoor Sensor Allows outdoor sensor function to be enabled or

System Start Tmp If outdoor sensor is enabled, this menu item allows

Setpoint Lo Limit Used to set the minimum allowable setpoint (40°F to

Setpoint Hi Limit Used to set the maximum allowable setpoint

Temp Hi Limit This is the maximum allowable outlet temperature

Max Valve Position Sets the maximum allowable valve position for the

in the Outdoor Reset Mode. Reset Ratio is adjustable from 0.1 to 9.9. Default is 1.2.

disabled. Default is disabled.

the system start temperature to be set from 30 to 100°F. Default is 60°F.

Setpoint Hi Limit). Default is 60°F

(Setpoint Lo Limit to 240°F). Default is 200°F.

(40 to 240°F). Any temperature above this setting will turn off the unit. The temperature must then drop 5° below this setting to allow the unit to run. Default Hi Limit is 210°F.

unit (40% to 100%). Default is 100%.

Pump Delay Timer Specifies the amount of time (0 to 30 min.) to keep

the pump running after the unit turns off. Default is zero.

Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.)

between activating the Aux Relay (due to a demand) and checking the pre-purge string to start the boiler. Default is 0 sec.

Failsafe Mode Allows the Failsafe mode to be set to either

Constant Setpoint or Shutdown. Default is Shutdown.

Analog Output Must be set to Valve Position 0-10V for Benchmark

3.0LN.

Lo Fire Timer Specifies how long (2 to 600 sec.) to remain in the

low fire position after ignition, before going to the desired output. Default is 2 sec.

Network Timeout Specifies the timeout value (seconds) before a

Modbus fault is declared. Available settings range from 5 to 999 seconds.

A-3

Page 78

APPENDIX A

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU (Cont.)

HI DB Setpt EN Operating at a Valve Position below this value will

Demand Offset This entry will reduce excessive ON/OFF cycling in

inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH.

Setting range is from 0 to 100. (Default is 30)

AUTO mode. When this entry is a non-zero value,

the unit will not turn on again until Valve Position In

reaches the Start Level value AND the Outlet

Temperature goes below the Active Setpoint – Demand Offset. In addition, the boiler will fire at the

29% Valve Position or below for a period of one minute.

When this entry is set to zero, the unit will turn on

again as soon as the Valve Position In reaches the Start Level value. There will not be a one minute

delay when firing at the 29% Fire Rate level.

Setting range is 0 to 25. (Default is 10)

Deadband High

Deadband Low

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

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

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

Setting range is 0 to 25. (Default is 2 for both Deadband High and Deadband Low)

A-4

Page 79

APPENDIX A

MENU LEVEL & OPTION DESCRIPTION

TUNING MENU

Prop Band Generates a fire rate based on the error that exists

between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%. If the error is equal to or greater than the proportional band setting, the fire rate will be 100%.

Integral Gain This sets the fraction of the output, due to setpoint

error, to add or subtract from the output each minute to move towards the setpoint. Gain is adjustable from 0.00 to 1.00 (Default is 0.10).

Derivative Time This value (0.0 to 20.0 min.) responds to the rate of

change of the setpoint error. This is the time that this action advances the output.

Reset Defaults? Allows Tuning Menu options to be reset to their

Factory Default values.

A-5

Page 80

Page 81

APPENDIX B

APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES

TABLE B-1. S TARTUP AND ST ATUS MESSAGES

MESSAGE DESCRIPTION

DEMAND DELAY

XX sec

DISABLED

HH:MM pm, pm

MM/DD/YY

FLAME PROVEN

IGNITION TRIAL

XX sec

PURGING

XX sec

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

WAIT Prompts the operator to wait.

WARMUP

XX sec

Displayed if Demand Delay is active.

Displayed if ON/OFF switch is set to OFF. The display also shows the time (am or pm) and date that the unit was disabled. Displayed after flame has been detected for a period of 2 seconds. Initially, the flame strength is shown in %. After 5 seconds has elapsed, the time and date are shown in place of flame strength. Displayed during ignition trial of startup sequence. The duration of cycle counts up in seconds. Displayed during the purge cycle during startup. The duration of the purge cycle counts up in seconds.

there is no demand for heat. The time and date are also displayed.

Displayed for 2 minutes during the initial warm-up only.

B-1

Page 82

APPENDIX B

FAULT MESSAGE FAULT DESCRIPTION

TABLE B-2. FAULT MESSAGES

AIRFLOW FAULT

DURING PURGE

AIRFLOW FAULT

DURING IGN

AIRFLOW FAULT

DURING RUN

DELAYED

INTERLOCK OPEN

DIRECT DRIVE SIGNAL FAULT

FFWD TEMP

SENSOR FAULT

FLAME LOSS

DURING IGN FLAME LOSS DURING RUN

HEAT DEMAND

FAILURE HIGH EXHAUST TEMPERATURE

HIGH GAS

PRESSURE

HIGH WATER

TEMPERATURE

HIGH WATER TEMP

SWITCH OPEN

IGN BOARD

COMM FAULT

IGN SWTCH CLOSED

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

INTERLOCK

OPEN

LINE VOLTAGE

OUT OF PHASE

LOW GAS

PRESSURE

LOW WATER

LEVEL

NETWORK COMM

FAULT

The Blower Proof Switch opened during purge, or air inlet is blocked.

The Blower Proof Switch opened during ignition.

The Blower Proof Switch opened during run.

The Delayed Interlock is open.

The direct drive signal is not present or is out of range.

The temperature measured by the Feed Forward (FFWD) Sensor is out of range. The Flame signal was not seen during ignition or lost within 5 seconds after ignition. The Flame signal was lost during run.

The Heat Demand Relays on the Ignition board failed to activate when commanded. The High Exhaust Temperature Limit Switch is closed.

The High Gas Pressure Limit Switch is open.

The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting. The High Water Temperature Limit Switch is open.

A communication fault has occurred between the PMC board and Ignition board. The Ignition Position Limit switch on the Air/Fuel Valve closed during purge. The Ignition Position Limit switch on the Air/Fuel Valve opened during ignition. The Remote Interlock is open.

The Line (Hot) and Neutral wires are reversed.

The Low Gas Pressure Limit Switch is open.

The Low Water Cutoff board is indicating low water level.

The RS-485 network information is not present or is corrupted.

B-2

Page 83

FAULT MESSAGE FAULT DESCRIPTION

OUTDOOR TEMP

SENSOR FAULT

OUTLET TEMP

SENSOR FAULT

PRG SWTCH CLOSED

DURING IGNITION

PRG SWTCH OPEN

DURING PURGE REMOTE SETPT

SIGNAL FAULT

RESIDUAL

FLAME

SSOV

SWITCH OPEN

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING IGN

SSOV FAULT DURING RUN SSOV RELAY

FAILURE

STEPPER MOTOR

FAILURE

APPENDIX B

TABLE B-2. FAULT MESSAGES - Continued

The temperature measured by the Outdoor Air Sensor is out of range. The temperature measured by the Outlet Sensor is out of range:

• OUTLET TEMPERATURE display = SHt Indicates sensor is shorted

• OUTLET TEMPERATURE display = OPn indicates sensor is open-circuited

The Purge Position Limit Switch on the Air/Fuel Valve closed during ignition. The Purge Position Limit Switch on the Air/Fuel Valve opened during purge. The Remote Setpoint signal is not present or is out of range.

The Flame signal was seen for more than 60 seconds during standby. The SSOV switch opened during standby.

The SSOV switch opened during purge.

The SSOV switch closed or failed to open during ignition.

The SSOV switch closed for more than 15 seconds during run. A failure has been detected in one of the relays that control the SSOV. The Stepper Motor failed to move the Air/Fuel Valve to the desired position.

B-3

Page 84

Page 85

APPENDIX C

TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART

(BALCO)

TEMP (°F) RES (OHMS) VOLTS*

-40

-30

-20

-10 0

10 20 30 40 50 60 70 80

90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

*Voltage at AUX & Common terminals in the I/O Box

779.0

797.5

816.3

835.4

854.8

874.6

894.7

915.1

935.9

956.9

978.3

1000.0

1022.0

1044.4

1067.0

1090.0

1113.3

1137.0

1160.9

1185.2

1209.5

1234.7

1260.0

1285.6

1311.4

1337.7

1364.2

1391.0

1418.2

1445.7

1.93

1.96

1.99

2.02

2.05

2.07

2.10

2.12

2.15

2.17

2.20

2.23

2.25

2.27

2.30

2.32

2.34

2.36

2.39

2.41

2.43

2.45

2.47

2.50

2.52

2.54

2.56

2.58

C-1

Page 86

Page 87

Air

Temp

50F 45F 40F 35F 30F 25F 20F 15F 10F

5F 0F

-5F

-10F

-15F

-20F

Air

Temp

60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F

5F 0F

-5F

-10F

-15F

-20F

APPENDIX D

APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS

Table D-1. Header Temperature for a Building Reference Temperature of 50F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

50 50 50 50 50 50 50 50 50 50 53 54 55 56 57 58 59 60 60 62 56 58 60 62 64 66 68 70 72 74 59 62 65 68 71 74 77 80 83 86 62 66 70 74 78 82 86 90 94 98 65 70 75 80 85 90 95 100 105 110 68 74 80 86 92 98 104 110 116 122 71 78 85 92 99 106 113 120 127 134 74 82 90 98 106 114 122 130 138 146 77 86 95 104 113 122 131 140 149 158 80 90 100 110 120 130 140 150 160 170 83 94 105 116 127 138 149 160 171 182 86 98 110 122 134 146 158 170 182 194 89 102 115 128 141 154 167 180 193 206 92 106 120 134 148 162 176 190 204 218

Table D-2. Header Temperature for a Building Reference Temperatrure of 60F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

60 60 60 60 60 60 60 60 60 60 63 64 65 66 67 68 69 70 71 72 66 68 70 72 74 76 78 80 82 84 69 72 75 78 81 84 87 90 93 96 72 76 80 84 88 92 96 100 104 108 75 80 85 90 95 100 105 110 115 120 78 84 90 96 102 108 114 120 126 132 81 88 95 102 109 116 123 130 137 144 84 92 100 108 116 124 132 140 148 156 87 96 105 114 123 132 141 150 159 168 90 100 110 120 130 140 150 160 170 180 93 104 115 126 137 148 159 170 181 192 96 108 120 132 144 156 168 180 192 204

99 112 125 138 151 164 177 190 203 216 102 116 130 144 158 172 186 200 214 105 120 135 150 165 180 195 210 108 124 140 156 172 188 204

D-1

Page 88

APPENDIX D

Table D-3. Header Temperature for a Building Reference Temperature of 65F

Air

Temp

65 60 55 50 45 40 35 30 25 20 15 10

5 0

-5

-10

-15

-20

Air

Temp

70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F

5F 0F

-5F

-10F

-15F

-20F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

65 65 65 65 65 65 65 65 65 65 68 69 70 71 72 73 74 75 76 77 71 73 75 77 79 81 83 85 87 89 74 77 80 83 86 89 92 95 98 101 77 81 85 89 93 97 101 105 109 113 80 85 90 95 100 105 110 115 120 125 83 89 95 101 107 113 119 125 131 137 86 93 100 107 114 121 128 135 142 149 89 97 105 113 121 129 137 145 153 161 92 101 110 119 128 137 146 155 164 173 95 105 115 125 135 145 155 165 175 185

98 109 120 131 142 153 164 175 186 197 101 113 125 137 149 161 173 185 197 209 104 117 130 143 156 169 182 195 208 107 121 135 149 163 177 191 205 219 110 125 140 155 170 185 200 215 113 129 145 161 177 193 209 116 133 150 167 201 218

Table D-4. Header Temperature for a Building Reference Temperature of 70F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

70 70 70 70 70 70 70 70 70 70

73 74 75 76 77 78 79 80 81 82

76 78 80 82 84 86 88 90 92 94

79 82 85 88 91 94 97 100 103 106

82 86 90 94 98 102 106 110 114 118

85 90 95 100 105 110 115 120 125 130

88 94 100 106 112 118 124 130 136 142

91 98 105 112 119 126 133 140 147 154

94 102 110 118 126 134 142 150 158 166

97 106 115 124 133 142 151 160 169 178 100 110 120 130 140 150 160 170 180 190 103 114 125 136 147 158 169 180 191 202 106 118 130 142 154 166 178 190 202 214 109 122 135 148 161 174 187 200 213 112 126 140 154 168 182 196 210 115 130 145 160 175 190 205 118 134 150 166 182 198 214 121 138 155 172 189 206 124 142 160 178 196 214

RESET RATIO

D-2

Page 89

APPENDIX D

Table D-5. Header Temperature for a Building Reference Temperature of 75F

RESET RATIO

Air

Temp

75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F

5F 0F

-5F

-10F

-15F

Air

Temp

80F 80 80 80 80 80 80 80 80 80 80 75F 83 84 85 86 87 88 89 90 91 92 70F 86 88 90 92 94 96 98 100 102 104 65F 89 92 95 98 101 104 107 110 113 116 60F 92 96 100 104 108 112 116 120 124 128 55F 95 100 105 110 115 120 125 130 135 140 50F 98 104 110 116 122 128 134 140 146 152 45F 101 108 115 122 129 136 143 150 157 164 40F 104 112 120 128 136 144 152 160 168 176 35F 107 116 125 134 143 152 161 170 179 188 30F 110 120 130 140 150 160 170 180 190 200 25F 113 124 135 146 157 168 174 190 201 212 20F 116 128 140 152 164 176 188 200 212 15F 119 132 145 158 171 184 197 210 10F 122 136 150 164 178 192 206

5F 125 140 155 170 185 200 215 0F 128 144 160 176 192 208

-5F 131 148 165 182 199 216

-10F 134 152 170 188 206

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

75 75 75 75 75 75 75 75 75 75

78 79 80 81 82 83 84 85 86 87

81 83 85 87 89 91 93 95 97 99

84 87 90 93 96 99 102 105 108 111

87 91 95 99 103 107 111 115 119 123

90 95 100 105 110 115 120 125 130 135

93 99 105 111 117 123 129 135 141 17

96 103 110 117 124 131 138 145 152 159

99 107 115 123 131 139 147 155 163 171 102 111 120 129 138 147 156 165 174 183 105 115 125 135 145 155 165 175 185 195 108 119 130 141 152 163 174 185 196 207 111 123 135 147 159 171 183 195 207 219 114 127 140 153 166 179 192 205 218 117 131 145 159 173 187 201 215 120 135 150 165 180 195 210 123 139 155 171 187 203 219 126 143 160 177 194 211 129 147 165 183 201 219

Table D-6. Header Temperature for a Building Reference Temperature of 80F

RESET RATIO

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

D-3

Page 90

APPENDIX D

Table D-7. Header Temperature for a Building Reference Temperature of 90F

RESET RATIO

Air

Temp

90F 85F 80F 75F 70F 65F 60F 55F 50F 45F 40F 35F 30F 25F 20F 15F 10F

5F 0F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

90 90 90 90 90 90 90 90 90 90

93 94 95 96 97 98 99 100 101 102

96 98 100 102 104 106 108 110 112 114

99 102 105 108 111 114 117 120 123 126 102 106 110 114 118 122 126 130 134 138 105 110 115 120 125 130 135 140 145 150 108 114 120 126 132 138 144 150 156 162 111 118 125 132 139 146 153 160 167 174 114 122 130 138 146 154 162 170 178 186 117 126 135 144 153 162 171 180 189 198 120 130 140 150 160 170 180 190 200 210 123 134 145 156 167 178 189 200 126 138 150 162 174 186 198 210 129 142 155 168 181 194 207 132 146 160 174 188 202 216 135 150 165 180 195 210 138 154 170 186 202 218 141 158 175 192 209 144 162 180 198 216

D-4

Page 91

APPENDIX E

MENU & OPTION FACTORY DEFAULT

BOILER DEFAULT SETTINGS

Setup Menu

Password 0

Language English

Unit of Temp Fahrenheit

Comm Address 0

Baud Rate 9600

Configuration Menu

Internal Setpt 130°F

Unit Type Boiler

Unit Size 1.5 MBTU

Boiler Mode Constant Setpoint

Remote Signal (If Mode = Remote Setpoint, Direct Drive or Combination)

Bldg Ref Temp (If Boiler Mode = Outdoor Reset)

4 – 20 mA / 1-5V

70°F

Reset Ratio (If Boiler Mode = Outdoor Reset)

Outdoor Sensor Disabled

System Start Tmp (If Outdoor Sensor = Enabled)

Setpt Lo Limit 60°F

Setpt Hi Limit 200°F

Temp Hi Limit

Max Fire Rate 100%

Pump Delay Timer 0 min

Aux Start On Dly 0 sec

Failsafe Mode Shutdown

Analog Output Fire Rate Out 0-10V

CAUTION: DO NOT Change

Lo Fire Timer 2 sec

Setpt Limit Band (If Setpt Limiting = Enabled) 5°F

1.2

60°F

215°F

E-1

Page 92

APPENDIX E

MENU & OPTION FACTORY DEFAULT

BOILER DEFAULT SETTINGS - Continued

Configuration Menu --Continued

Network Timeout 30 seconds

Hi DB Setpt En 30

Demand Offset 10

Deadband High 2

Deadband Low 2

Tuning Menu

Prop Band 70°F

Integral Gain 1.00

Derivative Time 0.0 min

E-2

Page 93

APPENDIX F

REV.

(71.1)

LIFTING LUGS

3/4" ELECTRICAL

7 15/16

MIN. RELIEF VA.

CONDUIT CONNECTION

(20.1)

CAPACITY MBH

3000

(38.0)

PANEL

DISPLAY

CONTROL

AP-A-811

(58.4)

DOOR SWING

(84.7)

64 (162.6)

6 7/8

(17.4)

(36.4)

14 5/16

(18.9)

7 7/16

OUTLET

8" EXHAUST

8" AIR INLET

78 (198.1)

(45.7)

(96.7)

THIS AREA TO BE

ACCESSIBLE FOR

MAINTENANCE.

(6.6)

2 5/8

4"-150# FLG'D

COLD WATER

INLET CONN.

PRESS. RELIEF VALVE

(201.4)

(93.2)

36 11/16

5 7/8

(14.9)

"B"

"C"

"A"

2" NPT NATURAL GAS

1" NPT GAS

VENT CONN.

INLET CONN.

FOR "IRI" GA S

TRAIN OPTION" ONLY

CONDENSATE PORT

NORTHVALE, NJ 07647

AERCO

CONDENSATE PORT

INLET CONN.

FOR DUAL-FUEL

2" NPT PROPANE GAS

1-1/2" NPT

OPTION ONLY

DRAIN CONN.

BENCHMARK 3 MIL. LOW NOx BTU

072606

GAS FIRED BOILER

UNIT FLUSH AT REAR

4" CONCRETE PAD - SET

SIZE

DATE

DIMENSIONAL DRAWINGS

DWN.BY

SCALE

REV.DATE

CHKD. APPD.

(32.4)

178

(39.2)

(64.6)

GAS TRAIN

13.5

(30.6)

12 1/16

(41.1)

16 3/16

(64.6)

25 7/16

WITH IRI

DUAL-FUEL

GAS TRAIN

SQ.FT.

HT'G SURFACE

240

TEST PRESS.

(PSIG)

SECTION VIII STAMP U (SECONDARY H.X.)

TEMP. (°F)

MAXIMUM

160 210

HEAT EXCHANGERS & COMBUSTION CHAMBER DESIGN STANDARDS

PRESS. (PSIG)

MAX. WORKING

ASME B & PV CODE: SECTION IV STAMP H (PRIMARY H.X.)

4"-150# FLG'D

PRESS./TEMP. GAUGE

HOT WATER OUTLET CONN. (SEE NOTE 3)

(137.0)

54 5/16

69 5/8

(176.9)

"C"

DIM.

"B"

DIM.

"A"

DIM.

MODEL

BMK3.0 LN

25 5/16

(64.3)

FOR IRI

N/A

(73.5)

28 15/16

ONLY

NAT. GAS

GAS TRAIN

42 1/8

(107.0)

OPTION

DUAL-FUEL

N/A

15 7/16

25 7/16

WITH FM

12 3/4

(34.3)

5 1/4

(13.3)

23 5/8 (60.0)

23 3/16 (58.8)

(LOCATED INSIDE THE BOILER) IS LEVEL OR SLOPING UP AS IT EXITS THE BOILER.

3) FIELD PIPING TO THE BOILER MUST ENSURE THAT THE HOT WATER OUTLET CONNECTION FLEXIBLE PIPING

2) RELIEF VALVE, TRIDICATOR & CONDENSATE TRAP ARE INCLUDED SEPARATELY IN SHIPMENT.

1) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS).

NOTES:

F-1

Page 94

APPENDIX F

(58.4)

(71.1)

REV.

(3.8)

1 1/2

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

GAS FIRED BOILER

AERCO

BENCHMARK 3 MIL. LOW NOx BTU

ANCHOR BOLT LOCATIONS

061506

DATE

SCALE

DWN.BY

SD-A-680

061506

DATE

APPD.

(93.7)

36 7/8

(157.5)

(162.6)

4 PL

ANCHOR HOLE 4 X Ø.75 (Ø1.91) THRU HOLES

(22.9)

(66.0)

F-2

3) ALL DIMENSIONS SHOWN ARE IN INCHES (CENTIMETERS)

1) DOTTED LINES REPRESENT BENCHMARK SHEET METAL

2) ALL HOLES ARE FLUSH WITH THE BOTTOM SURFACE OF THE FRAME

FRONT REAR

NOTES:

Page 95

APPENDIX F

REV.

TOP VIEWSIDE VIEW

24"

FRONT

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

GAS FIRED BOILER

BENCHMARK 3 MIL. BTU LOW NOx

AERCO

SD-A-683 C

061506

DATE

ZERO SIDE CLEARANCE INSTALLATION

APPD.

DWN.BY

SCALE

24"

56"

43"

(SEE NOTE)

REAR

18"

78"

101"

INSTALLATION CLEARANCES

LEFT AND RIGHT SIDES: 24''

FRONT: 24"

REAR: 43" (SEE NOTE)

CEILING HEIGHT: 101"

4) THE ZERO SIDE CLEARANCE OPTION CAN ONLY BE EMPLOYED IN

1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING

2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS:

3) THE INNER SIDE PANELS MUST BE REMOVED FROM BOTH UNITS

FOR ZERO SIDE CLEARANCE INSTALLATIONS

TWO UNIT SETS

79"

4" HIGH PAD

NOTE:

REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING

WHEN USING A REAR CLEARANCE OF LESS THAN 43", A 57" FRONT CLEARANCE

WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD.

COMPONENT SELECTION, ARRANGEMENT, AND LOCAL CODE REQUIREMENTS. HOWEVER,

F-3

Page 96

APPENDIX F

REV.

TOP VIEW

24"

FRONT

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

GAS FIRED BOILER

BENCHMARK 3 MIL. BTU LOW NOx

AERCO

SD-A-686 B

061506

DATE

INSTALLATION CLEARANCES

APPD.

DWN.BY

SCALE

28"

43"

(SEE NOTE)

REAR

SIDE VIEW

18"

78"

INSTALLATION CLEARANCES

LEFT AND RIGHT SIDES: 24''

FRONT: 24"

REAR: 43" (SEE NOTE)

CEILING HEIGHT: 101"

1) THIS APPLIANCE MAY BE INSTALLED ON COMBUSTIBLE FLOORING

2) MINIMUM CLEARANCES TO ADJACENT CONSTRUCTION ARE AS FOLLOWS:

101"

79"

4" HIGH PAD

REAR CLEARANCE MAY BE REDUCED TO 24" DEPENDENT UPON PIPING AND VENTING

NOTE:

COMPONENT SELECTION, ARRANGEMENT, AND LOCAL CODE REQUIREMENTS. HOWEVER,

WHEN USING A REAR CLEARANCE OF LESS THAN 43", A 57" FRONT CLEARANCE

WILL BE NEEDED TO ALLOW THE REMOVAL OF EXHAUST CONNECTING MANIFOLD.

F-4

Page 97

APPENDIX F

REV

1/8" NPT PLUG

(INSTALL MANOMETER HERE)

P/N: 22026-1

DRWN BY: SJD

DATE: 3/09/09

AP - A - 844

*NOT TO SCALE*

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

SWITCH

P/N: 61002-1

TO AIR/FUEL VALVE

ASSEMBLY

TEST COCK

LOW GAS PRESS

AERCO

ACTUATOR P/N: 64048

(INCLUDES RESISTOR)

SAFETY SHUT-OFF VALVE

P/N: 99017

P/N: 61002-3

PRESSURE SNUBBER

FM GAS TRAIN

BENCHMARK 3.0 LOW NOx

FM GAS TRAIN ASSY.

HIGH GAS PRESS SWITCH

2" NPT P/N: 123540

FULL PORT BALL VALVE

2" SCH. 40 PIPE

P/N: 124136

VALVE BODY

2" SAFETY SHUT-OFF

F-5

Page 98

APPENDIX F

TEST

(INSTALL

1/8" NPT PLUG

MANOMETER HERE)

COCK

SWITCH

P/N: 61002-1

LOW GAS PRESS.

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

BENCHMARK3.0 LOW NOx

IRI GAS TRAIN

SIZESCALE

DATE REV.

CZ 072806

NTS

AP-A-803

APPD.CHKD.

HIGH GAS PRESS.

AERCO

1" NORMALLY OPEN

VENT VALVE

SWITCH

P/N: 61002-3

SAFETY SHUT-OFF

VALVE ACTUATOR w/ GAS

PRESSURE ADJUSTMENT

P/N 64048

SAFETY SHUT-OFF

VALVE ACTUATOR

P/N 69038

P/N 123769

22026-2

ENTIRE ASSEMBLY PART NUMBER

DWN.BY

F-6

BOILER BOUNDARY

2" NPT

FULL PORT

P/N: 123540

BALL VALVE

TO AIR-FUEL VALVE ASS'Y

P/N: 124156

2" DOUBLE BODY

CONNECTING FLANGE

2" SAFETY SHUT-OFF

DOUBLE-BODY

GAS VALVE

P/N 124142

2"-SCH.40 PIPE

1"-SCH.40 PIPE

VENT TO ATMOSPHERE

PER ANSI Z223.1 (NFPA54)

Page 99

INTERNATIONAL, INC.

NORTHVALE, NJ 07647

APPENDIX F

REV.

PL-A-151 D

BURNER ACCESSORIES

072606

DATE

DWN.BY

APPD.

SIZE

CHKD.

SCALE

REV. DATE

BOLT, HEX HD SERRATED 1/4-20 X 1.75 LG

BENCHMARK 3.0 LOW NOx

QTY PART NUMBER DESCRIPTION

9 1 81019 GASKET, BURNER HOUSING

8 1 122377 SCREW, MACH #10-32 X 3/8 LG

7 2 9-75 PLUG, 1" NPT

6 1 59104 OBSERVATION PORT

5 1 24227 STAGED IGNITION ASSY, BMK LOW NOX

4 1 66006 FLAME ROD

3 1 46013 BURNER, BMK 3.0 LOW NOX

2 2 81030 GASKET, BURNER 9.65 DIA LOW NOX

19 1 44084 PLUG, GAS INJECTOR

18 1 81129 GASKET, PLUG

17 1 58023 IGNITOR-INJECTOR

16 4 123886 WASHER, FLAT #10

15 1 123534 PLUG, HEX 1/8 NPT

14 1 9-25 PLUG, 1/2" NPT

13 1 81048 GASKET, FLAME ROD LOW NOX

12 2 54016 SCREW, MACH #10-32 X .50 LG

11 1 54015 SCREW, MACH #8-32 X 3/8 LG

10 6 55027

1 1 43016 HOUSING, BURNER LOW NOX

NO.

ITEM

AERCO

F-7

Page 100

APPENDIX F

EXHAUST MANIFOLD

ITEM PART NO. QTY DESCRIPTION

39033 1 EXHAUST MANIFOLD

49102 3 EXHAUST MANIFOLD SEAL

39036 1 CONNECTING MANIFOLD

4 81098 1

GAS TRAIN ASSEMBLY

ITEM PART NO. QTY DESCRIPTION

22026-1

22026-2

(3)

ITEM PART NO. QTY DESCRIPTION

6 46013 1

8 24227 1

9 81030 2 BURNER GASKET

10 81019 1 BURNER HOUSING GASKET

22040-1

22040-2

BURNER & AIR/FUEL VALVE

24010

24010-1

EXHAUST MANIFOLD

ORIFICE GASKET

STD FM GAS TRAIN

ASSEMBLY

IRI GAS TRAIN ASSEMBLY

DUAL FUEL FM GAS TRAIN

DUAL FUEL IRI GAS TRAIN

BURNER

A/F VALVE ASSEMBLY

DUEL FUEL A/F VALVE ASSY.

BMK3.0LN STAGED

IGNITION ASSY.

HOSES,GASKETS, & INSULATION

ITEM PART NO. QTY DESCRIPTION

27 88003 1 O-RING #2-339

28 59041 1 HOSE ASSEMBLY, 4"

29 80024-8 1

30 80024-12 1

31 80021-12 1

32 80022 1 CONNECTING INSULATION

33 80023 2

34 4-58 3 4" FLANGE GASKET

35 62005 1 CORD GRIP

36 59030 1 HOSE ASSY, 4" (FLEXIBLE)

INSULATION 4" FLEX PIPE 8 LONG

INSULATION 4" FLEX PIPE 12" LONG

INSULATION 4" PIPE 12" LONG

TOP MANIFOLD INSULATION

HEAT EXCHANGER

ITEM PART NO. QTY DESCRIPTION

80018

12 80019 1

13 80020 1

14 28030 1 PRIMARY HEAT EXCH.

15 28029 1 SECONDARY HEAT EXCH.

ITEM PART NO. QTY DESCRIPTION

16 24045 1 BLOWER ASSEMBLY

17 123815 1 IRIS AIR DAMPER

18 123681 1

19 33028 1 BLOWER BRACKET

20 124245 4 5/16 DAMPENER

21 81057 1 BLOWER GASKET

22 96006 1 6" 90 DEG ELBOW

23 96009 1

24 96008 1 6" DIAM. x 4" LG DUCT

25 123990 1 REDUCER OFFSET COVER

26 123583 1 CLAMP HOSE SAE #96

PRIMARY HEAT EXCH.

UPPER INSULATION

PRIMARY HEAT EXCH.

LOWER INSULATION

SECONDARY HEAT EXCH.

INSULATION

BLOWER

8"x6" REDUCING COUPLING

6" DIAM. x 4" LG DUCT W/PORT

AERCO

INTERNATIONAL, INC. NORTHVALE, NJ 07647

BENCHMARK 3.0 LOW NOx

BOILER PARTS LIST

DRAWN BY SJD

DATE 2/18/09

PL - A - 150

(SHEET 1 OF 7)

F-8

AERCO BMK 3.0 LN Nat. Gas Jan 2011 User Manual Gas Jan 2011

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

Chapter 8- TROUBLESHOOTING GUIDE

APPENDIX A - BOILER MENU ITEM DESCRIPTIONS

APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES