Aerco Benchmark 2.0 LN User Manual
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Aerco Benchmark 2.0 LN User Manual

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Benchmark 2.0 LN Installation, Operation & Maintenance Manual
Benchmark 2.0LN
Low NOx Boiler
USER MANUAL
Natural Gas Fired
Installation, Operation and Maintenance
Modulating, Condensing,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable to Serial Numbers
G-12-0800 and above
Latest Update: DRAFT
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
OMM-0046_0J
Page 1 of 168
Ph.: 800-526-0288
GF-123
06/18/2015

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Summary of Contents for Aerco Benchmark 2.0 LN

  • Page 1 Modulating, Condensing, Forced Draft, Hot Water Boiler 2,000,000 BTU/H Input Applicable to Serial Numbers G-12-0800 and above Latest Update: DRAFT AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 1 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 2 The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    2.12.4 Ducted Combustion Air ......................31 2.12.5 Temporary Combustion Air Filtering During Construction ............31 2.13 BENCHMARK PUMP RELAY OPTION ..................32 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 3 of 168 Ph.: 800-526-0288...
  • Page 4 6.8 AIR FLOW FAULT TESTS ........................ 76 6.9 SSOV PROOF OF CLOSURE SWITCH ................... 77 6.10 PURGE SWITCH OPEN DURING PURGE ..................78 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 168 OMM-0046_0J 06/18/2015...
  • Page 5 APPENDIX I – RECOMMENDED PERIODIC TESTING CHECK LIST ..............163 APPENDIX J – BENCHMARK CONTROL PANEL FEATURES ................165 APPENDIX K – RECOMMENDED SPARE PARTS LISTS ................. 167 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 5 of 168 Ph.: 800-526-0288...
  • Page 6 Benchmark 2.0 LN Installation, Operation & Maintenance Manual (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 7 FORWARD Foreword The AERCO Benchmark 2.0 Low NOx (LN) Boiler is a modulating unit. It represents a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 8 Benchmark 2.0 LN Installation, Operation & Maintenance Manual FORWARD (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 9: Chapter 1. Safety Precautions

    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).

  • Page 10: Emergency Shutdown

    Chapter 6 of this manual be performed, to verify all system- operating parameters. If there is an emergency, turn off the electrical power supply to the AERCO boiler and close the manual gas valve located upstream the unit. The installer must identify the emergency shut-off device.
  • Page 11 It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 11 of 168 Ph.: 800-526-0288...
  • Page 12 The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions, and AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 168 OMM-0046_0J...
  • Page 13 End of Extracted Information From 248 CMR 5.08 (2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 13 of 168 Ph.: 800-526-0288...
  • Page 14 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 1 – SAFETY PRECAUTIONS (This page is intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 15: Chapter 2. Installation

    This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 2.0LN Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5.

  • Page 16: Site Preparation

    The unit must be installed with the prescribed clearances for service as shown in Figure 2-1. 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.

  • Page 17: Setting The Unit

    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. See Condensate Tank instructions in TID-0074 for details.

  • Page 18: Supply And Return Piping

    The physical location of the supply and return piping connections are on the rear of the unit as shown in Figure 2-3. Refer to Appendix F, Drawing AP-A-798 for additional dimensional data. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 168 OMM-0046_0J...

  • Page 19: Condensate Drain And Piping

    The procedure to install and connect the condensate drain is provided in paragraph 2.6.1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 19 of 168 Ph.: 800-526-0288...

  • Page 20: Exhaust Manifold Condensate Drain

    The condensate trap must be supported to ensure that its base is level (horizontal). • The trap must be removable for routine maintenance. AERCO recommends that a union be utilized between the exhaust manifold condensate drain port and the trap inlet port.

  • Page 21: Gas Supply Piping

    CHAPTER 2 – INSTALLATION Figure 2-5: Condensate Trap Installation 2.7 GAS SUPPLY PIPING The AERCO Benchmark 2.0LN Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

  • Page 22: Gas Supply Specifications

    2" MANUAL SHUTOFF VALVE DIRT TRAP GAS PRESS. REGULATOR (REQUIRED FOR MASSACHUSETTS INSTALLATIONS) Figure 2-6: Manual Gas Shut-Off Valve Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 23: Iri Gas Train Kit

    Figure 2-7: AC Input Terminal Block Location 2.8.1 Electrical Power Requirements The AERCO Benchmark 2.0LN Boiler accepts 120 VAC, single-phase, 60 Hz @ 20A. The Power Box contains a terminal block as shown in Figure 2-8. In addition, a wiring diagram showing the required AC power connections is provided on the front cover of the Power Box.

  • Page 24: Modes Of Operation And Field Control Wiring

    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 2.0LN Electrical Power Wiring Guide, (GF-2060LN). 120 VAC, 1 PHASE Figure 2-8: AC Terminal Block Configurations 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING...

  • Page 25: Constant Setpoint Mode

    Control System (ACS) can utilize only RS485 signaling to the Boiler. When using an AERCO BMS, BMS II, or ACS (AERCO Control System), the field wiring is connected between the BMS/BMS II/ACS Panel and each Boiler’s I/O Box terminal strip (Figure 2- 10).

  • Page 26: Combination Mode

    NOTE DO NOT make any connections to the I/O Box terminals labeled “NOT USED”. Attempting to do so may cause equipment damage. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 168 OMM-0046_0J 06/18/2015...

  • Page 27: Outdoor Sensor In (1)

    Operating Menu. The sensor must be wired to the positive (+) and negative (-) terminals of the AIR TEMP. SENSOR and must be similar to AERCO BALCO wire sensor Part No. 12449. A resistance chart for this sensor is provided in Appendix C.

  • Page 28: Pwm) In (4)

    2.10.10 Exhaust Switch In (11) These terminals permit an external exhaust switch to be connected to the exhaust manifold of the boiler. The exhaust switch should be a normally open type switch (such as AERCO Part No. 123463) that closes (trips) at 500°F.

  • Page 29: Remote Interlock In (10)

    U/L listed, positive pressure, watertight vent materials as specified in AERCO’s GF-2050, must be used for safety and code compliance. Since the unit is capable of discharging low temperature exhaust gases, horizontal sections of the flue vent system must be pitched back to the unit a minimum of 1/4 inch per foot to avoid condensate pooling and allow for proper drainage.

  • Page 30: Combustion Air

    The AERCO Benchmark 2.0LN Boiler is UL listed for 100% sealed combustion. It can also be installed using room air, provided there is an adequate supply. (See para. 2.13.3 for more information concerning sealed combustion air).

  • Page 31: Ducted Combustion Air

    In order to implement this option, you must remove the internal flex hose between the air inlet iris and the air/fuel valve and install an air filter (AERCO part number 59138) on the air/fuel valve’s inlet, as shown in the right-hand image in Figure 2-11.

  • Page 32: Benchmark Pump Relay Option

    Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION AERCO recommends that the temporary air filter be cut from a McMaster-Carr part no. 2122K315 Polyester Air Filter Roll Tackfield, ½” thick, 16” wide, or equivalent. Cover the Benchmark 2.0LN air inlet with the blue side of the filter material facing outward to hold the dust on the outside surface.
  • Page 33 CHAPTER 2 – INSTALLATION Diagram 2-1b: Schematic – System Pump Start using a Separate Contact Relay Figure 2-12: Identifying the Presence of BMK Pump Relay Option 69102 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 33 of 168 Ph.: 800-526-0288...
  • Page 34 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 2 – INSTALLATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 35: Chapter 3. Operation

    Table 3-1. Additional information on these items is provided in the individual operating procedures provided in this Chapter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 35 of 168 Ph.: 800-526-0288...
  • Page 36 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION VALVE POSITION Figure 3-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 37 Low Water Level alarm. Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 37 of 168 Ph.: 800-526-0288...
  • Page 38 VALVE POSITION 20 segment red LED bargraph continuously shows the Bargraph Air/Fuel Valve position in 5% increments from 0 to 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...

  • Page 39: Control Panel Menus

    The menu option choices do not wrap around. 7. To select and store a changed menu item, press the ENTER key. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 39 of 168 Ph.: 800-526-0288...

  • Page 40: Operating Menu

    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). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 168...

  • Page 41: Setup Menu

    Min. Upload Timer 9999 Unit Alpha Unit Year Unit Serial # 0000 9999 0000 Software Ver. 0.0 Ver. 9.9 Current AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 41 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 42: Configuration Menu

    (If Mode = Outdoor Reset) Outdoor Sensor Enabled or Disabled Disabled System Start Tmp 30°F 100°F 60°F (If Outdoor Sensor = Enabled) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 43 Only the Unit Sizes applicable to the selected Unit Type will be displayed. *CAUTION! DO NOT CHANGE the Analog Output Menu Item from its Default setting (Valve Position 0-10V). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 43 of 168 Ph.: 800-526-0288...

  • Page 44: Tuning Menu

    Table 3-6. Refer to the Combustion Calibration procedures in Chapter 4 for the procedures applicable to the type of fuel being used. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 168 OMM-0046_0J...

  • Page 45: Start Sequence

    2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. See Figure 3-3 for SSOV location. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 45 of 168 Ph.: 800-526-0288...
  • Page 46 The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. SSOV INLET TO AIR/FUEL VALVE MANUAL SHUT-OFF VALVE Figure 3-3: SSOV Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 47 CHAPTER 3 – OPERATION DIAL (DETAIL “A”) STEPPER MOTOR DETAIL “A” Figure 3-4: Air/Fuel Valve In Purge Position Figure 3-5: Blower Proof Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 47 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 48: Start/Stop Levels

    Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. Refer to Table 3-7 for the relationship between the energy input and Air/Fuel Valve position for a unit running on natural gas. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 168 OMM-0046_0J...
  • Page 49 (BTU/Hr) (% of Full Capacity) 100,000 (Stop Level) 5.0% 134,000 349,000 631,000 893,000 1,150,000 1,410,000 1,610,000 1,830000 100% 2,000,000 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 49 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 50 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 3 – OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 51: Chapter 4. Initial Start-Up

    Chapter 6 to complete all initial start-up requirements. AERCO Gas Fired Startup Sheets, included with each Benchmark Boiler, must be completed for each unit for warranty validation. A copy of these sheets must be returned promptly to AERCO at: AERCO International, Inc.

  • Page 52: Required Tools & Instrumentation

    4. Install a NPT-to-barbed fitting into the tapped plug port. 5. Attach one end of the plastic tubing to the barbed fitting and the other end to the 16” W.C. manometer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 168 OMM-0046_0J...

  • Page 53: Accessing The Analyzer Probe Port

    AIR/FUEL VALVE BLOWER IGNITOR- INJECTOR BURNER FLAME PLATE DETECTOR Observation Port STAGED BURNER IGNITION ASSEMBLY Figure 4-3: Observation Port Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 53 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 54: Combustion Calibration

    Factory Test Data sheets are shipped with each unit. These sheets must be filled out and returned to AERCO for proper Warranty Validation. It is important to perform the following procedure as outlined. This will keep readjustments to a minimum and provide optimum performance.
  • Page 55 Figure 4-5: Iris Air Damper Location/Adjustment NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 55 of 168 Ph.: 800-526-0288...
  • Page 56 31. The oxygen level at the 60% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 168 OMM-0046_0J...
  • Page 57 Table 4-5: Combustion Oxygen Levels for a Air/Fuel Valve Position Oxygen % Carbon Monoxide NOx ± 0.2 8.0 % <50 ppm <30 ppm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 57 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 58: Unit Reassembly

    5. Remove the combustion analyzer probe from the vent hole. Replace the NPT plug in the vent hole using a suitable pipe joint compound. 6. Replace the unit’s side panels and front door. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 168 OMM-0046_0J...

  • Page 59: Over-Temperature Limit Switches

    FOR MANUAL TEMPERATURE LIMIT SWITCH Alarm DIGITAL OVER- TEMPERATURE ALARM SWITCH DETAIL “A” Figure 4-6: Over Temperature Limit Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 59 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 60: Digital Alarm Switch Checks And Adjustments

    Alarm Switch. Access code value 0 should appear in the display. The switch comes from the factory with the code set at 0. AERCO recommends that you do not change this code. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 61 12. Once the programming mode has been exited, the display will show the current outlet water temperature of the boiler. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 61 of 168 Ph.: 800-526-0288...
  • Page 62 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 4 – INITIAL START-UP (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 63: Chapter 5. Mode Of Operation

    5.2.4 Indoor/ Outdoor Startup Startup in the Indoor/Outdoor Reset Mode is accomplished as follows: 1. Refer to the Indoor/Outdoor reset ratio charts in Appendix D. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 63 of 168 Ph.: 800-526-0288...

  • Page 64: Constant Setpoint Mode

    The unit is factory preset with settings that work well in most applications. Prior to changing any temperature-related parameters, other than the setpoint, it is suggested that an AERCO representative be contacted. For descriptions of temperature-related functions and their factory defaults, see Appendices A and E.

  • Page 65: Remote Setpoint Modes

    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.

  • Page 66: Remote Setpoint Startup

    Boiler Mode Direct Drive Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to paragraph 3.3 for instructions on changing menu options. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 67: Direct Drive Field Wiring

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

  • Page 68: Bms External Field Wiring

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

  • Page 69: Combination Control System Field Wiring

    These default settings work well in most applications. It is suggested that AERCO be contacted prior to changing settings other than the unit’s setpoint. For a complete listing of temperature related function defaults, see Appendix E.
  • Page 70 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 5 – MODE OF OPERATION (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 71: Chapter 6. Safety Device Testing

    6. The unit should shut down and display a LOW GAS PRESSURE fault message at approximately 2.6” W.C. The FAULT indicator should also start flashing. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 71 of 168 Ph.: 800-526-0288...

  • Page 72: High Gas Pressure Test

    4.7” W.C. The FAULT indicator should also start flashing. 7. Reduce the gas pressure back to 3.0” W.C. 8. Press the CLEAR button on the Control Box to clear the fault. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 168 OMM-0046_0J...

  • Page 73: Low Water Level Fault Test

    4. Reset the adjustable temperature limit switch to its original setting. 5. The unit should start once the adjustable temperature limit switch setting is above the actual outlet water temperature. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 73 of 168 Ph.: 800-526-0288...

  • Page 74: Interlock Tests

    (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. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 168 OMM-0046_0J...

  • Page 75: Remote Interlock

    The unit will execute a shutdown purge cycle for a period of 15 seconds and display WAIT FAULT PURGE. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 75 of 168 Ph.: 800-526-0288...

  • Page 76: Air Flow Fault Tests

    2. Start the unit in the Manual Mode at a valve position between 25% and 30%. 3. The unit should shut down and execute an IGNITION RETRY cycle by performing the following steps: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 168 OMM-0046_0J...

  • Page 77: Ssov Proof Of Closure Switch

    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. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 77 of 168 Ph.: 800-526-0288...

  • Page 78: Purge Switch Open During Purge

    4. Remove one of the two wires (#169 or #170) from the Ignition Switch (Figure 6-6). 5. Initiate a unit start sequence. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 168 OMM-0046_0J...
  • Page 79 Figure 6-5: Air/Fuel Valve Cover Location STEPPER MOTOR DIAL BLOWER IGNITION PURGE POSITION POSITION SWITCH SWITCH Figure 6-6: Air/Fuel Valve Purge and Ignition Switch Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 79 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 80: Safety Pressure Relief Valve Test

    6.12 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 168 OMM-0046_0J 06/18/2015...

  • Page 81: Chapter 7. Maintenance

    Inspect 2 hrs. Condensate Drain Trap *Inspect Inspect & Clean 30 mins. * Only performed 6 months after initial startup. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 81 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...

  • Page 82: Ignition Maintenance

    Disconnect the staged ignition assembly from the igniter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 168...
  • Page 83 These washers may be needed to properly position the gas injector tube of the igniter within the 120° angle range shown in Figure 7-3. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 83 of 168 Ph.: 800-526-0288...

  • Page 84: Flame Detector

    7. Reinstall the flame detector and flame detector gasket. 8. Reconnect the flame detector lead wire. 9. Reinstall the side and top panels on the unit. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 168 OMM-0046_0J...

  • Page 85: Combustion Calibration

    2. Remove the side and top panels from the unit. 3. Disconnect the lead wire from the flame detector installed on the burner plate. See Figure 7-4. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 85 of 168 Ph.: 800-526-0288...
  • Page 86 12. Disconnect the gas train from the air/fuel valve by removing the four (4) 1/2” bolts and nuts (Figure 7-4). 13. Disconnect the inlet air flex hose from the air/fuel valve by loosening the hose clamp. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 168 OMM-0046_0J...
  • Page 87 19. Beginning with the burner assembly removed in step 17, reinstall all the components in the reverse order that they were removed. During re-assembly, replace the gaskets for the blower and flame detector with new ones. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 87 of 168 Ph.: 800-526-0288...

  • Page 88: Condensate Drain Trap

    7. Reassemble all piping and hose connections to the condensate trap inlet and outlet. Reconnect trap to exhaust manifold drain. Figure 7-6: External Condensate Trap AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 168 OMM-0046_0J...

  • Page 89: Shutting The Boiler Down For An Extended Period Of Time

    4. Perform initial startup per Chapter 4. 5. Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 89 of 168 Ph.: 800-526-0288...
  • Page 90 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 7 – MAINTENANCE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 91: Chapter 8. Troubleshooting Guide

    7. If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 91 of 168 Ph.: 800-526-0288...
  • Page 92 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 93 Check Air/Fuel Valve position at 0%, 50% and 100% open positions. The positions on the VALVE POSITION bargraph should match the dial readings on the Air/Fuel Valve dial. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 93 of 168 Ph.: 800-526-0288...
  • Page 94 See CORRECTIVE ACTIONS from 3 to 12 for AIRFLOW PROBABLE CAUSES from 3 to 12 for FAULT DURING IGNITION. AIRFLOW FAULT DURING IGNITION applies for this fault AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...
  • Page 95 Ensure that the device and or its end switch are functional. (jumper may be temporarily installed to test interlock) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 95 of 168 Ph.: 800-526-0288...
  • Page 96 Staged ignition solenoid valve does ensure it is opening. not open. Remove and inspect staged ignition piece for blockage. Clogged staged ignition piece. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...
  • Page 97 See Figure 8-1. Ensure that the gas pressure snubber is Gas pressure snubber not installed. installed at the high gas pressure switch. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 97 of 168 Ph.: 800-526-0288...
  • Page 98 Press CLEAR button and restart unit. If fault persists, contact IGN BOARD between the PMC board and qualified Service Personnel. COMM FAULT Ignition/Stepper (IGST) board AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 99 Defective IGST Board Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 99 of 168 Ph.: 800-526-0288...
  • Page 100 If calibration is okay, the problem may be in the Air/Fuel Valve or IGNITION the Control Box. Refer fault to qualified service personnel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 168 OMM-0046_0J...
  • Page 101 Check continuity of wiring between source and boiler. Signal is not isolated (floating) if 4 to Check signal at source to ensure it is isolated. 20 mA. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 101 of 168 Ph.: 800-526-0288...
  • Page 102 Incorrectly wire switch Ensure that the SSOV Proof of Closure switch is correctly wired. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 168 OMM-0046_0J 06/18/2015...
  • Page 103 Defective IGST Board Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF every second. If not, replace IGST Board AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 103 of 168 Ph.: 800-526-0288...

  • Page 104: Additional Faults Without Specific Fault Messages

    Check to ensure that the IGST and Power Supply Boards are at the 80% Valve Boards in Control Box are Rev. E or higher. Position outdated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 105 Figure 8-1: High Gas Pressure Switch & Snubber Locations BURNER PLATE BURNER STAGED IGNITION INJECTOR SOLENOID Figure 8-2: Staged Ignition Solenoid Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 105 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 106 Benchmark 2.0 LN Installation, Operation & Maintenance Manual CHAPTER 8 – TROUBLESHOOTING GUIDE DAMPING ORIFICE SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT Figure 8-3: Damping Orifice Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 107: Chapter 9. Rs232 Communication

    Figure 9-1, but will allow you to specify the serial line to use (if your computer has more than one) and what speed (baud AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 107 of 168 Ph.: 800-526-0288...

  • Page 108: Running A Command On A Remote Machine Using Putty

    5. You are now ready to execute this command on the remote machine, simply click the Open button at the bottom of the dialog. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 168 OMM-0046_0J...

  • Page 109: Rs232 Communication Setup

    3. At the prompt, enter the valid RS232 password (jaguar) in lower case letters and press Enter. 4. “Welcome to Aerco” will appear in the laptop or “dumb terminal” display with a listing of the following available entry choices: = Display next Menu...

  • Page 110: Data Logging

    Data logged while the unit is running are run-length encoded. Data is logged or the run-length incremented every 30 seconds. For a new run record to be logged, the fire rate or AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 168...

  • Page 111: Sensor Log

    Run, Direct Drive 1/15/02 1:21pm Ignition 1/15/02 1:20pm Off, Switch 1/15/02 12:30pm Run, Manual 1/15/02 11:55am Ignition 1/15/02 11:55am Power-up 1/15/02 11:50am AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 111 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 112 OPEN OPEN OPEN OPEN 1/15/02 5:16pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:11pm OPEN OPEN OPEN OPEN OPEN 1/15/02 5:06pm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 113: Appendix A - Boiler Menu Item Descriptions

    Displays total run time of unit in hours from 0 to Run Hours 9,999,999. Fault Log Displays information on the last 20 faults. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 113 of 168 Ph.: 800-526-0288 GF-123...
  • Page 114 Code Plate. e.g. G-12-1234. Identifies the current software version of the control Software Version box (Ver 0.0 to Ver 9.9). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 114 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...
  • Page 115 Hi Limit is 195°F. Sets the maximum allowable valve position for the Max Valve Position unit (40% to 100%). Default is 100%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 115 of 168 Ph.: 800-526-0288...
  • Page 116 Start Level value. There will not be a one minute delay when firing at the 29% Valve Position level. Setting range is 0 to 25. (Default is 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 168 OMM-0046_0J...
  • Page 117 AC current on the input of the Spark Monitor Ignition Transformer. Displays the AC current on the input of the Ignition Spark Current Transformer. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 117 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 118 Range = 1-240 Default = 20 Allows Tuning Menu options to be reset to their Factory Reset Defaults? Default values. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 119 The Blower Motor remains “ON” in STANDBY Mode. Set Stdby V Out The motor speed is defined by setting this parameter to a value of 0.00 Volts. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 119 of 168 Ph.: 800-526-0288...
  • Page 120 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX A – BOILER MENU ITEM DESCRIPTIONS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 121: Appendix B - Startup, Status & Display Messages

    The time and date are also displayed. WAIT Prompts the operator to wait. WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 121 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 122 The Low Water Cutoff board is indicating low water level. NETWORK COMM The RS-485 network information is not present or is FAULT corrupted. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...
  • Page 123 A failure has been detected in one of the relays that control FAILURE the SSOV. STEPPER MOTOR The Stepper Motor failed to move the Air/Fuel Valve to the FAILURE desired position. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 123 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 124 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX B – STARTUP, STATUS & DISPLAY MESSAGES (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...

  • Page 125: Appendix C - Sensor Temperature Resistance

    1185.2 2.41 1209.5 2.43 1234.7 2.45 1260.0 2.47 1285.6 2.50 1311.4 2.52 1337.7 2.54 1364.2 2.56 1391.0 2.58 1418.2 1445.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 125 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 126 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX C – SENSOR TEMPERATURE RESISTANCE (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 127: Appendix D - Indoor/Outdoor Reset Ratio Charts

    -10F -15F -20F Table D-2: Header Temperature for a Building Reference Temperature of 60F RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 127 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 128 RESET RATIO Temp Table D-4: Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 129 RESET RATIO Temp -10F -15F Table D-6. Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 129 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 130 APPENDIX D – INDOOR/OUTDOOR RESET RATIO CHARTS Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...

  • Page 131: Appendix E - Boiler Default Settings

    (If Outdoor Sensor = Enabled) Setpt Lo Limit 60°F Setpt Hi Limit 195°F Temp Hi Limit 195°F Max Valve Position 100% AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 131 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 132 Prop Band 70°F Integral Gain 1.00 Derivative Time 0.00 min Warmup Prop Band Warmup Int Gain Warmup PID Timer Reset Defaults AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 133 CAL Voltage 45% 2.95v CAL Voltage 60% 3.60v CAL Voltage 80% 5.30v CAL Voltage 100% 9.10v SET Valve Position Blower Output .00v AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 133 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 134 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX E – BOILER DEFAULT SETTINGS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 135: Appendix F - Parts And Dimensional Drawings

    Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing Number: AP-A-798 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 135 of 168 Ph.: 800-526-0288...
  • Page 136 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing Number: SD-A-767 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 137 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing Number: SD-A-730 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 137 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 138 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing AP-A-842 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 139 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing Number: AP-A-843 rev D AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 139 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 140 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS Drawing Number: PL-A-159 rev G AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 141 AERCO Benchmark 2.0 LN Part List 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 1 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 141 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 142 Benchmark 2.0 LN Part List AERCO 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 2 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 143 AERCO Benchmark 2.0 LN Part List 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 3 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 143 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 144 AERCO Benchmark 2.0 LN Part List 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 4 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 145 AERCO Benchmark 2.0 LN Part List 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 5 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 145 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 146 Benchmark 2.0 LN Part List AERCO 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 6 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 147 AERCO Benchmark 2.0 LN Part List 07/11/2013 International, Inc. Blauvelt, NY 10913 28073-1 rev G (PL-A-158) Sheet 7 of 7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 147 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 148 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX F – PARTS AND DIMENSIONAL DRAWINGS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 149: Appendix G - Piping Drawings

    Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-870 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 149 of 168 Ph.: 800-526-0288...
  • Page 150 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-868 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 151 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-869 rev B AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 151 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 152 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX G – PIPING DRAWINGS Drawing Number: SD-A-874 rev C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 153: Appendix H - Wiring Schematics

    Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS APPENDIX H – WIRING SCHEMATICS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 153 of 168 Ph.: 800-526-0288 GF-123 06/18/2015...
  • Page 154 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS (This Page Is Intentionally Blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 155 APPENDIX H – WIRING SCHEMATICS WIRING SCHEMATIC, BMK 2.0 LN CP 120VAC, 60 Hz Drawing Number: 68023 rev G – Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 155 of 168 Ph.: 800-526-0288...
  • Page 156 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 157 APPENDIX H – WIRING SCHEMATICS WIRING SCHEMATIC, BMK 2.0 LN CP 120VAC, 60 Hz Drawing Number: 68023 rev G – Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 157 of 168 Ph.: 800-526-0288...
  • Page 158 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 159 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS Drawing Number: 68032 rev C – Sheet 1 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 159 of 168 Ph.: 800-526-0288...
  • Page 160 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...
  • Page 161 120 VAC, 60 Hz REF: 68032 REV. C (SHT. 2 OF 2) Drawing Number: 68032 rev C – Sheet 2 of 2 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 161 of 168 Ph.: 800-526-0288...
  • Page 162 Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX H – WIRING SCHEMATICS (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 163: Appendix I - Recommended Periodic Testing Check List

    Operator strength Panel Operating Menu. See paragraph 3.4. Low water level cut Weekly Operator See paragraph 6.4 off and alarm AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 163 of 168 GF-123 Ph.: 800-526-0288 06/018/2015...
  • Page 164 Vessel Code, Section IV See paragraph 7.6 Inspect burner Semi-Annually Service Tech. components Condensate Trap Semi-Annually Operator See paragraph 7.7 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 165: Appendix J - Benchmark Control Panel Features

    Benchmark 2.0 LN Installation, Operation & Maintenance Manual APPENDIX J – BENCHMARK CONTROL PANEL FEATURES APPENDIX J – BENCHMARK CONTROL PANEL FEATURES Figure J-1: Control Panel Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0046_0J Page 165 of 168 GF-123 Ph.: 800-526-0288...
  • Page 166 EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2: Control Panel Rear Panel AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288 GF-123...

  • Page 167: Appendix K - Recommended Spare Parts Lists

    Limit Control – Temperature Digital Controller 69177 NOTE 1 If boiler is installed in the State of Kentucky, contact your local AERCO Sales Representative for Temperature Switch rated for 200°F. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 168: Omm-0046_0J Aerco International, Inc. • 100 Oritani Dr. • Blauvelt, Ny 10913

    Combustion Air, added Direct Spark to Table 7.1 and section 7.2.2. DIR 196: Added AERLight ignition & Burkert valve proving circuit © AERCO International, Inc., 2015 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 168 OMM-0046_0J 06/18/2015 Phone: 800-526-0288...

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