Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BENCHMARK 6000
Gas-Fired Boiler
USER MANUAL
Natural Gas Modulating &
Installation, Opera ti on and Maintenance
Condensing Hot Water Boiler
Applicable to Serial Numbers:
N-14-0172 and Above
Latest Update: 03/20/14
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
Disclaimer
The information contain ed in this m anual is subjec t to change without not ice from AERC O
International, Inc. AERCO makes no warranty of any kind with respect to this material,
including but not lim ited to im plied warrant ies of merc hantabilit y and f itness f or a par ticular
application. AERCO International is not liable for erro rs appearing in this m anual. Nor for
incidental or consequential damages occurring in connection with the furnishing,
performance, or use of this material.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
FOREWORD .......................................................................................................................................... 7
CHAPTER 1. SAFETY PRECAUTIONS ................................................................................................ 11
1.1 WARNINGS & CAUTIONS ..................................................................................................................................... 11
1.2 EMERGENCY SHUTDOWN.................................................................................................................................... 12
1.3 PROLONGED SHUTDOWN ................................................................................................................................... 13
1.4 MASSACHUSETTS INSTALLATIONS ............................................................................................... 13
CHAPTER 2. INSTALLATION ............................................................................................................... 15
2.1 INTRODUCTION ................................................................................................................................................... 15
2.2 RECEIVING THE UNIT ........................................................................................................................................... 15
2.3 MOVING & UNPACKING THE UNIT ...................................................................................................................... 15
2.4 SITE PREPARATION .............................................................................................................................................. 16
2.4.1 Installation Clearances ................................................................................................................................. 16
2.4.2 Setting the Unit ............................................................................................................................................ 18
2.5 SUPPLY AND RETURN PIPING .............................................................................................................................. 19
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR INSTALLATION ............................................ 20
2.6.1 Pressure Relief Valve Installation ................................................................................................................. 20
2.6.2 Pressure/Temperature Gauge Installation ................................................................................................... 21
2.7 CONDENSATE DRAIN & PIPING ............................................................................................................................ 22
2.8 GAS SUPPLY PIPING ............................................................................................................................................. 23
2.8.1 Gas Supply Specifications ............................................................................................................................. 24
2.8.2 Manual Gas Shutoff Valve ............................................................................................................................ 24
2.8.3 External Gas Supply Regulator ..................................................................................................................... 24
2.8.3.1 Massachusetts Installations Only .......................................................................................................... 24
2.8.3.2 All Installations (Except Massachusetts) ............................................................................................... 24
2.9 AC ELECTRICAL POWER WIRING .......................................................................................................................... 25
2.9.1 Electrical Power Requirements .................................................................................................................... 27
2.10 FIELD CONTROL WIRING .................................................................................................................................... 27
2.10.1 OUTDOOR AIR IN Terminal ......................................................................................................................... 29
2.10.2 COMBUSTION AIR Terminal ....................................................................................................................... 30
2.10.3 O2 SENSOR Terminals ................................................................................................................................. 30
2.10.4 SPARK SIGNAL Terminals ............................................................................................................................ 30
2.10.5 ANALOG IN Terminals ................................................................................................................................. 30
2.10.6 B.M.S. (PWM) IN Terminals ........................................................................................................................ 30
2.10.7 SHIELD Terminals ........................................................................................................................................ 30
2.10.8 ANALOG OUT Terminals ............................................................................................................................. 30
2.10.9 RS485 Comm Terminals .............................................................................................................................. 31
2.10.10 RS232 Comm Terminals ............................................................................................................................ 31
2.10.11 VFD/BLOWER Terminals ........................................................................................................................... 31
2.10.12 Interlock Terminals ................................................................................................................................... 31
2.10.12.1 Remote Interlock In (OUT & IN)......................................................................................................... 31
2.10.12.2 Delayed Interlock In (OUT & IN) ........................................................................................................ 31
2.10.13 FAULT RELAY Terminals ............................................................................................................................ 32
2.10.14 AUX.RELAY Terminals ............................................................................................................................... 32
2.11 FLUE GAS VENT INSTALLATION ......................................................................................................................... 32
2.12 COMBUSTION AIR .............................................................................................................................................. 33
2.12.1 Combustion From Outside the Building ..................................................................................................... 33
2.12.2 Combustion Air from Inside the Building ................................................................................................... 33
2.13 DUCTED COMBUSTION AIR ............................................................................................................................... 34
2.14 SEQUENCING VALVE INSTALLATION .................................................................................................................. 34
CHAPTER 3. OPERATION .................................................................................................................... 37
3.1 INTRODUCTION ................................................................................................................................................... 37
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3.2 CONTROL PANEL DESCRIPTION ........................................................................................................................... 37
3.3 CONTROL PANEL MENUS ..................................................................................................................................... 41
3.3.1 Menu Processing Procedure ......................................................................................................................... 41
3.4 OPERATING MENU .............................................................................................................................................. 43
3.5 SETUP MENU ....................................................................................................................................................... 43
3.6 CONFIGURATION MENU ...................................................................................................................................... 44
3.7 TUNING MENU .................................................................................................................................................... 46
3.8 COMBUSTION CAL MENU .................................................................................................................................... 47
3.9 BST (Boiler Sequencing Technology ) Menu ........................................................................................................ 47
3.10 START SEQUENCE .............................................................................................................................................. 50
3.11 START/STOP LEVELS........................................................................................................................................... 55
CHAPTER 4. INITIAL START-UP.......................................................................................................... 59
4.1 INITIAL START-UP REQUIREMENTS ...................................................................................................................... 59
4.2 TOOLS AND INSTRUMENTATION FOR COMBUSTION CALIBRATION ................................................................... 59
4.2.1 Required Tools & Instrumentation ............................................................................................................... 60
4.2.2 Installing Gas Supply Manometer................................................................................................................. 60
4.2.3 Accessing the Analyzer Probe Port ............................................................................................................... 61
4.3 PILOT IGNITION ................................................................................................................................................... 62
4.4 NATURAL GAS COMBUSTION CALIBRATION ....................................................................................................... 62
4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION .............................................................................................. 67
CHAPTER 5. MODE OF OPERATION .................................................................................................. 69
5.1 INTRODUCTION ................................................................................................................................................... 69
5.2 INDOOR/OUTDOOR RESET MODE ....................................................................................................................... 69
5.2.1 Reset Ratio .................................................................................................................................................... 69
5.2.2 Building Reference Temperature ................................................................................................................. 69
5.2.3 Outdoor Air Temperature Sensor Installation .............................................................................................. 69
5.2.4 Indoor/Outdoor Reset Mode Startup ........................................................................................................... 69
5.3 CONSTANT SETPOINT MODE ............................................................................................................................... 70
5.3.1 Setting the Setpoint ...................................................................................................................................... 70
5.4 REMOTE SETPOINT MODES ................................................................................................................................. 71
5.4.1 Remote Setpoint Field Wiring ...................................................................................................................... 71
5.4.2 Remote Setpoint Startup .............................................................................................................................. 72
5.5 DIRECT DRIVE MODES ......................................................................................................................................... 72
5.5.1 Direct Drive Field Wiring............................................................................................................................... 73
5.5.2 Direct Drive Startup ...................................................................................................................................... 73
5.6 AERCO CONTROL SYSTEM (ACS) .......................................................................................................................... 73
5.6.1 ACS External Field Wiring ............................................................................................................................. 74
5.6.2 ACS Setup and Startup .................................................................................................................................. 74
5.7 COMBINATION CONTROL SYSTEM (CCS) ............................................................................................................. 74
5.7.1 Combination Control System Field Wiring ................................................................................................... 75
5.7.2 Combination Control System Setup and Startup .......................................................................................... 75
CHAPTER 6. SAFETY DEVICE TESTING ............................................................................................ 77
6.1 TESTING OF SAFETY DEVICES ............................................................................................................................... 77
6.2 LOW GAS PRESSURE FAULT TESTs ....................................................................................................................... 77
6.3 HIGH GAS PRESSURE FAULT TEST ........................................................................................................................ 79
6.4 LOW WATER LEVEL FAULT TEST .......................................................................................................................... 80
6.5 WATER TEMPERATURE FAULT TEST .................................................................................................................... 81
6.6 INTERLOCK TESTS ................................................................................................................................................ 82
6.6.1 Remote Interlock Test .................................................................................................................................. 82
6.6.2 Delayed Interlock Test .................................................................................................................................. 82
6.7 FLAME FAULT TESTs ............................................................................................................................................ 82
6.8 AIR FLOW FAULT TESTS ....................................................................................................................................... 83
6.8.1 Blower Proof Switch Test ............................................................................................................................. 84
6.8.2 Blocked Inlet Switch Test .............................................................................................................................. 85
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6.9 SSOV PROOF OF CLOSURE SWITCH ..................................................................................................................... 87
6.10 PURGE SWITCH OPEN DURING PURGE .............................................................................................................. 88
6.11 IGNITION SWITCH OPEN DURING IGNITION ...................................................................................................... 89
6.12 SAFETY PRESSURE RELIEF VALVE TEST............................................................................................................... 90
CHAPTER 7. MAINTENANCE ............................................................................................................... 91
7.1 MAINTENANCE SCHEDULE .................................................................................................................................. 91
7.2 PILOT BURNER ..................................................................................................................................................... 92
7.3 MAIN FLAME DETECTOR ...................................................................................................................................... 93
7.4 O2 SENSOR ........................................................................................................................................................... 94
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT ...................................................................... 95
7.5.1 Pilot Regulator Pressure Testing................................................................................................................... 95
7.5.2 Pilot Regulator Pressure Calibration ............................................................................................................. 97
7.6 SAFETY DEVICE TESTING ...................................................................................................................................... 98
7.7 BURNER ASSEMBLY INSPECTION ......................................................................................................................... 99
7.8 REFRACTORY REMOVAL & REPLACEMENT ........................................................................................................ 102
7.8.1 Rear Refractory Removal & Replacement .................................................................................................. 102
7.8.2 Front Refractory Removal & Replacement ................................................................................................. 106
7.9 CONDENSATE DRAIN TRAP ................................................................................................................................ 108
7.10 AIR FILTER CLEANING & REPLACEMENT .......................................................................................................... 109
7.11 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ............................................................. 110
7.12 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN .................................................. 110
CHAPTER 8. TROUBLESHOOTING GUIDE ...................................................................................... 111
8.1 INTRODUCTION ................................................................................................................................................. 111
8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ............................................................................ 124
CHAPTER 9. RS-232 COMMUNICATION ........................................................................................... 129
9.1 INTRODUCTION ................................................................................................................................................. 129
9.1.1 Aquiring the PuTTY Application .................................................................................................................. 129
9.1.2 Logging on to a Remote Machine Using PuTTY .......................................................................................... 129
9.1.3 Running a Command on a Remote Machine Using PuTTY ......................................................................... 130
9.2 RS-232 COMMUNICATION SETUP ..................................................................................................................... 131
9.3 MENU PROCESSING UTILIZING RS-232 COMMUNICATION ............................................................................... 131
9.4 DATA LOGGING .................................................................................................................................................. 132
9.4.1 Fault Log ..................................................................................................................................................... 133
9.4.2 Operation Time Log .................................................................................................................................... 133
9.4.3 Sensor Log .................................................................................................................................................. 134
CHAPTER 10. BOILER SEQUENCING TECHNOLOGY ...................................................................... 135
10.1 INTRODUCTION ............................................................................................................................................... 135
10.2 AERCO BST Quick Start Chart .......................................................................................................................... 136
10.3 BST Implementation Instruction ...................................................................................................................... 137
10.3.1 Option 1 - Constant Setpoint with DIRECT Wired Header Sensor ............................................................ 137
10.3.2 Option 2 - Constant Setpoint with MODBUS Wired Header Sensor......................................................... 138
10.3.3 Option 3 - Outdoor Reset with DIRECT WIRED Header Sensor AND DIRECT WIRED Outdoor Sensor ..... 139
10.3.4 Option 4 - Outdoor Reset with MODBUS Header Sensor AND MODBUS Outdoor Sensor ...................... 141
10.3.5 Option 5 - Remote Setpoint with DIRECT WIRED Header Sensor AND 4-20ma Setpoint Drive ............... 143
10.3.6 Option 6 - Remote Setpoint with DIRECT WIRED Header Sensor AND MODBUS Setpoint Drive............. 144
10.3.7 Option 7 - Remote Setpoint with MODBUS Header Sensor AND 4-20ma Setpoint Drive ........................ 145
10.3.8 Option 8 - Remote Setpoint with MODBUS Header Sensor AND MODBUS Setpoint Drive ..................... 147
APPENDIX A – BOILER MENU ITEM DESCRIPTIONS ................................................................................................. 149
APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES ........................................................................................ 157
APPENDIX C – SENSOR RESISTANCE/VOLTAGE CHART ............................................................................................ 161
APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS ...................................................................................... 163
APPENDIX E – BOILER DEFAULT SETTINGS .............................................................................................................. 167
APPENDIX F – CLEARANCE DRAWINGS .................................................................................................................... 169
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APPENDIX G – PARTS LIST DRAWINGS .................................................................................................................... 173
APPENDIX H – PIPING DRAWINGS ........................................................................................................................... 185
APPENDIX I: C-MORE WIRING DIAGRAMS .............................................................................................................. 189
APPENDIX J: RECOMMENDED PERIODIC TESTING .................................................................................................. 197
APPENDIX K – C-MORE CONTROL PANEL VIEWS ..................................................................................................... 199
APPENDIX L: RECOMMENDED SPARES ................................................................................................................... 201
APPENDIX M – LONG TERM BLOWER STORAGE ..................................................................................................... 203
APPENDIX N – ULTRA-LOW NOx CALIBRATION ....................................................................................................... 205
LIMITED WARRANTY ............................................................................................................................. 209
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Minimum
Maximum
Minimum
Maximum
FORWARD
FOREWORD
The AERCO Benchmark (BMK) 6000 MBH Boiler is a modulating and condensing unit. It
represents a true industry advancement that meets the needs of today's energy and
environmental concerns. Designed for application in any closed loop hydronic system, the
Benchmark's modulating capability relates energy input directly to fluctuating system loads. The
maximum turn down ratio for the BMK 6000 is 15:1. This BMK model provides extremely high
efficiency and makes it ideally suited for modern low temperature, as well as, conventional
heating systems.
The Benchmark Model BMK 6000 operates within the following input and output ranges:
Benchmark Model
BMK 6000 400,000 6,000,000 372,000 5,580,000
The output of the boiler is a function of the unit’s firing rate (valve position) and return water
temperature.
Input Range (BTU/hr.) Output Range (BTU/hr.)
When installed and operated in accordance with this Instruction Manual, the BMK 6000 MBH
Boiler complies with the NOx emission standards outlined in:
• South Coast Air Quality Management District (SCAQMD), Rule 1146.2
Whether used in singular or modular arrangements , the BMK 6000 offer the maximum venting
flexibility with minimum installation space requirements. These Boilers are Category II, III and IV,
positive pressure appliances. Single and/or multiple breeched units are capable of operation in
the following vent configurations:
• Conventional, Vertical
• Conventional, Sidewall
• Conventional, Direct Vent, Vertical
• Sealed, Direct Vent, Horizontal
These boilers are capable of being vented utilizing Polypropylene and AL29-4C vent systems.
The Benchmark's advanced electronics are available in several selectable modes of operation
offering the most efficient operating methods and energy management system integration.
IMPORTANT
Unless otherwise specified, all descriptions and procedures provided in this
Installation, Operation & Maintenance Manual apply to the Benchmark 6000
MBH boiler.
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Phrase, Abbreviation
Building Automation System, often used interchangeably with EMS
Symbol rate, or simply the number of distinct symbol changes
BLDG (Bldg)
Building
CCP
Combustion Control Panel
A control system developed by AERCO and currently used in all
COMM (Comm)
Communication
I.D.
Inside Diameter
FORWARD
Phrases, Abbreviations and Acronyms
or Acronym
Meaning
A (Amp) Ampere
ACS AERCO Control System, AERCO’s boiler management system
ADDR Address
AGND Analog Ground
ALRM Alarm
ASME American Society of Mechanical Engineers
AUX Auxiliary
BAS
(see below)
Baud Rate
(signaling events) transmitted per second. It is not equal to bits per
second, unless each symbol is 1 bit long.
BMK Benchmark series boilers
BST AERCO on-board Boiler Management Technology
BTU
British Thermal Unit. A unit of energy approximately equal to the heat
required to raise 1 pound of water 1° F.
C-More Controller
(or Control Box)
Benchmark, Innovation and KC1000 Series product lines.
CO Carbon Monoxide
Cal. Calibration
CNTL Control
DBB
Double Block and Bleed. Used to define boiler gas trains containing 2
Safety Shutoff Valves (SSOVs) and a solenoid operated vent valve.
Also known as IRI gas trains(see below)
DIP Dual In-Line Package
EMS Energy Management System; often used interchangeably with BAS
FM Factor y Mutual. Used to define boiler gas trains.
GND Ground
HDR Header
HX Heat Exchanger
Hz Hertz (Cycles Per Second)
IGN Ignition
IGST Board Ignition/Stepper Board contained in C-More Control Box
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Phrase, Abbreviation
or Acronym
sed to define gas
duplex data transmission protocol developed by AEG
Control Box used on all Benchmark units.
FORWARD
Phrases, Abbreviations and Acronyms - Continued
Meaning
INTLK (INTL’K) Interlock
I/O Input/Output
I/O Box
Input/Output (I/O) Box currently used on Benchmark, Innovation and
KC1000 Series products
IP Internet Protocol
IRI
Industrial Risk Insurers. A now discontinued code u
trains containing two SSOVs and a solenoid operated vent valve.
ISO Isolated
LED Light Emitting Diode
LN Low NOx
MA (mA) Milliampere (1 thousandth of an ampere)
MAX (Max) Maximum
MIN (Min) Minimum
Modbus®
A serial, half-
Modicon
NC (N.C.) Normally Closed
NO (N.O.) Normally Open
NOx Nitrogen Oxide
NPT National Pipe Thread
O2 Oxygen
O.D. Outside Diameter
PMC Board
A Primary Micro-Controller (PMC) board is contained in the C-More
PPM Par ts Per Million
PTP Point-to-Point (usually over RS-232 networks)
PWM Pul se Width Modulation
REF (Ref) Reference
RES. Resistive
RS232
(or EIA-232)
RS422
(or EIA-422)
RS485
(or EIA-485)
A standard for serial, full-duplex (FDX) transmission of data based on
the RS-232 Standard
A standard for serial, full-duplex (FDX) transmission of data based on
the RS-422 Standard
A standard for serial, half-duplex (HDX) transmission of data based on
the RS-485 Standard
RTN (Rtn) Return
SETPT (Setpt) Setpoint Temperature
SHLD (Shld) Shield
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Phrase, Abbreviation
or Acronym
order to prevent reflections that may cause invalid data in the
µA
Micro amp (1 millionth of an ampere)
FORWARD
Phrases, Abbreviations and Acronyms - Continued
Meaning
SSOV Saf ety Shut Off Valve
TEMP (Temp) Temperature
Terminating Resistor
A resistor placed at each end of a daisy-chain or multi-drop network in
communication
VAC Volts, Alternating Current
VDC Volts, Direct Current
VFD Vacuum Fluor escent Display, or Variable Frequency Drive
W Watt
W.C. Water Column
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
WARNING
WARNING
WARNING
CHAPTER 1 – SAFETY PRECAUTIONS
CHAPTER 1. SAFETY PRECAUTIONS
1.1 WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations. The
following warnings and cautions are general and must be given the same attention as specific
precautions included in these instructions. In addition to all the requirements included in this
AERCO Instruction Manual, the installation of units MUST conform with local building codes, or,
in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54)
for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers. Where applicable, the equipment
shall be installed in accordance with the current Installation Code for Gas Burning Appliances
and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should
be carefully followed in all cases. Authorities having jurisdiction should be consulted before
installations are made.
See pages 14 and 15 for important information regarding installation of units within the
Commonwealth of Massachusetts.
IMPORTANT
This Instruction Manual is an integral part of the product and must be
maintained in legible condition. It must be given to the user by the installer
and kept in a safe place for future reference.
DO NOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES
OF IGNITION TO CHECK FOR GAS LEAKS.
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
DAMAGE TO EQUIPMENT WHEN RELEASED. BE SURE TO SHUT OFF
ALL INCOMING AND OUTGOING WATER SHUTOFF VALVES.
CAREFULLY DECREASE ALL TRAPPED PRESSURES TO ZERO
BEFORE PERFORMING MAINTENANCE.
WARNING
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE
UNIT, SHUT OFF ALL GAS AND ELECTRICAL INPUTS TO THE UNIT.
WARNING
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER A
POSITIVE PRESSURE AND THEREFORE MUST BE COMPLETELY
SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO
LIVING SPACES.
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ELECTRICAL VOLTAGES UP TO 480 VAC MAY BE USED IN THIS
EQUIPMENT. THEREFORE THE COVER ON THE UNIT ’S POWER BOX
(LOCATED BEHIND T HE FRONT PANEL DOOR) MUST BE INSTALLED
AT ALL TIMES, EXCEPT DURING MAINTENANCE AND SERVICING.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
WARNING
CAUTION
CHAPTER 1 – SAFETY PRECAUTIONS
A THREE-POLE SWITCH MUST BE INSTALLED ON THE ELECTRICAL
SUPPLY LINE OF THE UNI T. THE SWITCH MUST BE INSTALL ED IN AN
EASILY ACCESSIBLE POSITION TO QUICKLY AND SAFELY
DISCONNECT ELECTRICAL SERVICE. DO NOT AFFIX SWITCH TO UNIT
SHEET METAL ENCLOSURES.
Many soaps used for gas pipe leak testing are corrosive to metals. The
piping must be rinsed thoroughly with clean water after leak checks have
been completed.
CAUTION
DO NOT use this boiler if any part has been under water. Call a qualified
service technician to inspect and replace any part that has been under
water.
1.2 EMERGENCY SHUTDOWN
If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve
(Figure 1-1) located external to the unit.
NOTE
The Installer must identify and indicate the location of the
emergency shutdown manual gas valve to operating personnel.
MANUAL GAS SHUT-OFF VALVE
Figure 1-1: Manual Gas Shutoff Valve
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VALVE OPEN VALVE CLOSED
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 1 – SAFETY PRECAUTIONS
1.3 PROLONGED SHUTDOWN
After prolonged shutdown, it is recommended that the startup procedures in Chapter 4 and the
safety device test procedures in Chapter 6 of this manual be performed to verify all systemoperating parameters. If there is an emergency, turn off the electrical power supply to the
AERCO boiler and close the manual gas valve located upstream of the unit. The installer must
identify the emergency shut-off device.
1.4 MASSACHUSETTS INSTALLATIONS
Boiler installations within the Commonwealth of Massachusetts must conform to the following
requirements:
• Boiler must be installed by a plumber or a gas fitter who is licensed within the
Commonwealth of Massachusetts.
• Prior to unit operation, the complete gas train and all connections must be leak tested
using a non-corrosive soap.
• AERCO provides an optional external CO Detector, part number 58092. It can be installed
and configured to simply sound an alarm or to shut down the boiler(s) if CO concentrations
rise above a configurable threshold. Contact your AERCO representative for details.
• The vent termination must be located a minimum of 4 f eet 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:
• INSTALLATION OF CARBON MONOXIDE DET ECTORS. At the time of installation of the
side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall
observe that a hard wired carbon monoxide detector with an alarm and battery back-up is
installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
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 t he services of q ualified licensed
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a
crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery
back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of
completion of installation, the owner shall have a period of thirty (30) days to comply with
the above requirements; provided, however, that during said thirty (30) day period, a batter y
operated carbon monoxide detector with an alarm shall be installed.
1. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as
required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/ UL
2034 listed and IAS certified.
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CHAPTER 1 – SAFETY PRECAUTIONS
2. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior
of the building at a minimum height of eight (8) feet above grade dir ectly 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".
3. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled
equipment shall not approve the installation unless, upon inspection, the inspector observes
carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR
5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in 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 PROVI DED.
When 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.
(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 referenced "special venting system" instructions shall be included with the appliance
or equipment installation instructions; 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 all Product Approved side wall horizontally vented
gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all
venting design instructions shall remain with the appliance or equipment at the completion of the
installation.
____________________________________________________________________________
[End of Extracted Information From 248 CMR 5.08 (2)]
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
CHAPTER 2. INSTALLATION
2.1 INTRODUCTION
This Chapter provides the descriptions and procedures necessary to unpack, inspect and install
the AERCO Benchmark Model BMK 6000 Boiler.
2.2 RECEIVING THE UNIT
Each Benchmark Boiler System is shipped as a single crated unit. The shipping weight for the
BMK 6000 Model is approximately 3500 pounds. T he unit must be moved with the proper rigg ing
equipment for safety and to avoid equipment damage. The unit should be completely inspected
for evidence of shipping damage and shipment completeness at the time of receipt from the
carrier and before the bill of lading is signed.
NOTE
AERCO is not responsible for lost or damaged freight. Each unit has a TipN-Tell indicator on the outside of the shipping container. This indicates if the
unit has been turned on its side during shipment. If the Tip-N-Tell indicator
is tripped, do not sign for the shipment. Note the information on the carrier’s
paperwork and request a freight claim and inspection by a claims adjuster
before proceeding. Any other visual damage to the packaging materials
should also be made clear to the delivering carrier.
2.3 MOVING & UNPACKING THE UNIT
While packaged in the shipping container, the unit can be moved using a forklift.
Carefully unpack the unit taking care not to damage the unit enclosure when cutting away
packaging materials
After unpacking, closely inspect the unit to make sure there is no evidence of damage not
indicated by the Tip-N-Tell indicator. Notify the freight carrier immediately if any damage is
detected.
The following accessories come standard with each unit and are either factory installed on the
unit or packed separately with the unit:
• Pressure/Temperature Gauge
• ASME Pressure Relief Valve
• Condensate Drain Trap (part no. 24060)
• 2” Gas Supply Shutoff Valve
When optional accessories are ordered, they may be packed with the unit, factory installed on
the unit, or packed and shipped in a separate container. Any standard or optional accessories
shipped loose should be identified and stored in a safe place until ready for installation or use.
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SHIPPING SKID
CHAPTER 2 – INSTALLATION
Figure 2-1: Benchmark 6000 Mounted on Shipping Skid
2.4 SITE PREPARATION
Ensure that the site selected for installation of the Benchmark Boiler includes:
• Access to AC Input Power at 208 VAC, Three-Phase, 60 Hz @ 30 Amps
OR 460 VAC, Three-Phase, 60 Hz @ 20 Amps
• Access to Natural Gas line at a minimum pressure of 14 inches W.C. with the unit in
operation (approximately 20” W.C. static).
2.4.1 Installation Clearances
The Benchmark Model 6000 Boiler dimensions and minimum acceptable clearances are shown
in Figure 2-2. The minimum clearance dimensions, required by AERCO, are listed below.
However, if Local Building Codes require additional clearances, these codes shall supersede
AERCO’s requirements. Minimum acceptable clearances required are as follows:
• Front : 36 inches (914 mm)
• Sides: 24 inches (610 mm)
• Rear: 24 inches (610 mm)
• Top: 18 inches (457 mm)
All gas piping, water piping and electrical conduit or cable must be arranged so that t hey do not
interfere with the removal of any panels, or inhibit service or maintenance of the unit.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Housekeeping pad
assembly
4” – 8”
CHAPTER 2 – INSTALLATION
IMPORTANT
Ensure that adequate clearance exists at the rear of the unit to permit
installation and service maintenance of the AERCO Condensate Trap. Refer
to section 2.7 for Condensate Trap installation details.
When using the AERCO Condensate Neutralizer Tank for condensate
drainage, the tank must be installed in a pit, OR the boiler and AERCO
Condensate Trap must be elevated higher than 4” above the floor. See
Condensate Neutralizer Tank Instructions TID-0074 for details.
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4” MINIMUM
Figure 2-2: Benchmark Boiler Model 6000 Clearances
should not extend
under the condensate
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
WARNING
CHAPTER 2 – INSTALLATION
KEEP THE UNIT AREA CLEAR AND FREE FROM ALL COMBUSTIBLE
MATERIALS AND FLAMMABLE VAPORS OR LIQUIDS
FOR MASSACHUSSETTS ONLY
For Massachusetts installations, the unit must be installed by a plumber or
gas-fitter who is licensed within the Commonwealth of Massachusetts. In
addition, the installation must comply with all requirements specified in
Chapter 1 (Safety Precautions), pages 14 and 15.
2.4.2 Setting the Unit
The unit must be installed on a concrete housekeeping pad, a minimum of 4 inches and a
maximum of 8 inches thick, to ensure proper condensate drainage (see NOTE below).
NOTE
When using the AERCO Condensate Neutralizer Tank for proper
condensate drainage, the Neutralizer Tank must be stored in a pit,
OR the boiler and AERCO Condensate Trap must be elevated
higher than 4” above the floor. Ensure that the condensate
assembly is not positioned above the housekeeping pad during
installation so as not to interference with condensate piping. See
Condensate Tank Instructions TID-0074 for details.
.
Two (2) lifting lugs are provided at the top of the primary heat exchanger as shown in Figure 2-3.
Cut the cardboard at marked locations to provide access to the lifting tabs.
Remove the four (4) lag screws securing the unit to the shipping skid, and, if still in place,
remove the front Top Panel. Lift the unit off the shipping skid and position it on the concrete
Housekeeping Pad (required) in the desired location.
WARNING
WHEN LIFTING OR MOVING THE BOILER: DO NOT ATTEMPT
TO MANIPULATE THE BOILER USING THE GAS TRAIN OR
BLOWER. A SPREADER BAR IS REQUIRED FOR ALL
VERTICAL LIFTS.
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LIFTING TABS
NOTE:
CHAPTER 2 – INSTALLATION
Remove the two top panels
to access the lifting tabs.
Figure 2-3: Boiler Lifting Provisions
If anchoring the unit, refer to the dimensional drawings in Appendix F for anchor locations.
In multiple unit installations, it is important to plan the position of each unit in advance. Sufficient
space for piping connections and future service/maintenance requirements must also be taken
into consideration. All piping must include ample provisions for expansion.
If installing a Combination Control Panel (CCP) system, it is important to identify the Combination
Mode Boilers in advance and place them in the proper physical location. Refer to Chapter 5 for
information on Combination Mode Boilers.
2.5 SUPPLY AND RETURN PIPING
The Benchmark Boiler utilizes 6” flanged fittings f or the water system supply and return piping
connections. The physical location of the supply and return piping connections are shown in
Figure 2-4. Refer to Appendix F, Drawing AP-A-901 for additional dimensional data.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
6” WATER OUTLET
AIR INLET
6” WATER INLET
2” GAS INLET
EXHAUST
CONDENSATE
CHAPTER 2 – INSTALLATION
MANIFOLD
DRAIN
Figure 2-4: Supply and Return Locations
2.6 PRESSURE RELIEF VALVE & PRESSURE/TEMPERATURE INDICATOR INSTALLATION
2.6.1 Pressure Relief Valve Installation
Depending on the pressure required, the Benchmark 6000 is supplied with either a single 2” or
two (2) 1¼“ ASME rated Pressure Relief Valves. The pressure rating for the relief valve must be
specified on the sales order. Available press ure ratings range from 30 psi to 160 psi, depending
on pressure vessel maximum rated pressure. Each pressure relief valve is furnished as a kit
(92102-Tab) which consists of the relief valve for the pressure rating specified on the Sales
Order. The appropriate size reducing bushing and nipple are also included in the kit. The
pressure relief valves, nipples and bushings are connected to 45º street elbows already installed
on the heat exchanger of the boiler. The relief valves are installed on the top of the boiler as
shown in Figure 2-5A. A suitable pipe joint compound should be used on all threaded
connections. Any excess should be wiped off to avoid getting any joint compound into the valve
body. Each relief valve must be piped to within 12 inches of the floor to prevent injury in the
event of a discharge. The discharge piping must be full size, without reduc t ion. No valves, or size
reductions are allowed in the discharge line. In multiple unit installations the discharge lines must
not be manifolded together. Each must be individually run to a suitable discharge location.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Figure 2-5: Pressure Relief Valve Installation Locations
2.6.2 Pressure/Temperature Gauge Installation
A manual Pressure/Temperature Gauge is included in the loose parts kit for installation for
installation in the boiler outlet piping. It must be installed so that the sensing bulb is inserted into
the hot water outlet flow from the boiler. Refer to Figure 2-5B for sample installations.
Figure 2-5B: Pressure/Temperature Gauge Installation Location
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
EXHAUST MANIFOLD
CONDENSATE DRAIN
ANALYZER PORT S
2” GAS INLET
CHAPTER 2 – INSTALLATION
2.7 CONDENSATE DRAIN & PIPING
The Benchmark Boiler is designed to condense water vapor from the flue products. Therefore,
the installation must have provisions for suitable condensate drainage or collection.
The condensate drain port is located on the exhaust manifold (Figure 2-6) at the rear of the unit.
This drain port must be connected to the condensate trap (part no. 24060), which is packed
separately within the unit’s shipping container. The condensate trap outlet connection features a
tapped 3/4” NPT drain port.
(2 EA., ONE ON
EACH SIDE)
OUTLET
Figure 2-6: Condensate Drain Connection Location
A sample condensate trap installation is shown in Figure 2-7. However, the actual installation
details for the trap will vary depending on the available clearances, housekeeping pad height/
dimensions and other prevailing conditions at the site. The following general guidelines must be
observed to ensure proper condensate drainage:
• The condensate trap inlet (Figure 2-7) must be level with, or lower than the exhaust
manifold drain port.
• The base of the condensate trap must be supported to ensure that it is level (horizontal).
• The trap must be removable for routine maintenance. AERCO recommends that a union
be utilized between the exhaust manifold condensate drain port and the trap inlet port.
While observing the above guidelines, install the condensate trap as follows:
Condensate Trap Installat ion
1. Connect the condensate trap inlet to the exhaust manifold drain connection by sliding the
trap inlet onto the drain port. Tighten the thumbscrew on the trap inlet.
2. At the condensate trap outlet, install a stainless steel or PVC 3/4” NPT nipple.
3. Connect a length of 1” I.D. polypropylene hose to the trap outlet and secure with a hose
clamp.
4. Route the hose on the trap outlet to a nearby floor drain.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CAUTION
WARNING
CAUTION
EXHAUST
gravity flow
COMBUTION
PROBE PORT
EXHAUST
MANIFOLD
3/4” NPT
NIPPLES
HOSE
CLAMP
T O
DRAIN
TRAP INLET INTEGRAL
1” DIAM.
HOSE
NOTE
ASSEMBLY.
4” MINIMUM
8” MAXIMUM
4”
CHAPTER 2 – INSTALLATION
If a floor drain is not available, a condensate pump can be used to remove the condensate to
drain. The maximum condensate flow rate is 40 GPH. The condensate drain trap, associated
fittings and drain line must be removable for routine maintenance.
Use PVC, stainless steel, aluminum or polypropylene for condensate drain
ANALYZER
piping (Figure 2-6). DO NOT use carbon or copper components.
ADAPTOR AND THUMBSCREW
TOP COVER
THUMB SREWS
(4 each)
CONDENSATE
TRAP (P/N 24060)
HOUSKEEPING
PAD MUST NOT
EXTEND
UNDER THE
CONDENSATE
2.8 GAS SUPPLY PIPING
The AERCO Benchmark Gas Components and Supply Design Guide, GF-2030 must be
consulted prior to designing or installing any gas supply piping.
MANIFOLD
DRAIN PORT
Tilt down 2° for
Figure 2-7: Sample Condensate Trap Installation
NEVER USE MATCHES, CANDLES, FLAMES OR OTHER
SOURCES OF IGNITION TO CHECK FOR GAS LEAKS
.
Many soaps used for gas pipe leak testing are corrosive to metals.
Therefore, piping must be rinsed thoroughly with clean water after
leak checks have been completed.
FLOOR
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CHAPTER 2 – INSTALLATION
NOTE
All gas piping must be arranged so that it does not interfere with
removal of any covers, inhibit service/maintenance, or restrict
access between the unit and walls, or another unit.
Benchmark 6000 MBH units contain a 2 inch NPT gas inlet connection on the back of the unit as
shown in Figure 2-4.
Prior to installation, all pipes should be de-burred and internally cleared of any scale, metal chips
or other foreign particles. Do not install any flexible connectors or unapproved gas fittings.
Piping must be supported from the floor, ceiling or walls only and must not be supported by the
unit.
A suitable piping compound, approved for use with natural gas, should be used. Any excess
must be wiped off to prevent clogging of components.
To avoid unit damage when pressure testing gas piping, isolate the unit from the gas supply
piping. At no time should the gas pressure applied to t he unit exceed 56” W.C. (2 psig). Leak
test all external piping thoroughly using a soap and water solution or suitable equivalent. The gas
piping used must meet all applicable codes.
2.8.1 Gas Supply Specifications
The gas supply input specifications to the unit for Natural Gas are as follows:
• The maximum static pressure to the unit must not exceed 56 inches W.C. (2 psi).
• The gas supply piping and pressure to the unit must be sufficient to provide 6000 cfh while
maintaining a gas pr essure of 14 inches W.C. for FM gas trains while in operation.
2.8.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line upstream of the boiler as shown
in Figure 2-8. Maximum allowable gas pressure to the boiler is 56” W.C. (2 psi).
2.8.3 External Gas Supply Regulator
An external gas pressure regulator is required on the gas inlet piping under most conditions (see
sections 2.8.3.1 and 2.8.3.2, below). Regulators must conform to the following specifications:
• The external natural gas regulator must be capable of regulating 300,000 – 6,000,000
BTU/HR of natural gas while maintaining a gas pressure of 14” W.C. minimum to the unit.
• A lock-up style regulator MUST be used when gas supply pressure will exceed 2 PSI.
2.8.3.1
For Massachusetts installations, a mandatory external gas supply regulator must be positioned
as shown in Figure 2-8. The gas supply regulator must be properly vented to outdoors. Consult
the local gas utility for detailed requirements concerning venting of the supply gas regulator.
Massachusetts Installations Only
2.8.3.2
For multi-unit installations (other than Massachusetts) that EXCEED 1 PSI gas pressure, a
separate external gas supply regulator, as shown in Figure 2-8, is highly recommended. No
regulator is required for gas pressures below 1 PSI of pressure, but above 2 PSI it is
mandatory. Consult the local gas utility for detailed requirements concerning venting of the
supply gas regulator.
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All Installations (Except Massachusetts)
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
NATURAL
2” MANUAL
GAS PRESSURE
CHAPTER 2 – INSTALLATION
GAS
SUPPLY
GAS SHUTOFF VALVE
REGULATOR
Figure 2-8: Manual Gas Shut-Off Valve Location
2.9 AC ELECTRICAL POWER WIRING
The AERCO Benchmark Electrical Power Wiring Guide, GF-2060, must be consulted prior to
connecting any AC power wiring to the unit. External AC power connections are made to the unit
inside the Power Box on the fr ont of the unit. Remove the unit’s front panel to access the Power
Box, which is mounted in the upper right corner of the unit as shown in Figure 2-9. Loosen the
four Power Box cover screws and remove the cover to access the AC terminal block
connections, and other internal components shown in Figure 2-10.
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Power Box,
FUSE BLOCKS (2)
TERMINAL BLOCKS
CHAPTER 2 – INSTALLATION
located in the
unit’s upper-
right corner.
TRANSFORMER
24V POWER
SUPPLY
12V POWER
SUPPLY
Figure 2-9: Power Box With Closed Cover
WIRE CONDUITS
POWER
BREAKER
With the exception of the transformer shown in Figur e 2-10, all of the components in the Power
Box are mounted on a DIN rail.
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Figure 2-10: Power Box Internal Components
NOTE
All electrical conduit and hardware must be installed so that it does
not interfere with the removal of any unit covers, inhibit
service/maintenance, or prevent access between the unit and walls
or another unit.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
2.9.1 Electrical Power Requirements
The Benchmark Boiler is available in two voltage configurations: either 208 VAC, three-phase, 60
Hz @ 30A or 460 VAC, thr ee-phase, 60 Hz @ 15A. The Power Box contains terminal blocks as
shown in Figure 2-10. In addition, a label showing the required AC power connections is
provided on the front cover of the Power Box, as shown in Figure 2-11.
Figure 2-11: Power Box Cover Labels – 208VAC (Left) and 460VAC (Right)
Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD
BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.
A double-pole switch must be installed on the electrical supply line in an easily accessible
location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet
metal enclosures of the unit.
After placing the unit in service, the ignition safety shutoff device must be tested. If an external
electrical power source is used, the installed boiler must be electrically bonded to ground in
accordance with the requirements of the authority having jurisdiction. In the absence of such
requirements, the installation shall conform to National Electrical Code (NEC), ANSI/NFPA 70
and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.
For electrical power wiring diagrams, see the AERCO Benchmark Electrical Power Guide, (GF-
2060).
2.10 FIELD CONTROL WIRING
Each unit is fully wired from the factory with an internal operating control system. No field control
wiring is required for normal operation. However, the C-More Control system used with all
Benchmark units does allow for some additional control and monitoring features. Wiring
connections for these features are made on the Input/Output (I/O) board located behind the
removable front panel assembly of the unit. The I/O board is located in the I/O Box. The I/O
board terminal strip connections are shown in Figure 2-13. All f ield wiring is installed fro m the
rear of the panel by routing the wires through one of the four bushings provided on the sides of
the I/O board.
Refer to the wiring diagram provided below the I/O Box (Figure 2-13) when making all wiring
connections.
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I/O Box,
CHAPTER 2 – INSTALLATION
located in the
unit’s upper-left
corner.
Figure 2-12a: Input/Output (I/O) Box Location
I/O PCB
BOARD
TERMINAL STRIPS
Figure 2-12b: Input/Output (I/O) Box Interior
NOTE
Use Figure 2-13 to determine the functions of the I/O PCB
connections. Do not use the silkscreened labels on the PCB itself,
as these may not match t he funct ion names. There is a diagram of
the connection functions on the cover of the I/O Box as well.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CAUTION
CHAPTER 2 – INSTALLATION
DO NOT make any connections to the I/O Box terminals labeled “NOT
USED”. Attempting to do so may cause equipment damage.
Figure 2-13: I/O Box Terminal Strips
2.10.1 OUTDOOR AIR IN Terminal
An OUTDOOR AIR IN terminal is used f or connecting an outdoor temperature sensor (AERCO
P/N GM-123525) as required primarily for the Indoor/Outdoor reset mode of operation. It can
also be used with another mode if it is desired to use the outdoor sensor enable/disable feature.
This feature allows the boiler to be enabled or disabled based on the outdoor air temperature.
The factory default for the outdoor sensor is DISABLED. To enable the sensor and/or select an
enable/disable outdoor temperature, see the Configuration menu in Chapter 3.
The outdoor sensor may be wired up to 200 feet from the boiler. It is connected to the
OUTDOOR AIR IN and AIR SENSOR COMMON terminals of the I/O Box (see Figure 2-13).
Wire the sensor using a twisted shielded pair wire between 18 and 22 AWG. There is no polarity
to observe when terminating these wires. The shield is to be connected only to the terminals
labeled SHIELD in the I/O Box. The sensor end of the shield must be left free and ungrounded.
When mounting the sensor, it must be located on the North side of the building where an
average outside air temperature is expected. The sensor must be shielded fr om direct sunlight
as well as impingement by the elements. If a shield cover is used, it must allow for free air
circulation.
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CHAPTER 2 – INSTALLATION
2.10.2 COMBUSTION AIR Terminal
The COMBUSTION AIR terminal is used to monitor the combust ion air temperature sensor. T h is
input is always enabled and is a “to view only” input that can be seen in the operating menu. The
sensor is an AERCO BALCO wire sensor Part No. 12449. A resistance chart for this sensor is
provided in APPENDIX C. This sensor is an active part of the combustion control system and
must be operational for accurate air/fuel mixing control.
2.10.3 O2 SENSOR Terminals
The O2 SENSOR (–) and O2 SENSOR (+) terminals are used to connect an external oxygen
sensor to the I/O box. The O
Control system after a 60 second warm-up period.
2.10.4 SPAR K SIGNAL Terminals
The SPARK SIGNAL terminals are not in use on the Benchmark 6000.
2.10.5 ANALOG IN Terminals
The ANALOG IN terminals (+ and –) are used when an external signal is used to change the
setpoint (Remote Setpoint Mode) of the boiler.
concentration is displayed in the operating menu of the C-More
2
Either a 4 to 20 mA /1 to 5 VDC or a 0 to 20 mA/ 0 to 5 VDC signal may be used to vary the setpoint or air/fuel valve position. The factory default setting is for 4 to 20 mA / 1 to 5 VDC, however
this may be changed to 0 to 20 mA / 0 to 5 VDC using the Configuration Menu described in
Chapter 3.
If voltage rather than current is selected as the drive signal, a DIP switch must be set on the
PMC Board located inside the Control Box. Refer to Appendix D of the C-More Control Panel
OMM, GF-112, for information on setting DIP switches.
All supplied signals must be floating (ungrounded) signals. Connections between the source and
the boiler’s I/O Box must be made using twisted shielded pair of 18–22 AWG wire such as
Belden 9841. Polarity must be maintained and the shield must be connected only at the source
end and must be left floating (not connected) at the Boiler’s I/O Box.
Whether using voltage or current for the drive signal, they are linearly mapped to a 40°F to 240°F
setpoint or a 0% to 100% air/fuel valve position. No scaling for these signals is provided
2.10.6 B.M.S. (PWM) IN Terminals
The two B.M.S. (PWM) IN terminals are only used to connect the legacy AERCO Boiler
Management Systems (BMS), which utilize a 12 millisecond, ON/OFF duty cycle and is Pulse
Width Modulated (PWM) to control valve position. A 0% valve position = a 5% ON pulse and a
100% valve position = a 95% ON pulse. Note that these connections cannot be used with the
ARECO Control System (ACS).
2.10.7 SHIELD Terminals
The two SHIELD terminals are used to terminate any shields used on sensor wires connected to
the unit. Shields must only be connected to these terminals.
2.10.8 ANALOG OUT Terminals
The ANALOG OUT terminals (+ & -) output from 0 to 20 mA and may be used to monitor
Setpoint, Outlet Temperature, Valve Position 4-20 mA, Valve Position 0-10v or be set to OFF.
Default sett ing in the C-More controller is Valve Position 0-10v and settings behave as follows:
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
• When 0-10VDC is selected, the voltage output is used by the controller to modulate the
combustion blower via the I/O Box terminals labeled VFD/Blower (Section 2.10.11).
• If On Board Boiler Sequencing Technology (BST) is enabled, the Analog Output terminals
are used to drive the isolation valve, open and closed.
• When the 4-20mA is selected for the Analog Output, the 0-10VDC is disabled at the
VFD/Blower terminals, and the selected output is available at the terminals labeled
Analog Output +/-.
2.10.9 RS485 Comm Terminals
The RS-485 communication terminals (+, GND, & -) are used when the boiler plant is being
controlled by an Energy Management System (EMS) or AERCO ACS (formerly BMS/BMS-II)
using Modbus (RS-485) communication.
2.10.10 RS232 Comm Terminals
The RS-232 communication terminals (TxD, RxD) permit a laptop computer or other suitable
terminal to be connected to the boiler. The RS-232 communication feature permits viewing or
changing of Control Panel menu options and also provides access to data logs showing fault and
sensor log displays.
2.10.11 VFD/BLOWER Terminals
These terminals (0-10 & AGND) send an analog sig nal to control the blower speed. When any of
the 4-20mA options is selected for the Analog Outputs (Section 2.10.8), the output from the
VFD/Blower terminals is disabled.
2.10.12 Interlock Terminals
The unit offers two interlock circuits for interfacing with Energy Management Systems and
auxiliary equipment such as pumps or louvers or other accessories. These interlocks are called
the Remote Interlock and Delayed Interlock ((REMOT E INTL’K IN and DELAYED INTL’K IN in
Figure 2-12). Both interlocks, described below, are factory wired in the closed position (using
jumpers).
NOTE
Both the Delayed Interlock and Remote Interlock must be in the
closed position for the unit to fire.
2.10.12.1
The remote interlock circuit is provided to remotely start (enable) and stop (disable) the unit
if desired. The circuit is 24 VAC and comes factory pre-wired closed (jumped).
2.10.12.2
The Delayed Interlock terminals can be used in one of two ways:
Remote Interlock In (OUT & IN)
Delayed Interlock In (OUT & IN)
• In conjunction with the optional external sequencing valve (see section 2.14 and
Chapter 10 – BST), a component of AERCO’s on-board Boiler Sequencing
Technology (BST) solution. By default a cable of the boiler’s wiring harness is
connected to these terminals. If BST is implemented, the other end of that cable is
connected to the sequencing valve.
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CHAPTER 2 – INSTALLATION
• If BST is NOT implemented, the second use is typically in conjunction with the
AUXILIARY RELAY CONTACTS described in section 2.10.14. This interlock circuit is
located in the purge section of the start string. It can be connected to the proving
device (end switch, flow switch etc.) of an auxiliary piece of equipment started by the
unit’s auxiliary relay. If the delayed interlock is connected to a proving device that
requires time to close (make), a time delay (AUX START ON DLY) that holds the
start sequence of the unit long enough for a proving switch to make (close) can be
programmed.
To use this option, you must disconnect the harness from the Delayed Interlock
terminals and connect the proving device in its place.
Should the proving switch not prove within the programmed time frame, the unit will
shut down. The AUX START ON DLY can be programmed from 0 to 120 seconds.
This option is located in the Configuration Menu (Chapter 3).
2.10.13 FAULT RELAY Terminals
The fault relay is a single pole double throw (SPDT) relay having a normally open and normally
closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 VDC. The
relay energizes when any fault condition occurs and remains energized until the fault is cleared
and the CLEAR button is depressed. The fault relay connections are shown in Figure 2-13.
2.10.14 AUX.RELAY Terminals
Each unit is equipped with a single pole double throw (SPDT) auxiliary relay that is energ ized
when there is a demand for heat and de-energized after the demand for heat is satisfied. The
relay is provided for the control of auxiliary equipment, such as pumps and louvers, or can be
used as a unit status indictor (firing or not firing). Its contacts are rated for 120 VAC @ 5 amps.
Refer to Figure 2-13 to locate the AUX.RELAY terminals (N.C., COM, & N.O.) for wiring
connections.
2.11 FLUE GAS VENT INSTALLATION
The AERCO Gas Fired Venting and Combustion Air Guide, GF-2050 must be consulted before
any flue or combustion air venting is designed or installed. Suitable, U/L approved, positive
pressure, watertight vent materials MUST be used for safety and UL certification. Because the
unit is capable of discharging low temperature exhaust gases, the flue must be pitched back
towards the unit a minimum of 1/4" per foot to avoid any condensate pooling and to allow for
proper drainage.
While there is a positive flue pressure during operation, the combined pressure drop of vent and
combustion air systems must not exceed 140 equivalent feet or 1.9” W.C. Fittings as well as
pipe lengths must be calculated as part of the equivalent length. For a natural draft installation
the draft must not exceed - 0.25” W.C. These factors must be planned into t he vent inst allation. If
the maximum allowable equivalent lengths of piping are exceeded, the unit will not operate
properly or reliably.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Selkirk Corporation - Heatfab Division
Watertown Supply
M. A. Peacard
Glover Sheet Meatal, Inc.
CHAPTER 2 – INSTALLATION
For Massachusetts installations, the following companies provide vent systems which conform to
all applicable requirements for installations within the Commonwealth of Massachusetts. Contact
infor mation i s as follows:
130 Industrial Blvd.
Turners Falls, MA 01376
Phone: 1-800-772-0739
www.heat-fab.com
1250 Massachusetts Ave.
Boston MA 02125-1689
Phone: (617) 288-0629
www.mapeacard.com
33Grove St.
Watertown, MA 02472
Phone: (617) 924-2840
http://www.watertownsupply.com/
44 Riverdale Ave.
Newton, MA 02485
Phone: (617) 527-8178
www.gloversheetmetal.com
2.12 COMBUSTION AIR
The AERCO Benchmark Boiler Venting and Combustion Air Guide, GF-2050 MUST be
consulted before any flue or inlet air venting is designed or installed. Air supply is a direct
requirement of ANSI 223.1, NFPA-54, CSA B149.1 and local codes. These codes should be
consulted before a permanent design is determined.
The combustion air must be free of chlorine, halogenated hydrocarbons or other chemicals that
can become hazardous when used in gas-fired equipment. Common sources of these
compounds are swimming pools, degreasing compounds, plastic processing, and refrigerants.
Whenever the environment contains these types of chemicals, combustion air MUST be supplied
from a clean area outdoors for the protection and longevity of the equipment and warranty
validation.
The more common methods of combustion air supply are outlined in the following sections. For
combustion air supply from ducting, consult the AERCO GF-2050, Gas Fired Venting and
Combustion Air Guide.
2.12.1 Combustion From Outside the Building
Air supplied from outside the building must be provided through two permanent openings. For
each unit these two openings must have a free area of not less than one square inch for each
4000 BTUs input of the equipment or 1,500 square inches of free area. The free area must take
into account restrictions such as louvers and bird screens. For Canada installations, refer to the
requirements specified in CSA B149.1-10, sections 8.4.1 and 8.4.3.
2.12.2 Combustion Air from Inside the Building
When combustion air is provided from within the building, it must be supplied through two
permanent openings in an interior wall. Each opening m ust have a f r ee area of not less than one
square inch per 4000 BTUH of total input or 1500 square inches of free area. The free area must
take into account any restrictions, such as louvers.
The source of internal combustion air must be positive or neutral in
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pressure. Negative pressure inside a boiler room may have an adverse
effect on combustion equipment.
NOTE
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
HOT WATER
SEQUENCING
CHAPTER 2 – INSTALLATION
2.13 DUCTED COMBUSTION AIR
For ducted combustion air installations, the air ductwork must then be at tached directly to the air
inlet connection on the sheet metal enclosure.
In a ducted combustion air application, the combustion air ducting pressure losses must be taken
into account when calculating the total maximum allowable venting run. See the AERCO
Benchmark Venting and Combustion Air Guide, GF-2050. When using the unit in a ducted
combustion air configuration, each unit must have a minimum 8 inch d iameter connection at the
unit.
2.14 SEQUENCING VALVE INSTALLATION
All Benchmark units are shipped with a connection for an optional motorized external sequencing
valve (p/n 92084-TAB) included in the shipping container. This valve is an integral component of
the AERCO’s on-board Boiler Sequencing Technology (BST) solution. BST allows sites with
multiple boilers to have one boiler, acting as a “master” to manage the other boilers at the site in
such a way that the efficiency of the entire boiler array is maximized.
The implementation of BST, and the installation and use of this valve is optional.
The boiler IS pre-wired to accept the sequencing valve. Installation consists of installing the
sequencing valve in the hot water outlet pipe, and then connecting it into the shell harness, as
described below.
1. Install the sequencing valve in the boiler’s hot water outlet pipe.
VALVE
OUTLET
Figure 2-13: Sequencing Valve Installed
2. The boiler’s shell harness has one unused cable. One end of this cable is connected to the
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DELAYED INTERLOCK IN terminals in the I/O board (see Figure 2-14) while the other end
contains a Molex connector with a jumper wire inserted in it (this jumper wire allows units
that do not have a sequencing valve to operate normally). Find the free end of this cable
inside the unit’s enclosure.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 2 – INSTALLATION
Figure 2-14: Sequencing Valve Installed
3. Remove the jumper wire from the Molex connector and then plug it into the sequencing
valve’s connector.
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CHAPTER 2 – INSTALLATION
(This Page Is Intentionally Blank)
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CAUTION
CHAPTER 3 – OPERATION
CHAPTER 3. OPERATION
3.1 INTRODUCTION
The information in this Chapter provides a guide t o the operation of the Benchmark Boiler using
the Control Panel mounted on the front of the unit. It is imperative that the initial startup of this
unit be performed by factory trained personnel. Operation prior to initial startup by factory trained
personnel may void the equipment warranty. In addition, the following WARNINGS and
CAUTIONS must be observed at all times.
WARNING
ELECTRICAL VOLTAGES IN THIS SYSTEM INCLUDE 460 OR 208, 120
AND 24 VOLTS AC. IT MUST BE SERVICED ONLY BY FACTORY
CERTIFIED SERVICE TECHNICIANS.
WARNING
DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTING THE UNIT
WITHOUT A FULL WATER LEVEL CAN SERIO USLY DAMAG E THE UNIT
AND MAY RESULT IN INJURY TO PERSONNEL OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID ANY WARRANTY.
All of the installation procedures in Chapter 2 must be completed before
attempting to start the unit.
3.2 CONTROL PANEL DESCRIPTION
All Benchmark Series Boilers utilize the C-More Control Panel shown in Figure 3-1. This panel
contains all of the controls, indicators and displays necessary to operate, adjust and troubleshoot
the boiler. These operating controls, indicators and displays are listed and described in Table 3-
1. Additional information on these items is provided in the individual operating procedures and
menu descriptions provided in this Chapter.
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3 1 8 9 10
11 7 6
5
*4
12
2
CHAPTER 3 – OPERATION
Figure 3-1: Control Panel Front View
*NOTE
If there is a requirement to use the RS232 port (Item 4) on the CMore controller front panel, contact AERCO to purchase the RS232
Adaptor Cable (P/N 124675), which is designed for this purpose.
This cable features a DB9 connector for connection to older
computers with serial ports or can be used with a Serial-to-USB
adaptor for use in modern computer USB ports.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
indicate whether the displayed temperature is in degrees
blinks when
On a BST Master, display flashes & shows header temperature.
• BST Messages
permits a Laptop Computer or External Modem to be
connected to the unit’s Control Panel. AERCO offers for
purchase the RS232 Adaptor Cable (P/N 124675), which is
designed to work with this port. This cable features a DB9
USB adaptor for use in modern
and cannot be cleared by simply pressing this key.
8
CHAPTER 3 – OPERATION
Table 3-1: Operating Controls, Indicators and Displays
ITEM
1
2
3
FEATURE FUNCTION
LED Status Indicators
Four Status LEDs indicate the current operating status as follows:
COMM
MANUAL
REMOTE
DEMAND
OUTLET
TEMPERATURE
Display
VFD Display
Lights when RS-232 communication is occurring.
Lights when the valv e position (fire rat e) is being contr olled using
the front panel keypad. This mode of operation is for service
technician use only.
Lights when the unit is bein g controlled b y an external s ignal from
an Energy Management System.
Lights when there is a demand for heat.
3–Digit, 7–Segm ent LED display continuousl y displays the outlet
water temperature. T he °F or °C LED next t o the dis pla y lights to
Fahrenheit or degrees Celsius. The °F or °C
operating in the Deadband Mode.
Vacuum Fluorescent Display (VFD) consists of 2 lines each
capable of displaying up to 16 alphanumeric characters. The
information displayed includes:
• Startup Messages
• Fault Messages
• Operating Status Messages
• Menu Selection
Port
RS-232 Port
4
connector for connection to older computers with serial ports or
can be used with a Serial-tocomputer USB ports.
FAULT Indicator
5
CLEAR Key
6
READY Indicator
7
ON/OFF Switch
LOW WATER LEVEL
9
TEST/RESET Switches
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Red FAULT LED indicator lights when a boiler alarm condition
occurs. An alarm message will appear in the VFD.
Turns off the FAULT indicator and clears the alarm message if
the alarm is no longer valid. Lockout type alarm s will be latched
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 t he water level pro be circuit and sim ulates
a Low Water Level alarm.
Pressing RESET resets the water level monitor circuit.
Pressing the CLEAR key (item 6) resets the display.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
key will select the displayed menu category. If the
status LED lights.
Bargraph
CHAPTER 3 – OPERATION
Table 3-1: Operating Controls, Indicators and Displays – Continued
ITEM
10
FEATURE FUNCTION
MENU Keypad
Six (6) keys provide the following functions for the Control Panel Menus:
MENU
BACK
▲ (UP) Arrow
▼ (DOWN) Arrow
CHANGE
ENTER
Steps through the main m enu categories shown in Figure 3-2. The
Menu categories wrap around in the order shown.
Allows you to go back to the prev ious menu level without changing
any information. Continuo usly pressing this key will bring you back
to the default status display in th e VFD. Also, this key allows you to
go back to the top of a main menu category.
When in one of the main m enu categories (Figur e 3-2), pressing t he
▲ arrow
CHANGE key was pres sed and the menu item is flashing, pressing
the ▲ arrow key will increment the selected setting.
When in one of the main menu cate gories (Figure 3-2), 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). W hen the CHANGE key is
pressed, the displa yed menu item will begin t o f lash. Pressing the ▲
or ▼ arrow k e y when th e i t em is flashing will inc rement or decrement
the displayed setting.
Saves the modified m enu settings in memor y. The display will stop
flashing.
11 AUTO/MAN Switch
12
VALVE POSITIO N
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
Manual operation is for service onl y.
When in the Automatic ( AUTO) mode, the MANUAL stat us LED will
be off and the front panel controls disabled.
20 segment red LED bar gr aph c ont in uously shows the Air/Fuel Va lve
position in 5% increments from 0 to 100%
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 3 – OPERATION
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 password levels to prevent unauthorized use.
Prior to entering the correct password, the options contained in the Operation, Setup,
Configuration and Tuning Menu categories can be viewed. However, with the exception of
Internal Setpoint Temperature (Configuration Menu), none of the viewable menu options can be
changed.
Once the valid level 1 password (159) is entered, the options listed in the Setup. Configuration
and Tuning Menus can be viewed and changed, if desired. The Combustion Cal Menu is
protected by the level 2 password (6817), which is used in Chapter 4 to perform combustion
calibration prior to service use.
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:
Menu Processing Procedure
1. The Control Panel will normally be in the Operating Menu and the VFD will display the
current unit status. Pressing the ▲ or ▼ arrow key will display the other available data
items in the Operating Menu.
2. Press the MENU key. The display will show the Setup Menu, which is the next menu
category shown in Figure 3-2. This menu contains the Password option which must be
entered if other menu options will be changed.
3. Continue pressing the MENU key until the desired menu is displayed.
4. With the desired menu displayed, press the ▲ or ▼ arrow key. The first option in the
selected menu will be displayed.
5. Continue to press the ▲ or ▼ arrow key until the desired menu option is displayed.
Pressing the ▲ arrow key will display the available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will display the options in the Bottom-Up sequence.
The menu options will wrap-around after the first or last available option is reached.
6. To change the value or set ting of a displayed menu option, press the CHANGE key. The
displayed option will begin to flash. Press the ▲ or ▼ arrow key to scroll through the
available menu option choices for the option to be changed. The menu option choices do
not wrap around.
7. To select and store a changed menu item, press the ENTER key.
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CHAPTER 3 – OPERATION
* Only if BST is enabled (see Chapter 10)
Figure 3-2: Menu Structure
NOTE
The following sections provide brief descriptions of the options
contained in each menu. Refer to Appendix A for detailed
descriptions of each menu option. Refer to Appendix B for listings
and descriptions of displayed startup, status and error messages.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Minimum
Maximum
Active Setpoint
40°F
240°F
Inlet Temp
40°F
140°F
Air Temp
-70°F
245°F
Outdoor Temp*
-70°F
130°F
Valve Position In
0%
100%
Valve Position Out*
0%
100%
Exhaust Temp
°F
°F
Flame Strength
0%
100%
Oxygen Level
0%
21%
Run Cycles
0
999,999,999
Run Hours
0
999,999,999
Fault Log
0
19
0
CHAPTER 3 – OPERATION
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).
Table 3-2: Operating Menu
Menu Item Display
Available Choices or Limits
Default
*NOTE
The Outdoor Temp and Valve Position Out display items 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).
3.5 SETUP MENU
The Setup Menu (Table 3-3) permits the operator to enter the unit password (159) which is
required t o 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.
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Available Choices or Limits
Minimum
Maximum
Upload Timer
0 0
Unit Alpha
A Z A
Unit Serial #
0000
9999
0000
Unit Year
0
99
00
CHAPTER 3 – OPERATION
Table 3-3: Setup Menu
Menu Item Display
Default
Password 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
C-More Year 0 99 11
C-More Serial # 0 9999 0000
C-More Alpha A Z A
IP Address
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 m enu contains a number of other
configuration settings which may or may not be displayed, depending on the current operating
mode setting.
NOTE
The Configuration Menu settings shown in Table 3-4 are FactorySet in accordance with the requirements specified for each
individual order. Therefore, under normal operating conditions, no
changes will be required.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Available Choices or Limits
Minimum
Maximum
CHAPTER 3 – OPERATION
Table 3-4: Configuration Menu
Menu Item Display
Internal Setpt
Unit Type
Unit Size
(Only the unit sizes
available for the Unit
Type will be displayed)
Fuel Type
Boiler Mode
Remote Signal
(If Mode = Remote
Setpoint, Direct Drive
or Combination)
Default
Lo Temp Limit Hi Temp Limit 130°F
KC Boiler, KC Boiler LN,
BMK Blr Std, BMK Blr Std Dual,
BMK Blr LN, BMK Blr LN Dual
KC Water Heater,
BMK Boiler LN
KC Water Heater LN,
Innovation WH
750 MBH, 1000 MBH,
1500 MBH, 2000 MBH,
2500 MBH, 3000 MBH,
6000 MBH
6000 MBH
Natural Gas or Propane Natural Gas
Constant Setpoint,
Remote Setpoint,
Direct Drive,
Combination,
Constant
Setpoint
Outdoor Reset
4 – 20 mA/1 – 5V
0 -20 mA/0 – 5V
PWM Input
(Legacy BMS), Network
4 – 20 mA,
1-5V
Outdoor Sensor
*Bldg Ref Temp
Enabled or Disabled Disabled
40°F 230°F 70°F
(If Mode = Outdoor
Reset)
*Reset Ratio
0.1 9.9 1.2
(If Mode = Outdoor
Reset)
*System Start Tmp
30°F 100°F 60°F
(If Outdoor Sensor =
Enabled)
Setpt Lo Limit
Setpt Hi Limit
Temp Hi Limit
40°F Setpt Hi Limit 60°F
Setpt Lo Limit 210°F 140°F
40°F 210°F 160°F
*NOTE
The Bldg Ref Temp and Reset Ratio Menu Items are only
displayed when the Outdoor Sensor is set to “Enabled”.
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Available Choices or Limits
Minimum
Maximum
Available Choices or Limits
Minimum
Maximum
CAUTION
CHAPTER 3 – OPERATION
Table 3-4: Configuration Menu – Continued
Menu Item Display
Max Valve Position
Pump Delay Timer
Aux Start On Dly
40% 100% 100%
0 min. 30 min. 0 min.
0 sec. 120 sec. 0 sec.
Default
Failsafe Mode Shutdown or Constant Setpt Shutdown
Low Fire Timer 2 sec. 600 sec. 2 sec.
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 0
Network Timeout 5 Sec 999 Sec 30 Sec
HI DB Setpt EN 0% 100% 30%
Demand Offsert 0 25 0
Deadband High 0 25 0
Deadband Low 0 25 0
* Spark Monitor Enabled or Disabled Disabled
* Spark Current Display
NOTE
Spark Monitor and Spar k Current are not used on the Benchmark
6000.
DO NOT change the Analog Output Menu Item from its Default
setting (Valve Position 0-10V).
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.
Table 3-5: Tuning Menu
Menu Item Display
Prop Band
Integral Gain 0.00 2.00 1.6
Derivative Time 0.0 min 2.00 min 0.10 min
Warmup Prop Band 0 °F 120 °F 95 °F
Warmup Int Gain 0 2.0 0.50
1°F 120°F 8°F
Default
Warmup PID timer 0 sec. 240 sec. 20 sec.
Reset Defaults? Yes, No, Are You Sure? No
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Available Choices or Limits
Minimum
Maximum
CAL Voltage 14%
1.70
2.70
2.20
CAL Voltage 30%
1.90
2.50
2.00
CAL Voltage 40%
1.90
3.40
2.25
CAL Voltage 50%
2.20
3.50
2.70
CAL Voltage 70%
3.20
4.40
3.95
CAL Voltage 100%
7.20
10.00
8.00
SET Valve Position
0%
100%
Variable
Blower Output
Monitor Blower Output Voltage
Set Stdby Volt
0
4.00 V
0/2.00 V
Oxygen Level
0%
25%
Variable
CHAPTER 3 – OPERATION
3.8 COMBUSTION CAL MENU
The Com bustion Cal (Calibration) Menu is protected by the level 2 password (6817) which must
be entered to view or change the menu items shown in Table 3-6. These menu items are used to
vary the speed of the unit’s blower motor based on air temperature and air density at prescribed
Air/Fuel Valve positions (% open). This is accomplished by providing a DC drive voltage to the
motor which adjusts the rotational speed of the blower to maximize combustion efficiency and
ensure the unit conforms to the Nitrogen Oxide (NOx) and Carbon Monoxide (CO) emissions
specified in Chapter 4. The valve positions (%) and default drive voltages are listed in Table 3-6.
Table 3-6: Combustion Cal Menu
Menu Item Display
Default
3.9 BST (BOILER SEQUENCING TECHNOLOGY ) MENU
The BST Menu must be Enabled in order to be displayed and accessed. The BST Enable item is
located at the end of the Configuration Menu.
The Boiler Sequencing Technology (BST) Menu contains all of the items required to Configure,
Operate and Monitor the functionality of the BST System. There are over 50 items in this menu,
and selecting any particular item from the list, for inspection or modification, could be time
consuming. As a result, the BST Menu has been segmented into FIVE logical groups based on
functionality.
The five Item groups are:
1. BST Monitor Items
2. BST SETUP MENU*
3. * OPERATE MENU *
4. *TEMP CTRL MENU*
5. *BST COMM MENU*
These displayed item groups are displayed in UPPER CASE letters, and are bounded by an
asterisk * in order to readily identify them within the item list.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BST Mode
Header Temp
(°F)
Outdoor Temp
(°F)
*BST SETUP MENU*
Disabled
Enabled
Disabled
0-20 mA/0-5
Vdc;
Yes
conjunction with this feature.
System
Shutdown
On-Outlet
Temp
CHAPTER 3 – OPERATION
The Items contained in group 1 (BST Monitor Items) are ALWAYS displayed within the menu, as
these items are critical for proper system operation. Therefore, the BST Monitor Items Header
itself is NOT displayed.
The Items contained in groups 2-5 are NOT DISPLAYED unless that particular item group has
been enabled from the C-More keypad.
Table 3-7: BST Menu
Menu Item Display
BST Setpoint BST Setpt Lo Limit BST Setpt Hi Limit 130°F
Header Temp NA
BST Fire Rate 0 100% Fire rate %
BST Ave Fire Rate 0 100% Avg Fire Rate %
BST Outdoor Temp NA
Units Available 0 8 Units Present
Units Ignited 0 8 Units firing
BST Valve State 0 (CLOSED) 1 (OPEN) 0
1 Comm Errors 8 0 9 0
1 BST Units 8 0 (see table) 0 (see table) 0
BST Setpoint Mode Constant Setpoint Remote Setpoint Outdoor Reset Constant Setpt
Head Temp Source Network FFWD Temp FFWD Temp
Header Temp Addr 0 255 240
Header Temp Point 0 255 14
BST Outdoor Sens Disabled Enabled Disabled
Outdr Tmp Source Outdoor Temp Network Outdoor Temp
Outdoor Tmp Addr 0 255 240
Outdoor Tmp Pnt 0 255 215
Available Choices or Limits
Default
Minimum Maximum
Off BST Slave BST Master Off
BST Remote Signal 4-20 mA/1-5 Vdc;
BST Auto Mstr No
BST Auto Timer 10 sec 120 sec 30 sec
Remote Intlk Use Boiler Shutdown System Shutdown
One Boiler Mode Off
1 Blr Threshold 10 35 25
Setpoint Setback Disable Enable Disable
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Network Network
NOTE! A Modbus temperature
transmitter must be installed in
On-Avg Temp Off
No
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Available Choices or Limits
MENU*
MENU*
*BST COMM MENU*
CHAPTER 3 – OPERATION
Menu Item Display
Setback Setpoint BST Setpt Lo Limit BST Setpt HI Limit 130°F
Setback Start 12:00am 11:59pm 12.00am
Setback End 12:00am 11:59pm 12.00am
Rate Threshold 1°F 30°F 15°F
*BST OPERATE
BST Next On VP 16% 100% 50%
BST Max Boilers 1 8 8
BST On Delay 30 sec 300 sec 60 sec
BST On Timeout 15 sec 300 sec 60 Sec
Valve Override Off Closed Open Off
Valve Off Delay 0 15 min 1 min
BST Sequencing Run Hours Unit Size Select Lead Run Hours
Select Lead Unit 0 127 0
Select Lag Unit 0 127 0
Lead/Lag Hours 25 hours 225 hours 72 hours
Minimum Maximum
Disabled Enabled Disabled
Default
*BST TEMP CTRL
BST Temp Hi Limit 40°F 210°F 210°F
BST Setpt Lo Limit 40°F BST Setpt HI Limit 60°F
BST Setpt HI Limit BST Setpt Lo Limit 220°F 195°F
BST Prop Band 1°F 120°F 100°F
BST Intgral Gain 0.00 2.00 0.50
BST Deriv Time 0.00 Min 2.00 Min 0.10 Min
BST Deadband Hi 0 25 1
BST Deadband Lo 0 25 1
Deadband En Time 0 120 Sec 30 Sec
BST FR Up Rate 1 120 20
BST Bldg Ref Tmp 40°F 230°F 70°F
BST Reset Ratio 0.1 9.9 1.2
System Start Tmp 30°F 120°F 60°F
Comm Address 0 127 0
BST Min Addr 1 128 1
BST Max Addr 1 128 8
SSD Address 0 250 247
SSD Poll Control 0 1000 0
Disabled Enabled Disabled
Disabled Enabled Disabled
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Available Choices or Limits
CHAPTER 3 – OPERATION
Menu Item Display
Minimum Maximum
Err Threshold 1 9 5
SSD Temp Format Degrees Points Degrees
BST Upld Timer 0 9999 sec 0
Default
3.10 START SEQUENCE
When the Control Box ON/OFF switch is set to the ON position, it checks all pre-purge saf ety
switches to ensure they are closed. These switches include:
• Downstream Safet y Shut-Off Valve (SSOV) Proof of Clos u re (POC) switch
• Low Water Level switch
• High Water Temperature switch
• High Gas Pressure switch
• Low Gas Pressure switch
• Blowe r Proof switch
• Blocked Inlet switch
NOTE
The downstream Low Gas Pressure switch is not checked prior to
starting the pre-purge.
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, if the required
conditions are not observed at any point during the start sequence,
appropriate messages will be displayed and the unit will go into
fault mode.
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 the downstream SSOV location.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
STEPPER
TO BLOWER
100
AIR IN
DOWNSTREAM
TO AIR/FUEL
VALVE
GAS INLET
MANUAL SHUT-OFF VALVE
UPSTREAM
CHAPTER 3 – OPERATION
SSOV WITH
POC SWITCH
SSOV WITH POC &
AUX SWITCH
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 the blower.
b) The Air/Fuel Valve rotates to the full-open purge position and closes purge position
c) The VALVE POSITION bargraph will show 100%.
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switch. The dial on the Air/Fuel Valve will read 100 (Figure 3-4) to indicate that it is
full-open (100%).
MOTOR
Figure 3-4: Air/Fuel Valve In Purge Position
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BLOCKED INLET
BLOWER PROOF
AIR/FUEL VALVE
ASSEMBLY
MANUAL SHUT-
OFF VALVE
BLOWER
CHAPTER 3 – OPERATION
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.
SWITCH
SWITCH
Figure 3-5: Blower Proof Switch
NOTE
A Function Timing Chart for the BMK6000 Proved Pilot Control
System is provided in Figure 3-7, below.
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) position and closes the
ignition switch. The Dial on the Air/Fuel Valve will r ead bet ween 45 and 50 (Figure 3-6)
to indicate that the valve is in the low-fire position.
b) Power is supplied to the Spark Igniter.
c) Power is supplied to the Pilot Gas Solenoid.
d) The Optical Pilot Flame Sensor proves the Pilot Flame and the red LED stops
blinking and changes to steady ON.
e) Ignition relay 1 (R1) closes allowing the main Burner ignition sequence to start.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
50
STEPPER
TO BLOWER
CHAPTER 3 – OPERATION
MOTOR
Figure 3-6: Air/Fuel Valve In Ignition Position
6. W hen ignition relay 1 (R1) closes, power is supplied to the SSOVs and the following events
occur:
f) The SSOVs open allowing gas to flow into the Air/Fuel Valve.
g) The Main Burner ignites.
h) Main Burner flame is sensed by the C-More Controller.
i) The Control Box turns off power to the ignition transformer and Pilot solenoid valve.
j) Relay 2 (R2) remains energized via the POC Normally Open (N.O.) c ontact of the
upstream SSOV actuator.
7. A maximum of 7 seconds are allowed for the entire ignition sequence, from applying power
to the ignition transformer through actual Burner flame establishment. The igniter relay will
be turned off one second after flame is detected.
8. 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.
9. W ith the unit firing properly, it will be controlled by the temperature controller circuitr y. The
boiler’s VALVE POSITION will be continuously displayed on the front panel bargraph.
Once the demand for heat has been satisfied, the C-More Controller will turn off the SSOV gas
valves. The blower relay will be deactivated and the Air/Fuel Valve will be closed. Standby will
be displayed.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BMK 6000 Function Timing Chart For Proved Pilot Control System
OPERATING STATE
C-MORE
PRE-PURGE
COMPONENT
C-MORE CONTROL BOX
Scanner Power
Ignition Power
SSOV Power
PILOT VALVE
Pilot Valve Closed
Pilot Valve Open
IGNITION TRANSFORMER
Transformer Off
Transformer On
UV SCANNER
Powered
"Ignored"
In Use
RELAY 1 (R1)
Coil
C-NC
C-NO
RELAY 2 (R2)
Coil Power from R1
Coil Power from SKP 15 AUX
C-NC
C-NO
UPSTREAM SSOV (SKP15)
Power through R1
Power through R2 and AUX
POC C-NC
POC C-NO
AUX C-NC
AUX C-NO
DOWNSTREAM SSOV (SKP25)
Power through R1
Power through R2 and AUX
POC C-NC
POC C-NO
CHAPTER 3 – OPERATION
STANDBY
PFEP MFEP
RUN
T=0s 30≤T≤60s T= 7 sec
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03/20/14 Ph.: 800-526-0288 GF-133
Figure 3-7: Timing Chart For Proved Pilot System
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Air Fuel Valve Position
Boiler Energy Input
Turndown
BTU/Hr
(% of Full
Capacity)
0%
0 0 0.0
10%
0 0 0.0
18% (Stop Level)
385,000
6
15.6
20%
400,000
7
15.0
30%
540,000
9
11.1
40%
770,000
13
7.8
50%
1,160,000
19
5.2
60%
1,650,000
28
3.6
70%
2,386,000
40
2.5
80%
3,515,000
59
1.7
90%
4,650,000
78
1.3
100%
6,000,000
100
1.0
CHAPTER 3 – OPERATION
3.11 START/STOP LEVELS
The start and stop levels are the Air/Fuel Valve posit ions (% open) that start and stop the unit,
based on load. These levels are Factory preset as follows:
Start Level: 22%
Stop Level: 18%
Normally, these settings should not require adjustment.
Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. Refer
to Table 3-8 and the chart in Figure 3-8 for the relationship between the energy input and
Air/Fuel Valve position for a BMK 6000 MBH boiler running on natural gas.
The boiler has a downstream low pressure gas switch that will shut down the boiler when the gas
pressure drops below 7” W.C. See Table 3-9.
Table 3-8: Relationship Between Air / Fuel Valve Position and Energy Input
For 6000 MBH Unit Running On Natural Gas
(% Full Open)
Ratio
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Gas Pressure @
SSOV (inches W.C.)
Inlet
Outlet
56 8 6,000,000
5.40
0%
14 8 6,000,000
5.40
0%
13 8 5,860,000
5.45
2%
12
7.95
5,860,000
5.41
2%
11.5
7.5
5,740,000
5.77
4%
11
7.1
5,610,000
6.17
6%
CHAPTER 3 – OPERATION
Table 3-9: Gas Pressure De-Rating Chart
Energy Input
(BTU/hr)
Oxygen
(%O2)
DeRating
(% Full Fire)
Figure 3-8: Relationship Between Air/Fuel Valve Position and Energy Input
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 3 – OPERATION
Figure 3-9: Burner Ignition Sequence Flowchart
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 3 – OPERATION
(This page intentionally blank)
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
WARNING
CHAPTER 4 – INITIAL START-UP
CHAPTER 4. INITIAL START-UP
4.1 INI TIAL START-UP REQUIREMENTS
The requirements for the initial start-up of the Benchmark 6000 MBH boiler consists of the
following:
• Complete installation (Chapter 2)
• Set proper controls and limits (Chapter 3)
• Perform combustion calibration (Chapter 4)
• Test safety devices (Chapter 6)
All applicable installation procedures in Chapter 2 must be fully completed prior to performing the
initial start-up of the unit. The initial start-up must be successfully completed 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 must be performed ONLY by AERCO factory trained start-up and service
personnel. After performing the start-up procedures in this Chapter, it will be necessary to
perform the Safety Device Testing procedures specified in Chapter 6 to complete all initial unit
start-up requirements.
An AERCO Gas Fired Startup Sheet, included with each Benchmark, must be completed for
each unit for warranty validation and a copy must be returned promptly to AERCO at:
AERCO International, Inc.
100 Oritani Drive
Blauvelt, New York 10913
(FAX: 845-580-8090)
DO NOT ATTEMPT TO DRY FIRE THE UNIT. STARTI NG THE
UNIT WITHOUT A FULL WATER LEVEL CAN SERIOUSLY
DAMAGE THE UNIT AND MAY RESULT IN INJURY TO
PERSONNEL OR PROPERTY DAMAGE. THIS SITUATION W ILL
VOID ANY WARRANTY.
NOTE
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 sections outline the necessary tools and
instrumentation as well as their installation.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
DOWNSTREAM SSOV WITH
LOW GAS PRESSURE
TO AIR/FUEL
GAS
LOW GAS
HIGH GAS
(10.5” W.C.)
1/4" NPT PLUG
(Install Manometer here for Combustion Calibration)
MANUAL SHUT-OFF VALVE
LEAK
CHAPTER 4 – INITIAL START-UP
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.
• 1/4 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 (or gauge) is used to monitor the gas pressure on the downstream
side of the SSOV during the Combustion Calibration procedures described in section 4.4.
The gas supply manometer is installed at the downstream location shown in Figure 4-1.
PRESSURE
PRESSURE
(6.9” W.C.)
DETECTION
BALL VALVE
VALVE
POC SWITCH
SWITCH
SWITCH (8.5” W.C.)
INLET
SWITCH
Figure 4-1: 1/4 Inch Gas Plug Location for Combustion Calibration
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
ANALYZER PROB E PO RTS
PARTIAL REAR VIEW
CONDENSATE DRAIN
EXHAUST MANIFOLD
CHAPTER 4 – INITIAL START-UP
Install the 16” W.C. manometer(s) as described in the following steps:
Installing Gas Supply Manom eter
1. Turn off the main gas supply upstream of the unit.
2. Remove the top panel and front panel from the boiler to access the gas train components.
3. To monitor the gas pressure on the downstream side of the SSOV during Combustion
Calibration (section 4. 4), remove the 1/4” NPT plug from the ball valve on the downstream
side of the SSOV as shown in Figure 4-1.
4. Install a NPT-to-barbed fitting into the tapped plug port.
5. Attach one end of the plastic tubing to the barbed f itting and the other end to the 16” W.C.
manometer.
4.2.3 Accessing the Analyzer Probe Port
For easy access, the unit contains a total of two (2) 1/4” NPT ports. One port is located on t he
left side of the exhaust manifold and the other is on the right side (see Figure 4-2).
Prepare the selected port for the combustion analyzer probe as follows:
Accessing the Analyzer Probe Port
1. Refer to Figure 4-2 and remove the 1/4” NPT plug from the desired location on the exhaust
manifold.
2. If necessary, adjust the stop on the combustion analyzer probe. DO NOT install the pr obe
at this time.
(2) WITH 1/4” PLUG
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Figure 4-2: Analyzer Probe Hole Location
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 4 – INITIAL START-UP
4.3 PILOT IGNITION
The Boiler is equipped with an interrupted pilot ignition system. The pilot is ignited by a spark
discharge within the Pilot Burner inside the combustion chamber. The input of the Pilot f lame is
approximately 18,000 BTU/hr. The Pilot Burner f lame will stay ignited until the main Burner flame
has stabilized and “Flame Proven” appears in the C-More Controller display.
A Pilot gas supply regulator reduces the supply pressure from line pressure to 4.9” W.C. An
orifice (0.073” dia.) further restricts the gas flow to the Pilot in accordance with UL safety test
requirements.
The Pilot Burner should be inspected at the beginning of each heating season, or every 6
months for continuous operation units. It is constructed of high quality, heat resistant stainless
steel materials, however some darkening of the metal is to be expected. No adjustment of the
Pilot should be required, however the gas pressure downstream of the regulator should be
checked if an ignition issue is encountered. Refer to Figure 4-1 for test port location.
The Pilot flame is proven by the AERCO BST Sensors located above and below the Pilot. Th e
boiler has two Pilot Flame Detectors. The AERCO BST is an optical sensor inserted in a
viewport. The sensor has a red LED which changes from flashing to steady- ON when the sensor
encounters the flicker of a flame that meets or exceeds the internal sensing threshold. The
sensor is inserted into a tube with a quartz window and observes the Pilot through a hole in the
refractory. The hole in the refractory should be check ed annually to ensure that the optical path
to the Pilot Burner is clear.
NOTE
The AERCO BST sensor switches the signal to neutral when the
flame is proven.
4.4 NATURAL GAS COMBUSTION CALIBRATION
NOTE
When installed and operated in accordance with the requirements
specified in this section, the Benchmark 6000 boiler delivers low
NOx emissions of <20 ppm at all firing rates. Alternatively, these
boilers can be combustion calibrated to provide Ultra-low NOx
emissions of <9 ppm.
To combustion calibrate the boiler to produce low NOx emissions
of <20 ppm, complete the instructions in this section. To
combustion calibrate the boiler to produce ultra-low NOx
emissions of <9 ppm, first complete t he instructions in this section
and then, in addition, complete the instructions in Appendix N.
The Benchmark 6000 boiler is combustion calibrated at the factory prior to shipping. The gas
pressure, measured at 100% fire rate (Air/Fuel Valve % open position) on the downstream side
of the SSOV, must be within the range of 7.9” W.C. ±0.4” W.C. Recalibration as part of initial
start-up is necessary due to changes in t he local altitude, gas BTU content, gas supply piping
and supply regulators. Combustion Calibration Test Data sheets are shipped with each unit.
These sheets must be filled out and returned to AERCO for proper Warranty Validation.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BRASS HEX HEAD
CHAPTER 4 – INITIAL START-UP
It is important to perform the following procedure as outlined. This will keep readjustments to a
minimum and provide optimum performance.
Natural Gas Combustion Calibration
1. Open the water supply and ret urn valves to the unit and ensure that the system pumps
are running.
2. Open the natural gas supply valve to the unit and then slowly open the Pilot gas valve.
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 with the present position in %. 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 and the
manometer is attached and functioning properly.
8. Set the ON/OFF switch to the ON position.
9. Change the valve position to 50% using the ▲ arrow key. The unit should begin its start
sequence and fire.
10. Next, verify that the gas pressure downstream of the SSOV is set to 7.5” to 8.3” W.C. If
gas pressure adjustment is required, remove the brass hex nut on the SSOV actuator to
access the gas pressure adjustment screw (Figure 4-3). Make gas pressure adjustments
using a flat-tip screwdriver to obtain a gas pre ssure between 7.5” and 8.3” W.C.
(Remove to access
the Gas Pressure
Adjustment Screw).
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Figure 4-3: Gas Pressure Adjustment Screw Location
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 4 – INITIAL START-UP
Natural Gas Combustion Calibration (Cont. )
11. Using the ▲ arrow key, increase the valve open position to 100%. Verify that the gas
pressure on the downstream side of the SSOV settles within the required range of 7.9 ±
0.4” W.C. Readjust the gas 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 reading to stabilize.
13. Compare the oxygen readings on the combustion analyzer to the on-board O
sensor value
2
displayed in the Operating Menu of the C-More Control Panel. If the values differ by more
than ±1.5% and your combustion analyzer is correctly calibrated, the on-board O2 sens or
may be defective and need to be replaced.
14. Compare the measured oxygen level to the oxygen range shown below. Also, ensure that
the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the values
shown. If you are not in a “NOx-limited” area and/or do not have a NOx meas urement in
your analyzer, set the oxygen (O
) at 5.1% ± 0. 5% .
2
Combustion Calibration Readings
Valve Position Oxygen (O2) % Nitrogen Oxide (NOx) Carbon Monoxide (CO)
100% 5.4% - 6.3% <20 ppm <100 ppm
15. If the oxygen level is not within the required tolerance, the gas pressure on the
downstream side of the SSOV must be adjusted using the gas pressure adjustment screw
on the SSOV (Figure 4-3). Slowly rotate the gas pressure adjustment (approximately 1/4turn increments). Allow the combustion analyzer to stabilize following each adjustment.
Clockwise rotation reduces the oxygen level, while counterclockwise rotation increases the
oxygen level.
16. Once the oxygen level is within the specified range at 100%, record the O
readings on the Combustion Calibration Data Sheets provided with the unit.
, NOx and CO
2
17. Lower the valve position to 80% using the ▼arrow key.
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 valve positions of 80%, 60%, 45%, 30%
and 18% as described in the following steps. These steps assume
that the inlet air temperature is within the range of 50°F to 100°F. If
NOx readings exceed the target values shown, increase the O
2
level up to 1% higher than the listed calibration range. Record the
increased O
value on the Combustion Calibration sheet.
2
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CHAPTER 4 – INITIAL START-UP
Natural Gas Combustion Calibration (Cont.)
18. 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.
19. Press the MENU key on the front panel of the C-MORE until Combustion Cal Menu
appears on the display.
20. Press the ▲ arrow key until SET Valve Position appears on the display.
21. Press the CHANGE key. SET Valve Position will begin to flash.
22. Press the ▲ arrow key until the SET Valve Position reads 80%. Press the ENTER key.
23. Next, press the down (▼) arrow key until CAL Voltage 70% is displayed.
24. Press the CHANGE key and observe that CAL Voltage 70% is flashing.
25. The oxygen level at the 70% valve position should be as shown below. Also, ensure t hat
the nitrogen oxide (NOx) and carbon monoxide (CO) readings do not exceed the following
values:
Combustion Calibration Readings
Valve Position Oxygen (O2) % Nitrogen Oxid e (NOx) Carbon Monoxide (CO)
70% 6.0% - 6.5% <20 ppm <100 ppm
26. 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.
27. Once the oxygen level is within the specified range at 70%, press the ENTER key to store
the selected blower output voltage for the 80% valve position. Recor d all readings on the
Combustion Calibration Sheets provided.
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CHAPTER 4 – INITIAL START-UP
Natural Gas Combustion Cal ibration (Cont.)
28. Repeat steps 20 through 27 f or valve pos itions of 50%, 40%, 30% and 18%* (see *NOTE
below). The oxygen (O
within the same limits for all valve positions as shown in the following table.
Set the Valve Position at 18% but make adjustments to the
Combustion Calibration value designated as 16%.
If NOx readings exceed the target values shown (<20 ppm),
increase the O
range shown in the table. Record the increased O
Combustion Calibration sheet.
), nitrogen oxide (NOx) and carbon monoxide (CO) should remain
2
*NOTE
NOTE
level up to 1% higher than the listed calibration
2
value on the
2
Combustion Calibration Readings
Valve Position Oxygen (O2) % Nitrogen Oxid e (NOx) Carbon Monoxide (CO)
50% 6% - 7% <20 ppm <100 ppm
40% 6% - 7% <20 ppm <100 ppm
30% 6% - 7% <20 ppm <100 ppm
18% 5% - 7% <20 ppm <100 ppm
29. If the oxygen level at the 18% valve position is too high and the Blower voltage is at the
minimum value, you can adjust the idle screw (TAC valve) which is recessed in the top of
the Air/Fuel Valve (see Figure 4-4, below). Rotate the screw 1/2 turn clockwise (CW) to
add fuel and reduce the O
to the specified level. Recalibration MUST be performed again
2
from 50% down to 14% after making a change to the idle screw (TAC valve).
30. This completes the Natural Gas combustion calibration procedures.
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CHAPTER 4 – INITIAL START-UP
Figure 4-4: TAC Valve Adjust (Idle Screw)
TAC VALVE
IDLE SCREW
4.5 REASSEMBLY AFTER COMBUSTION CALIBRATION
Once the combustion calibration adjustments are properly set, the unit can be reassembled for
service operation.
Reassembly
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 fr om the 1/4” vent hole in the exhaust manifold.
Replace the 1/8” NPT plug in the manifold.
6. Replace all previously removed sheet metal enclosures on the unit.
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CHAPTER 5 – MODE OF OPERATION
CHAPTER 5. MODE OF OPER ATION
5.1 INTRODUCTION
The boiler is capable of being operated in any one of six different modes. The following sections
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 bui lding reference tem perature and
a reset ratio.
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.
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 AIR IN and AIR SENSOR COM
inside the I/O Box. Use shielded 18 to 22 AWG wire for connections. A wiring diagram is
provided on the cover of the I/O Box. Refer to Chapter 2, section 2.9.1 for additional wiring
information.
5.2.4 Indoor/Outdoor Reset Mode Startup
Startup in the Indoor/Outdoor Reset Mode is accomplished as follows:
NOTE
A design engineer typically provides design outdoor air
temperature and supply header temperature data
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arrow keys (40°F to 240°F)
CHAPTER 5 – MODE OF OPERATION
Indoor/Outdoor Reset Mode Startup Procedure
1. Refer to the Indoor/Outdoor reset ratio charts in Appendix D.
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.
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). If necessary, refer to section 3.3 for detailed
instructions on menu changing.
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.
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.
No external sensors are required to operate in this mode. W hile it is necessary to set the desired
setpoint temperature, it is not necessary to change any other temperature-r elated 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 f actory
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 ▼
Refer to section 3.3 for detailed instructions on changing menu options.
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CHAPTER 5 – MODE OF OPERATION
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 Remot e Setpoint mode can
also driven by a RS-485 Modbus Network signal from an EMS or BAS.
The Remote Setpoint modes of operation can be used to drive single as well as multiple units.
NOTE
If a voltage, rather than current signal is used to control the r emote
setpoint, a DIP switch adjustment must be made on the PMC
Board located in the Control Panel Assembly. Refer to GF-112,
Appendix D for DIP switch settings, or 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 section 3.3 for detailed instructions on changing menu options.
If the Network setting is selected f or RS-485 Modbus operation, a valid Comm Address must be
entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional
information.
While it is possible to change the settings of temperature related functions, the unit is factory
preset with settings that work well in most applications. It is suggested that an AERCO
representative be contacted, prior to changing any temperature related function settings. 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 RS485 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
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CHAPTER 5 – MODE OF OPERATION
must be observed. The source end of the shield must be connected at the source. W hen 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 set point 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. T he REMOTE LED will
go off and the MANUAL LED will light .
To change back to the Remote Setpoint mode, simply press the AUTO/MAN 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 RS-485 Modbus Network signal from an EMS or BAS.
When in a Direct Drive mode, the unit is a slave to the EMS or BAS and does not have a role in
temperature control. Direct Drive can be used to drive single, or multiple units.
NOTE
If a voltage, rather than current signal is used to control t he remote setpoint,
a DIP switch adjustment must be made on the PMC Board located in the
Control Box Assembly. Refer to GF-112, Appendix D for DIP switch
settings, or 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 section 3.3 for instructions on changing menu options.
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Menu Option
Setting
CHAPTER 5 – MODE OF OPERATION
If the Network setting is selected f or RS-485 Modbus operation, a valid Comm Address must be
entered in the Setup Menu. Refer to Modbus Communication Manual GF-114 for additional
information.
5.5.1 Direct Drive Field Wiring
The only wiring connections necessary for Direct Drive mode are connect ion 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 f rom 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 LE D will light when
the signal is present.
To operate the unit in manual mode, press the AUTO/MAN switc h. 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 AERCO CONTROL SYSTEM (ACS)
NOTE
ACS is for installations with 9 or more boilers. It utilizes only RS485 signaling to the boiler. Installations with 1 to 8 boilers can use
BST (see Chapter 10).
The ACS mode of operation is used in conjunction with an AERCO Control System. The ACS
mode is used when it is desired to operate multiple units in the most efficient manner possible.
For this mode of operation, an ACS Header Sensor must be installed between 2 and 10 feet
downstream of the LAST boiler in the boiler plant's supply water header. The ACS can control up
to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS-485) network
communication. The ACS can control up to 32 b oilers via RS-485 network communication. For
programming, operation, and Header Sensor installation details, see GF-131 (ACS) Operations
Guide. For operation via an RS-485 Modbus network, refer to Modbus Communication Manual
GF-114.
To enable the ACS Mode, the following menu settings must be made in the Configuration Menu:
Boiler Mode Direct Drive
Remote Signal Network (RS-485)
Refer to section 3.3 for instructions on changing menu options.
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5.6.1 ACS External Field Wiring
Wiring connections for RS-485 Modbus control are made between the 485 A- and 485 B+
terminals on the ACS (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 ACS RS485 COMM wiring connections. Shields should be terminated only at the
ACS and the boiler end must be left floating. Each unit’s wiring must conform to the above.
5.6.2 ACS Setup and Startup
This mode of operation is factory preset and the ACS 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 switc h. The REMOTE LED will go
off and the MANUAL LED will light
To change back to the ACS mode, simply press the AUTO/MAN switch. The REMOTE LED will
again light and the MANUAL LED will go off.
5.7 COMBINATION CONTROL SYSTEM (CCS)
NOTE
Only ACS can be utilized for the Combination Control System.
A Combination Control System (CCS) is one that uses multiple boilers to cover both spaceheating and domestic hot water needs. The theory behind this type of system is that the
maximum space-heating load and the maximum domestic hot water load do not occur
simultaneously. Therefore, boilers used for domestic hot water are capable of switching between
constant setpoint and ACS control.
For a typical CCS, an adequate number of boilers are installed to cover the space-heating load
on the design-day. However, one or more units are used for the domestic hot water load as well.
These boilers are the combination units and are referred to as the combo boilers. The combo
boilers heat water to a constant setpoint temperature. That water is then circulated through a
heat exchanger in a domestic hot water storage tank.
Only the AERCO Control System (ACS) is necessary to configure this system if only a single
valve is used to switch from space heating to domestic hot water. However, the ACS Relay
Panel is req uired in combination with the ACS when there are up to two isolation valves, boiler
interlocks, and/or a Domestic Hot Water (DHW) pump in a Combination heating plant where
AERCO boilers are being used for both Building Heat and Domestic Hot Water heating.
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Menu Option
Setting
CHAPTER 5 – MODE OF OPERATION
The following two options are available for using a combination system; one that uses only the
ACS, and one that requires the optional ACS Relay Box:
• OPTION 1 - T his option is selected when the ACS controls a boiler plant containing up to
eight combination boilers that are Domestic Hot Water Priority (DHW PRIORITY) boilers,
along with building heat (BLDG HEAT) boilers, and one hydronic isolat ion valve in the main
header between the BLDG HEAT boilers and the DHW PRIORITY boilers.
• OPTION 2 – When this option is selected, the ACS Relay Panel must be used in
conjunction with the ACS. For this option, the ACS controls a boiler plant containing up to
eight combination boilers that are divided up into Building Priority (BLDG PRIORITY) boilers
and Domestic Hot Water Priority (DHW PRIORITY) boilers, along with building heat (BLDG
HEAT) boilers, and using two hydronic isolation valves in the main header, one between the
BLDG HEAT and BLDG PRIORITY boilers, and the other between the BLDG PRIORITY
and the DHW PRIORITY boilers.
In Option 2, when the space-heating load is such that when all the space-heating boilers are at
the 100% valve position, the ACS will then ask the ACS Relay Box for the domestic boilers to
become space-heating boilers. Provided the domestic hot water load is satisfied, the combo (hot
water) boilers will then become space-heating boilers. If the domestic hot water load is not
satisfied, the combo boiler(s) remain on the domestic hot water load. If the combo boilers switch
over to space heating, but there is a call for domestic hot water, the ACS Relay Box switches the
combo units back to the domestic load. T he ACS in combination with the ACS Relay Box will ask
the BLDG PRIORITY boilers to help with domestic hot water heating if the DHW PRIORITY
boilers are not able to satisfy the domestic hot water demand.
When the combo units are satisfying the domestic load, they are in the constant setpoint mode of
operation. When the combo units switch over to space heating, their mode of operation changes
to follow the ACS command. For more information concerning the operation of the ACS, consult
the ACS Operations Guide, GF-131. For more information on the ACS Relay Box, see section
2.14 in the same manual.
5.7.1 Combination Control System Field Wiring
Wiring for this system is between the ACS, the ACS Relay Box, and the terminals in the I/O Box.
Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units,
each unit’s wiring must conform to the above.
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 190°F.
Enter the following settings in the Configuration Menu:
Boiler Mode Combination
Remote Signal Network
Internal Setpt 40°F to 190°F
Refer to section 3.3 for instructions on changing menu options.
While it is possible to change other temperature-related functions for combination mode, these
functions are preset to their factory default values. These default settings work well in most
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CHAPTER 5 – MODE OF OPERATION
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 ACS control, the ACS controls the valve position. There are no
setup requirements to the boiler(s) in this mode.
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CHAPTER 6 – SAFETY DEVICE TESTING
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 boiler control system comprehensively monitors all combustionrelated 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. Also, 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 208-230 OR
460, 120 AND 24 VOLTS AC. POW ER MUST BE REMOVED PRIOR TO
PERFORMING W IRE REMOVAL OR OT HER TEST PROCEDURES THAT
CAN RESULT IN ELECTRICAL SHOCK.
6.2 LOW GAS PRESSURE FAULT TESTS
The location for the Low Gas Pressure switch is shown in Figure 6-1A. The steps and pressure
setting required to check the switch are described below. This switch is in the normally open
(N.O.) position.
Prior to starting this test, ensure that the external gas supply ball valve is shut off.
Refer to Figure 6-1A to locate the Low Gas Pressure switch and the pr oper location to connect
the water column manometer or gauge when performing the test.
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TO AIR/FUEL
GAS
INLET
HIGH GAS
MANUAL
VALVE
TEE WITH 1/4" NPT PLUG
test)
UPSTREAM LOW GAS PRESSURE
BALL VALVE WI T H N PT 1/4" PLUG
(Install manometer here for Downstream Low Gas Pressure test)
CHAPTER 6 – SAFETY DEVICE TESTING
VALVE
PRESSURE
SWITCH
(10.5” W.C.)
SHUT-OFF
(Install manometer here for
Upstream Low Gas Pressure
SWITCH (8.5” W.C.)
Figure 6-1A: Low Gas Pressure Switch Locations & Test Point Locations
The upstream Low Gas Pressure switch is set at 8.6” W.C. and is tested as follows:
Low Gas Pressure Fault Test
1. Remove the 1/4“ plug from the Tee at the Low Gas Pressure switch shown in Figure 61A.
2. Install a NPT-to-barbed fitting and connect a 0 – 16“ W.C. manometer where the 1/4" plug
was removed.
3. Open the external gas supply ball valve upstream of the unit.
4. Place the unit in Manual Mode and adjust the Air/Fuel Valve position (% open) to 50%.
5. While the unit is firing, slowly close the external gas supply shut-off va lve.
6. The unit should shut down and display a GAS PRESSURE fault message at approximately
8.5” W.C. The FAULT indicator should also start flashing.
7. Fully open the external gas supply ball 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.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
TO AIR/FUEL
GAS
DOWNSTREAM LOW
HIGH GAS
MANUAL SHUT-OFF VALVE
UPSTREAM LOW GAS
PRESSURE SWITCH (8.5” W.C.)
BALL VALVE WITH 1/4" NPT PLUG
(Install manometer here for High Gas Pressure test)
CHAPTER 6 – SAFETY DEVICE TESTING
Low Gas Pressure Fault Test – Continued
9. Upon test completion, close the external ball valve to shut down the unit. Remove the
manometer and NPT-to-barbed fitting. Replace the 1/4“ plug removed in step 1.
6.3 HIGH GAS PRESSURE FAULT TEST
To simulate a high gas pressure fault, refer to Figure 6-1B and perform the following steps:
VALVE
PRESSURE
SWITCH
(10.5” W.C.)
GAS PRESSURE
SWITCH (6.9” W.C.)
1. Remove the 1/4“ plug from the ball valve shown in Figure 6-1B.
2. Install a NPT-to-barbed fitting and a 0 – 16” W.C. manometer where the 1/4” plug was
removed. Open the ball valve at the High Gas Pressure switch.
3. Open the external gas supply ball valve upstream of the unit.
INLET
Figure 6-1B: High Gas Pressure Test
High Gas Pressure Fault Test
4. Start the unit in the Manual mode at a valve position (% open) between 25 and 30%.
5. W ith the unit running, monitor the gas pressure on the manometer installed in step 2 and
record the gas pressure reading.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 6 – SAFETY DEVICE TESTING
High Gas Pressure Fault Test – Continued
6. Increase the gas pressure using the adjustment screw on the downstream SSOV (see
Figure 4-3).The unit should shut down and display a GAS PRESSURE fault message
when the gas pressure exceeds 10.5” W.C. The FAULT indicator should also start
flashing.
7. Reduce the gas pressure back to the value recorded in step 5. This pressure should be
within the range of 7.9” W.C. ± 0.4” 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 1/4“
plug removed in step 1.
6.4 LOW WATER LEVEL FAULT TEST
To simulate a low water level fault, proceed as follows:
Low Water Level Fault Test
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.
5. Place the unit in the Manual Mode and raise the valve position above 30%.
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 t o 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.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
MANUAL
MANUAL SWITCH
ADJUSTABLE
OVER TEMPCONTROLLER
CHAPTER 6 – SAFETY DEVICE TESTING
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 front of the unit as shown in Figure 6-2.
Water Temperature Fault Tes t
1. Start the unit in the normal operating mode. Allow the unit to stabilize at its setpoint.
2. Lower the adjustable over-temperature switch setting to match the displayed OUTLET
TEMPERATURE.
3. Once the adjustable over-temperature switch setting is approximately at, or j ust 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.
4. Reset the adjustable over-temperature switch to its original setting.
5. The unit should start once the adjustable temperature limit switch setting is above the
actual outlet water temperature.
ERATURE DIGIT AL
TEMPERATURE
LIMIT SWITCH
RESET BUTTON
TEMPERATURE
LIMIT SWITCH
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Figure 6-2: Temperature Limit Switch Setting
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 6 – SAFETY DEVICE TESTING
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 2-13) and ar e 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 Test
Remote Interlock Test
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 Test
Delayed Interlock Test
1. Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals.
2. Start the unit in the Manual Mode at a valve position between 25% and 30%.
3. 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.
4. The unit should shut down and display a DELAYED INTERLOCK OPEN fault message.
The FAULT LED should be flashing.
5. Reconnect the wire or jumper removed in step 3 to restore the interlock.
6. Press the CLEAR button to reset the fault
7. 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:
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
AIR FILTERS
MANUAL GAS
GAS TRAIN
AIR/FUEL VALVE
BLOWER
Y-DUCT
CHAPTER 6 – SAFETY DEVICE TESTING
Flame Fault Tests
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%.
3. Close the manual gas shutoff valve located between the Safety Shut-Off Valve (SSOV)
and the Air/Fuel Valve (see Figure 6-3).
4. Set the ON/OFF switch to the ON position to start the unit.
5. The unit should purge and light the Pilot flame and then shut down after reac hing the main
Burner 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 (Figure 6-3).
9. The unit should shut down and Lock out. A flashing FLAME LOSS DURING RUN should
appear in the display.
10. Open the valve previously closed in step 8.
11. Press the CLEAR button. The unit should restart and fire.
SHUT-OFF VALVE
6.8 AIR FLOW FAULT TESTS
These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in
Figure 6-4.
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Figure 6-3: Bare Boiler – Partial View
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
BLOCKED INLET
BLOWER PROOF
AIR/FUEL VALVE
ASSEMBLY
MANUAL SHUT-
OFF VALVE
BLOWER
CHAPTER 6 – SAFETY DEVICE TESTING
SWITCH
SWITCH
Figure 6-4: Blower Proof Switch & Blocked Inlet Switch Locations
6.8.1 Blower Proof Switch Test
Blower Proof Switch Test
1. Disable the blower output drive voltage as follows:
a) Press the MENU key until CONFIGURATION MENU is displayed.
b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, t hen press
the CHANGE key.
c) Press the ▼ arrow key until OFF is 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 Lockout, showing AIRFLOW FAULT DURING PURGE in
the display.
4. The unit should perform one IGNITION RETRY cycle and then shut down, since the blower
is disabled. The unit will then display AIRFLOW FAULT DURING PURGE.
5. Re-enable the blower output drive voltage by performing the following steps:
a) Press the MENU key until CONFIGURATION MENU is displayed.
b) Press the ▲ arrow key until the ANALOG OUTPUT function is displayed, t hen press
the CHANGE key.
c) Press the ▲ arrow key until VALVE POSITION 0-10V is displayed, then press the
ENTER key.
d) Press the CLEAR button to clear the airflow fault.
6. Once the unit has proved flame, turn off the blower again by going to the Configuration
7. The Blower Proof Switch will open and the blo wer should stop. The unit should shut down
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Menu, Analog Output menu item and select OFF.
and display AIRFLOW FAULT DURING RUN.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
TO WIRE HARNESS
Flame Detector
Flame Signal Generator
CHAPTER 6 – SAFETY DEVICE TESTING
Blower Proof Switch Test – Continued
8. Go to the Configuration Menu, Analog Output item and select VALVE POSITION 0-10v.
6.8.2 Blocked Inlet Switch Test
This test will be run in simulated fire mode, with the Blocked Inlet Switch isolated from the rest of
the control circuitry.
Blocked Inlet Switch Test
1. Turn off the main ON/OFF switch on the front of the Control Panel.
2. For units that get combustion air from a Combustion Air Duct, remove that duc t, locat ed on
the top panel of the boiler (see Figure 6.5, below). For units that have an air filter in place
of a Combustion Air Duct (not shown), remove the three (3) hex head screws securing the
Y-Duct and air filters to the Air/Fuel valve (see Figure 6-3, above) and carefully remove the
Y-Duct and air filter assembly.
WARNING
THE BLOWER SUCTION IS VERY STRONG AND CAN PULL NEARBY
OBJECTS INTO THE BLOWER’S FAN BLADE S. DO ALLOW ANYTHING
TO BE PULLED INTO THE BLOW ER. DO NOT W EAR ANYTHING THAT
COULD GET CAUGHT AND PULL YOU INTO THE BLOWER.
3. Turn off the gas supply ball valve to the boiler and then complete the following steps:
a) Use jumper wires to jump out the Low Gas Pressure Switch and the Blower Proof
Switch.
b) Remove the black connector boot from the Flame Detector.
c) Connect the Flame Signal Generator to the black connector boot.
Connector Boot
Figure 6.4a: Connecting the Flame Signal Generator
d) Keep the alligator clip away from bare metal parts until step 4c.
4. Complete the following with the boiler operating in Manual mode:
a) Ramp the boiler up to 100% fire rate and then turn on the main ON/OFF switch on the
front of the Control Panel.
b) Push the BACK button three (3) times to return to the upper level menu.
c) When the Controller gets into the ig nition phase, the Control Panel will show IGNITION
TRIAL. At that point attach the alligator clip (see Figure 6.4a) to any bare metal surface
or ground. The C-More display should now show FLAME PROVEN and begin to ramp
up to 100% fire rate. Note that no gas or flame is present in the boiler at this time.
5. W ait for the boiler to ramp up to at least 90% before continuing.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
EXHAUST
HOT WATER
FRONT
REAR
CHAPTER 6 – SAFETY DEVICE TESTING
Blocked Inlet Switch Test – Continued
6. Cover the combustion air inlet opening with a solid, flat object, such as a piece of thick
plywood or a thick metal plate.
7. The unit should shut down and display AIRFLOW FAULT DURING RUN. This step
confirms proper operation of the Blocked Inlet Switch.
8. Remove the cover from the air inlet opening and reinstall the Combustion Air Duct or YDuct and air filters.
9. Remove the jumper wires installed in step 2 and replace the black connector boot on the
Flame Detector.
10. Press the CLEAR button. The unit should restart.
OUTLET
Figure 6-5: Boiler Top View Showing Air Inlet Location
AIR INLET
(Combustion Air
Duct removed)
MANIFOLD
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
SSOV
ACTUATOR
CHAPTER 6 – SAFETY DEVICE TESTING
6.9 SSOV PROOF OF CLOSURE SWITCH
The downstream SSOV shown in Figure 6-1 contains the proof of closure (POC) switch. The
proof of closure switch circuit is checked as follows:
SSOV Proof of Closure Switch
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 downstream SSOV.
4. Remove the cover from the SSOV by loosening the screw shown in Figure 6-6. Lift off the
cover to access the terminal wiring connections.
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 the ON position 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.
COVER
SCREW
ACTUATOR
COVER
Figure 6-6: Downstream SSOV Actuator Cover Location
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 6 – SAFETY DEVICE TESTING
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:
Purge Switch Open During Purge
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 (see
Figure 6-7).
3. Remove one of the two wires (#171 or #172) from the Purge Switch (Figure 6-8).
4. Initiate a unit start sequence.
5. The unit should begin its 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.
AIR/FUEL VALVE COVER
(ROTATE CCW TO REMOVE)
Figure 6-7: Air/Fuel Valve Cover Location
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Stepper Motor
Purge Position
Ignition Position
Dial
AIR IN
TO BLOWER
CHAPTER 6 – SAFETY DEVICE TESTING
Switch
Switch
Figure 6-8: Air/Fuel Valve Purge and Ignition Switch Locations
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:
Ignition Switch Open During Ignition
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 6-7) 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 6-8).
5. Initiate a unit start sequence.
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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.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 6 – SAFETY DEVICE TESTING
6.12 SAFETY PRESSURE REL IEF VALVE TEST
Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel
Code, Section VI.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Labor
Time
Pilot Burner
(29700)
Main Flame Detector
(65136)
7.4
O2 Sensor (61026)
*Inspect
Inspect
15 mins.
Combustion
Calibration
Testi ng of Saf ety
Devices
See ASME
CSD-1 Chart
7.7
Burner
Inspect
2 hrs.
Condensate Drain
Trap
Inspect, Clean &
Replace Gaskets
Inspect, Clean &
Replace Gaskets
WARNING
CHAPTER 7 – MAINTENANCE
CHAPTER 7. MAINTENANCE
7.1 MAINTENANCE SCHEDULE
The unit requires regular routine maintenance to keep up efficiency and reliability. For best
operation and life of the unit, the following routine maintenance pr ocedures should be performed
in the time periods specified in Table 7-1. For a complet e inspection check list s ee ASME CSD-1
chart.
In order to perform the maintenance tasks specified in Table 7-1, the f ollowing maintenance k its
are available through your local AERCO Sales Representative:
• Annual Maintenance Kit, Part No. 58025-11
• 24-Month Waterside/Fireside Inspection Kit, Part No. 58025-12 (See NOTE below)
NOTE
The 24-Month W aterside/Fireside Inspection Kit also includes the
items contained in the Annual Maintenance Kit (58025-11).
Theref ore, only Kit Part No. 58025-12 is required when performing
the waterside/fireside inspections. Refer to Appendix L for
recommended spares.
TO AVOID PERSONAL INJURY, PRIOR TO SERVICI NG ENSURE THAT
THE FOLLOWING GUIDELINES ARE STRICTLY OBSERVED:
• DISCONNECT THE AC SUPPLY BY TURNING OFF THE SERVICE
SWITCH AND AC SUPPLY CIRCUIT BRE AKER.
• SHUT OFF THE GAS SUPPLY AT THE MANU AL SHUT-OFF VALVE
PROVIDED WITH THE UNIT
• ALLOW THE UNIT TO COOL TO A SAFE WATER TEMPERATURE TO
PREVENT BURNING OR SCALDING
Table 7-1: Maintenance Schedule
Section Item 6 Mos. 12 Mos. 24 M os.
7.2
7.3
7.5
7.6
*Inspect Inspect Replace 15 mins.
*Inspect Inspect Replace 15 mins.
*Check Check 1 hr.
45 mins.
7.9
7.10 Air Filter (88014) Replace Replace 15 mins.
* Only performed after initial 6 month period after initial startup.
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*Inspect
30 mins.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
SIGHT GLASS
MAIN FLAME
TO PILOT
BLOWER
BLOWER FLANGE
BURNER PLATE
PILOT
PILOT FLAME
CHAPTER 7 – MAINTENANCE
7.2 PILOT BURNER
The Pilot Burner (P/N 29700) is located on the right-front of the Burner Plate. It contains an
ignition cable and a Pilot gas line connected to the bushing. Fig ure 7-1 shows the location of t he
Pilot Burner and related components.
DETECTOR
BURNER
DETECTOR
GAS LINE
Figure 7-1: Pilot Burner, Main & Pilot Flame Detector Mounting Locations
The Pilot Burner may be hot, therefore care should be exercised to avoid burns. It is easier to
remove the Pilot Burner from the unit after it has cooled to room temperature. To inspect/replace
the Pilot Burner, perform the following procedure:
Pilot Burner Maintenance Procedure
1. Set the ON/OFF switch on the control panel, to t he OFF position. Disconnect AC power
from the unit
2. For easy access, open the front panel and right side door. If you are working on the left unit
of a t wo-unit, zero side clearance installation, you may want to remove the top panel and
service the unit from above.
3. Disconnect the ignition cable from the Pilot Burner (Figure 7-1).
4. Using a 1/2” open-end wrench, disconnect the Pilot gas line from the reducer fitting and
elbow shown in Figure 7-1.
5. First, remove the reducer fitting and then the elbow from the Pilot Burner.
6. Remove one of the two Pilot Flame Detectors to provide clearance for Pilot Burner
7. Using a 1-1/2” open end wrench, loosen and remove the Pilot Burner from the Burner
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removal.
Plate.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
Pilot Burner Maintenance Procedur e – Continued
8. Check the Pilot Burner tip for evidence of erosion or carbon build-up. If there is evidence of
substantial erosion or carbon build-up, the Pilot Burner should be replaced. If carbon buildup is present, clean the component using a wire brush. Check to ensure that the vanes are
not bent out of the proper position of a 20º incline. Repeated carbon build-up is an
indication that the combustion settings of the unit should be checked. Refer to Chapter 4
for combustion calibration procedures.
9. Prior to reinst alling the Pilot Burner, a high temperature, conductive, anti-seize compound
must be applied to the threads.
10. Reinstall the Pilot Burner on the Burner Plate. Ensure that the tapped hole for the elbow is
facing outward toward the edge of the Burner Plate to permit connection of the Pilot Burner
gas line. Torque to 170 - 180 in-lbs.
11. Reassemble the remaining components in the reverse order that they were removed.
12. Reconnect the ignition cable.
13. Close the right side door and front panel. Replace the top panel if the unit was serviced
from above.
7.3 MAIN FLAME DETECTOR
The Main Flame Detector (part no. 65136) is located on the Blower Flang e near the top of the
unit (see Figures 7-1). The Main F lame Detector may be hot. Allow the unit to cool sufficiently
before removing the Main Flame Detector. Inspect or replace the Main Flame Detector as
follows:
Main Flame Detector Maintenance Procedure
1. Set the control panel ON/OFF switch to the OFF position. Disconnect AC power from the
unit.
2. Remove the front panel from the unit by grasping the top handle and pulling straight out.
3. Disconnect the Main Flame Detector lead wire. Be careful not to yank the wire when it
pops off the Main Flame Detector.
4. Remove the Main Flame Detector from the Blower Flange.
5. Thoroughly inspect the Main Flam e Detector. If eroded, the detector should be replaced.
Otherwise clean the detector with a fine emery cloth.
6. Apply a small amount of high temper ature TFE-Based thread sealant and reinstall the Main
Flame Detector on the Blower Flange.
7. Reconnect the Main Flame Detector lead wire.
8. Replace the front panel on the unit.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
7.4 O2 SENSOR
The O2 sensor (part no. 61026) is located on the back plate at the r ight side of t he unit as shown
in Figure 7-2. As this Figure shows, there is also a g as suction line that supplies a sampling of
the exhaust gases from the exhaust manifold to ensure accurate sampling of the O
sensor and the suction line may be hot, therefore allow the unit to cool sufficiently before
removing or replacing the O
sensor.
2
NOTE
The O2 Sensor needs to be replaced only once every 5 years.
le vels. The
2
The O
Sensor is removed and inspected by performing the following procedural steps:
2
O2 Sensor Maintenance Procedures
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit.
2. Remove the rear right-side panel from the unit by removing the screws at the top and rear
(Figure 7-2).
3. Disconnect t he O
connector.
4. Next, loosen and remove the O
15/16" open-end wrench.
5. Thoroughly inspect the O
the hole in the refractory is clean and that the gas sample suction tube is not clogged.
6. Reinstall the O
7. Reconnect the sensor lead wire.
8. Reinstall the rear right side panel on the unit.
s ensor lead wire by pushing in on the release tab and pulling apart the
2
sensor and crush washer from the back plate using a
2
sensor. If corroded, the sensor should be replaced. Ensur e that
2
sensor and crush washer on the back plate.
2
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
O2 SENSOR
GAS SUCTION
EXHAUST
CHAPTER 7 – MAINTENANCE
LINE FROM
EXHAUST
MANIFOLD
7.5 COMBUSTION CALIBRATION & PILOT REGULATOR ADJUSTMENT
Combustion settings must be checked at the intervals shown in Table 7-1 as part of the
maintenance requirements. Refer to Chapter 4 for combustion calibration instructions. Pilot
Regulator tests and adjustments are performed using the procedures in sections 7. 5.1 and 7.5.2
which follow.
7.5.1 Pilot Regulator Pressure Testing
The BMK6000 unit has a Pilot Regulator system in the gas train that should be pressure tested
annually as described in the following procedure. However, if the pressure is above 5.0” W.C. or
below 4.0” W.C., then the Pilot pressure regulator must be recalibrated using the instructions
provided in section 7.5.2.
The Pilot Regulator pressure test is performed as follows:
OMM-0086_0D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 95 of 210
GF-133 Ph.: 800-526-0288 03/20/14
MANIFOLD
Figure 7-2: O2 Sensor Mounting Location
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
Pilot Regulator Pressure Test Procedure
1. Ensure that gas supply shut-off valve upstream of the unit is still turned OFF.
2. Turn OFF electrical power to the system.
3. Remove the 1/4” NPT plug from the Tee on the outlet side of the Pilot Regulator (Figure 7-
3) and insert a NPT-to-barbed adapter fitting.
4. Attach one end of t he plastic tubing to the barbed f itting and the other end to the 16” W.C.
manometer.
5. Remove the cap from the Pilot Regulator to access t he gas pressure adjustment. Rotate
the regulator adjustment (beneath cap) clockwise (CW) to its highest possible pressure
setting.
6. Next, rotate the adjustment screw 2 turns counterclockwise (CCW).
7. OPEN the main gas supply upstream of the unit.
8. Turn ON electrical power to the system.
9. Start the boiler in MANUAL Mode. Observe the manometer pressure when the Pilot
solenoid “clicks” open after purge. It should now provide a reading of 4.9 ± 0.2” W.C.
10. Pull out the optical flame scanner and look into the observation port on the front plate.
Ensure that you observe the orange glow of the Pilot flame during the ignition trial period.
11. If the pressure is within specifications, return the unit to service. Make sure that the unit is
operating in AUTO Mode. The “MAN” light in the upper left of the control box should NOT
be lit when in AUTO Mode.
12. If the Pilot Regulator is NOT with in spec if icat ions, proc eed to section 7.5.2 and perform the
Pilot Regulator Pressure Calibration procedure.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
TO AIR/FUEL
GAS INLET
DOWNSTREAM
HIGH GAS
(10.5” W.C.)
MANUAL
UPSTREAM LOW
SWITCH
LEAK DETECTION PORT WITH BALL VALVE & 1/4" NPT PLUG
TEE WITH
PILOT
PILOT
VALVE
CHAPTER 7 – MAINTENANCE
VALVE
PRESSURE SWITCH
LOW GAS PRESSURE
SWITCH (6.9” W.C.)
SHUT-OFF
REGULATOR
SOLENOID
Figure 7-3: Pilot Regulator Mounting Location
1/4" NPT PLUG
(Install manometer
here for Pilot
Regulator tests)
GAS PRESSURE
7.5.2 Pilot Regulator Pressure Calibration
If the Pilot Regulator pressure is above 5.0”W.C. or below 4.0” W.C., the Pilot Regulator
pressure must be calibrated using the following procedure:
Pilot Regulator Pressure Calibration Procedur e
1. Ensure that gas supply shut-off valve upstream of the unit is still turned OFF.
2. Turn OFF electrical power to the system.
3. Remove the pipe plug from the 1/4” NPT port on the outlet side of the Pilot Regulator
(Figure 7-3) and insert a NPT-to-barbed adapter fitting.
4. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16” W.C.
manometer.
5. Remove the cap from the Pilot pressure regulator and rotate the regulator adjustment
(beneath cap) clockwise (CW) to its highest possible pressure setting.
6. OPEN the main gas supply upstream of the unit.
7. Turn ON electrical power to the system.
8. Start the boiler in the MANUAL Mode. Observe the manometer pressure when the Pilot
solenoid “clicks” open after purge. The manometer should now provide a reading of 4.9”
W.C.
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
CHAPTER 7 – MAINTENANCE
Pilot Regulator Pressure Calibration Procedure – Continued
NOTE
If you DO NOT see the orange glow, contact AERCO technical
support to ascertain the problem. If you DO see it, proceed to the
next step.
9. Pull out the optical flame scanner and look into the observation port in the front plate.
Ensure that the orange glow of the Pilot flame is observed during the ignition trial period.
10. If the manometer reading is less than 4.8” W.C., increase the regulator setting by rotating
the adjustment screw clockwise (CW).
11. Repeat steps 8 through 10 until the gas pressure at the outlet of the Pilot Regulator
pressure reads between 4.8” W.C. and 5.0” W.C. on the monometer.
12. Once the pressure reading is between 4.8” W.C. and 5.0” W.C., conduct at least three safe
Pilot ignitions while observing the observation port. Assure the igniter lights immediately
with a strong orange flame after the Pilot ignition solenoid valve opens.
NOTE
Clear any Flame Loss During Ignition messages during the tests by
pressing the CLEAR key on control panel.
13. Close the external ga s supply valve . Disconnect the manometer, tubing and barbed fitting
from the 1/4” NPT port hole.
14. Replace the 1/4” plug where the barbed fitting was removed.
15. OPEN the gas supply upstream of the unit.
16. Ensure power is restored and Boiler is turned on in the MANUAL Mode.
17. Refer to section 4.4 in Chapter 4 - I nitial Start-up, t o perform the Combustion Calibration
procedure.
18. Return the unit to service following successful completion of the Combustion Calibration
procedures. Make sure that the unit is operating in the AUTO Mode. The “MAN” light in the
upper left of the control box should NOT be lit in AUTO Mode.
7.6 SAFETY DEVICE TESTING
Systematic and thorough tests of the operating and safety devices should be performed to
ensure that they are operating as designed. Certain code requirements, such as ASME CSD-1,
require that these tests be performed on a scheduled basis. Test schedules must conform to
local jurisdictions. The results of the tests should be rec orded in a log book. See Chapter 6 for
Safety Device Testing Procedures.
Page 98 of 210 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0086_0D
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Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
Part No.
Description
81159
Burner Gaskets (2)
WARNING
CHAPTER 7 – MAINTENANCE
THE HEAT EXCHANGER INSULATION UTILIZES CERAMIC FIBER
MATERIAL. WEAR A FITTED NIOSH-APPROVED PARTICULATE
RESPIRATOR (3M N95 OR EQUIV.) WHEN SERVICING THE HEAT
EXCHANGER AND BURNER ASSEMBLIES. AT HIGH TEMPERATURES,
CERAMIC FIBERS CAN BE CONVERTED TO CRYSTALINE SILICA
FIBERS WHICH HAVE BEEN IDENTIFIED AS CARCINOGENIC WHEN
INHALED.
7.7 BURNER ASSEMBLY INSPECTION
The Burner assembly is locat ed at the front of the unit's heat exchanger. The Burner assembly
may be hot. Therefore, allow the unit to cool sufficiently before removing the Burner assembly.
The following parts will be required for reassembly after Burner inspection:
To inspect or replace the Burner assembly, proceed as follows:
Burner Assembly Inspection and M aintenance Procedures
1. Set the ON/OFF switch on the control panel, to the OFF position. Disconnect AC power
from the unit and turn off the gas supply.
2. Remove the front panel, top panel and front side panels from the unit by grasping and
lifting straight up and outward. This will expose the blower assembly for removal.
3. Disconnect the lead wire from the Main Flame Detector installed on the Blower Flange
(Figure 7-1).
4. Remove the Main Flame Detector from the Blower Flange.
5. Remove the Pilot sensors and observation ports from the Burner Plate (Figure 7-4a).
6. Disconnect the cable from the Pilot Burner by pulling straight out.
7. Using a 1/2” open-end wrench, disconnect the Pilot g as line from the reducer fitting and
elbow shown in Figure 7-1.
8. First, remove the reducer fitting and then the elbow from the Pilot Burner.
9. Next, loosen and remove the Pilot Burner from the Burner Plate using a 1-1/2" open-end
wrench.
10. Remove the blower support turn-buckle (Figure 7-4).
11. Attach a hoist rig, capable of lifting 300 pounds, to the lifting lugs on the blower motor and
fan housing.
12. Remove the two inlet air filters from the galvanized Y-fitting.
13. Loosen and remove the eight (8) 3/8” hex nuts and washers from the Blower Flange where
14. Remove the Blower from the Burner by pulling outward. Be careful not to allow it to swing
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it is attached to the Burner Plate (see Figure 7-4, sheets 1 & 2).
and damage other equipment components. Refer to the exploded view in Figure 7-5.
Benchmark 6000 Boiler Installation, Operation & Maintenance Manual
AIR FILTERS
GAS TRAIN
AIR/FUEL VALVE
“Y” DUCT
BURNER ASSEMB L Y
BLOWER FLANGE
TURN-BUCKLE
MAIN FLAME DETECTOR
3/8-16 HEX NUTS &
PILOT BURNER
BLOWER
PILOT FLAME DETECTORS
BURNER PLATE
CHAPTER 7 – MAINTENANCE
Burner Assembly Inspection and Mai ntenance Procedures – Continued
NOTE
The Blower assembly is heavy, weighing approximately 200 lbs
15. Lower the Blower/Air/Fuel Valve assembly down approximately 16” until it is clear of the
Burner Flange.
16. Remove the Burner by pulling straight out.
17. Gently slide the Burner out of the boiler using care to avoid tearing the mesh burner fabric,
or cock the Burner to one side or the other.
18. Remove and replace the two (2) Burne r Gaskets (see Figure 7-5).
19. To reassemble, begin with the Burner assembly and reinstall all the components in the
reverse order that they were removed. The Burner may have a nut installed at the base
position to keep the Burner level while insta llin g the Blower (Figure 7-5).
20. Ensure that the Pilot Burner and Pilot Flame D etectors cutouts in the Blower Flange are
properly aligned with the Burner Plate.
WASHERS (8)
Figure 7-4a: Burner Assembly Mounting Details
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