Aerco Benchmark 2.0 Installation, Operation & Maintenance Instructions Manual
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Aerco Benchmark 2.0 Installation, Operation & Maintenance Instructions Manual

Low nox gas fired boiler system
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Instruction
GF-123
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
Installation, Operation
& Maintenance Instructions
Benchmark
2.0 Low NOx
Gas Fired
Boiler System
Natural Gas or Propane Fired
Condensing, Modulating,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable for Serial Numbers G-10-0927 and above
REVISED JUNE 14, 2010
Printed in U.S.A.

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Summary of Contents for Aerco Benchmark 2.0

  • Page 1: Maintenance Instructions

    Instruction GF-123 AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA Installation, Operation & Maintenance Instructions Benchmark 2.0 Low NOx Gas Fired Boiler System Natural Gas or Propane Fired Condensing, Modulating, Forced Draft, Hot Water Boiler 2,000,000 BTU/H Input Applicable for Serial Numbers G-10-0927 and above REVISED JUNE 14, 2010 Printed in U.S.A.
  • Page 2 AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable...

  • Page 3: Chapter 5 – Mode Of Operation

    FOREWORD 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 5: Table Of Contents

    CONTENTS GF-123 - AERCO BENCHMARK 2.0LN GAS FIRED LOW NOx BOILER Operating & Maintenance Instructions FOREWORD Chapter 1 – SAFETY PRECAUTIONS Para. Subject Page Para. Subject Page Warnings & Cautions Prolonged Shutdown Emergency Shutdown Chapter 2 – INSTALLATION Para. Subject Page Para.
  • Page 6 CONTENTS Chapter 5 – MODE OF OPERATION Para. Subject Page Para. Subject Page Introduction Boiler Management System Indoor/Outdoor Reset Mode (BMS) Constant Setpoint Mode Combination Control System Remote Setpoint Mode (CCS) Direct Drive Modes Chapter 6 – SAFETY DEVICE TESTING PROCEDURES Para.

  • Page 7: Table Of Contents

    CONTENTS Chapter 9 – RS232 COMMUNICATION Para. Subject Page Para. Subject Page Introduction Menu Processing Utilizing RS232 Communication Setup RS232 Communication Data Logging APPENDICES Subject Page Subject Page Boiler Menu Item Descriptions Dimensional and Part Drawings Startup, Status and Fault Piping Drawings Messages Wiring Schematics...

  • Page 9: Chapter 1 – Safety Precautions

    LEAKS. precautions included in these instructions. WARNING! addition to all the requirements included in this AERCO Instruction Manual, the installation of FLUIDS UNDER PRESSURE MAY units MUST conform with local building codes, CAUSE INJURY TO PERSONNEL or, in the absence of local codes, ANSI Z223.1...

  • Page 10: Emergency Shutdown

    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 Figure 1-1 identify the emergency shut-off device.

  • Page 11: Safety Precautions

    SAFETY PRECAUTIONS Extracted Information From 248 CMR 5.08 (2) – Continued a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

  • Page 13: Chapter 2 Installation

    The following accessories come standard with procedures necessary to unpack, inspect and each unit and are either packed separately install the AERCO Benchmark 2.0 Low NOx within the unit’s packing container or are factory (LN) Boiler. Brief descriptions are also provided installed on the boiler: for each available mode of operation.

  • Page 14: Chapter 7 – Maintenance Requirements

    INSTALLATION 18" 44.5" 24" 79" 101" 30" 24" 24" REAR FRONT 4" HIGH PAD Figure 2-1 Benchmark 2.0LN Boiler Clearances WARNING USE THE TABS SHOWN IN FIGURE 2-2 TO LIFT AND MOVE THE UNIT. Remove the top KEEP THE UNIT AREA CLEAR AND panel from the unit to provide access to the FREE FROM ALL COMBUSTIBLE lifting tabs.
  • Page 15 DRAIN BOILER RETURN VALVE 4" – 150# FLANGE • The trap must be removable for routine CONNECTION maintenance. AERCO recommends that a EXHAUST union be utilized between the exhaust MANIFOLD manifold condensate drain port and the trap inlet port. 1. While observing the above guidelines,...

  • Page 16: Gas Supply Piping

    The maximum static gas supply pressure to the unit must not exceed 2 psi. The specifications GAS SUPPLY PIPING for natural gas and propane are as follows: Natural Gas: AERCO Benchmark 2.0LN Components and Supply Design Guide, GF- The gas supply pressure to the unit must be...

  • Page 17: Ac Electrical Power Wiring

    INSTALLATIONS) Figure 2-6 2.8.1 Electrical Power Requirements Manual Gas Shut-Off Valve Location The AERCO Benchmark 2.0LN Boiler accepts 120 VAC, single-phase, 60 Hz @ 20A. The 2.7.4 IRI Gas Train Kit Power Box contains a terminal block as shown in Figure 2-8. In addition, a wiring diagram...
  • Page 18 I/O Box (Figure 2-10) when making temperature as outdoor temperatures decrease. all wiring connections. An outside air temperature sensor (AERCO Part Brief descriptions of each mode of operation, No. 122790) is required. The sensor MUST BE and their wiring requirements, are provided in wired to the I/O Box wiring terminals (see Figure the following paragraphs.
  • Page 19 AERCO BMS. application. For more information on wiring the The boiler end of the shield must be left floating. 4 to 20 mA / 1 to 5VDC or the 0 to 20 mA / 0 to 5 For additional instructions, refer to Chapter 5, VDC, see paragraph 2.9.3.
  • Page 20 I/O Box terminals COMMON terminals and must be similar to shown in Figure 2-10 are described in the AERCO BALCO wire sensor Part No. 12449. A following paragraphs. resistance chart for this sensor is provided in Appendix C.
  • Page 21 The fault relay is a single pole double throw of the boiler. The exhaust switch should be a (SPDT) relay having a normally open and normally open type switch (such as AERCO Part normally closed set of relay contacts that are No. 123463) that closes (trips) at 500°F.
  • Page 22 AERCO Benchmark Venting The AERCO Benchmark 2.0LN Boiler is UL Combustion Air Guide, GF-2050, must be listed for 100% sealed combustion. It can also consulted before any flue gas vent or inlet air be installed using room air, provided there is an venting is designed or installed.
  • Page 23 INSTALLATION 2.13.3 Sealed Combustion AERCO recommends that the temporary air filter be cut from a McMaster-Carr part no. 2122K315 The AERCO Benchmark 2.0LN Boiler is UL Polyester Air Filter Roll Tackfield, ½” thick, 16” listed for 100%-sealed combustion. For sealed wide, or equivalent.

  • Page 25: Chapter 3 – Control Panel Operating Procedures

    CONTROL PANEL OPERATING PROCEDURES CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 2.0LN 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.
  • Page 26 CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION LED Status Indicators Four Status LEDs indicate the current operating status as follows: COMM Lights when RS-232 communication is occurring MANUAL Lights when the unit is being controlled using the front panel keypad.
  • Page 27 CONTROL PANEL OPERATING PROCEDURES Table 3-1 Operating Controls, Indicators and Displays – Continued ITEM CONTROL, INDICATOR OR DISPLAY FUNCTION MENU Keypad Consists of 6 keys which provide the following functions for the Control Panel Menus: MENU Steps through the main menu categories shown in Figure 3- 2.
  • Page 28 CONTROL PANEL OPERATING PROCEDURES available menu options in the Top-Down 3.3 CONTROL PANEL MENUS sequence. Pressing the ▼ arrow key will The Control Panel incorporates an extensive display the options in the Bottom-Up menu structure which permits the operator to set sequence.
  • Page 29 CONTROL PANEL OPERATING PROCEDURES NOTE 3.5 SETUP MENU The following paragraphs provide brief The Setup Menu (Table 3-3) permits the descriptions of the options contained in each operator to enter the unit password (159) which menu. Refer to Appendix A for detailed is required to change the menu options.
  • Page 30 CONTROL PANEL OPERATING PROCEDURES Table 3-3. Setup Menu Available Choices or Limits Menu Item Display Minimum Maximum Default Passsword 9999 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 Baud Rate 2400, 4800, 9600, 19.2K 9600...
  • Page 31 CONTROL PANEL OPERATING PROCEDURES Table 3-4. Configuration Menu - Continued Available Choices or Limits Menu Item Display Minimum Maximum Default Remote Signal 4 – 20 mA/1 – 5V 4 – 20 mA, (If Mode = Remote 0 -20 mA/0 – 5V 1-5V Setpoint, Direct Drive PWM Input (BMS)
  • Page 32 CONTROL PANEL OPERATING PROCEDURES 3.7 TUNING MENU positions (% open). This is accomplished by providing a DC drive voltage to the motor which The Tuning Menu items in Table 3-5 are Factory adjusts the rotational speed of the blower to set for each individual unit.
  • Page 33 CONTROL PANEL OPERATING PROCEDURES 1. The DEMAND LED status indicator will light. (b) The igniter relay is activated and provides ignition spark. 2. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream (c) The gas Safety Shut-Off Valve (SSOV) Safety Shut-Off Valve (SSOV) is closed.
  • Page 34 CONTROL PANEL OPERATING PROCEDURES 8. With the unit firing properly, it will be controlled by the temperature controller circuitry. The boiler’s VALVE POSITION will be continuously displayed on the front panel bargraph. Once the demand for heat has been satisfied, the Control Box will turn off the dual SSOV gas valves.

  • Page 35: Chapter 4 – Initial Start-Up

    4.1 INITIAL START-UP REQUIREMENTS All applicable installation procedures The requirements for the initial start-up of the in Chapter 2 must be completed Benchmark 2.0 Low NOx (LN) Boiler consist of the following: before attempting to start the unit. 4.2 TOOLS AND INSTRUMENTATION •...
  • Page 36 BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit. These sheets must be Figure 4-1. filled out and returned to AERCO for proper 1/8" NPT Plug Location On Leak Warranty Validation. Detection Ball Valve It is important to perform the following procedure as outlined.
  • Page 37 INITIAL START-UP gas pressure adjustment screw (Figure 4-3). 14. If necessary, adjust the iris air damper Make gas regulator adjustments using a flat- shown in Figure 4-4 until the oxygen level is tip screwdriver to obtain 2.8” W.C. within the range specified in Table 4-1. 15.
  • Page 38 INITIAL START-UP 16. Press the MENU Key on the front panel of 26. Press the ▲ arrow key until SET Valve the C-MORE and access the Setup menu. Position appears on the C-MORE display. Enter password 6817 and then press the 27.
  • Page 39 INITIAL START-UP 50. Press the ▲ arrow key until SET Valve Combustion Oxygen Level at Position appears on the C-MORE display. 45% Valve Position 51. Press the CHANGE key. SET Valve Position will begin to flash. Oxygen % Carbon ± 0.2 Monoxide 52.
  • Page 40 13. Compare the measured oxygen % level to shipped with each unit. These sheets must be the range shown below. Also, ensure that filled out and returned to AERCO for proper the carbon monoxide (CO) and nitrogen Warranty Validation. oxide (NOx) readings do not exceed the values shown.
  • Page 41 INITIAL START-UP 16. Press the MENU Key on the front panel of 26. Press the ▲ arrow key until SET Valve the C-MORE and access the Setup menu. Position appears on the C-MORE display. Enter password 6817 and then press the 27.
  • Page 42 INITIAL START-UP Combustion Oxygen Level at 51. Press the CHANGE key. SET Valve Position 45% Valve Position will begin to flash. 52. Press the ▼ arrow key until the SET Valve Oxygen % Carbon Position reads 20%, then press the ENTER ±...
  • Page 43 INITIAL START-UP 4.6 OVER-TEMPERATURE LIMIT SWITCHES The unit contains both automatic and manual reset over-temperature limit switches. These switches are mounted on a plate as shown in Figure 4-5. The switches can be accessed by opening the front panel door of the unit. The manual reset switch is not adjustable and is permanently fixed at 210°F.

  • Page 45: Mode Of Operation

    MODE OF OPERATION CHAPTER 5 MODE OF OPERATION 5.1 INTRODUCTION 5.2.3 Outdoor Air Temperature Sensor Installation The boiler is capable of being operated in any one of six different modes. The following The outdoor air temperature sensor must be paragraphs in this Chapter provide descriptions mounted on the North side of the building in an of each of these operating modes.
  • Page 46 The unit is factory preset with settings CPU Board located in the Control Panel that work well in most applications. Prior to Assembly. Contact your local AERCO changing any temperature-related parameters, representative for details. other than the setpoint, it is suggested that an AERCO representative be contacted.
  • Page 47 It is suggested that an AERCO 4-20 mA/1-5 Vdc representative be contacted, prior to changing 0-20 mA/0-5 Vdc any temperature related function settings.
  • Page 48 Model 5R5-384 can utilize only RS485 signaling to the Boiler. This mode of operation is factory preset and the AERCO BMS controls the firing rate (air/fuel The BMS mode of operation is used in valve % open position). There are no setup conjunction with an AERCO Boiler Management instructions for each individual unit.
  • Page 49 100% valve values. These default settings work well in most position, the BMS will then ask the Combination applications. It is suggested that AERCO be Control Panel for the domestic boilers to contacted prior to changing settings other than become space-heating boilers.

  • Page 51: Safety Device Testing

    SAFETY DEVICE TESTING CHAPTER 6 SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES 4. Place the unit in Manual Mode and adjust the air/fuel valve position (% open) between Periodic safety device testing is required to 25 and 30%. ensure that the control system and safety devices are operating properly.
  • Page 52 SAFETY DEVICE TESTING shut the unit off immediately and refer fault 6.3 HIGH GAS PRESSURE TEST to qualified service personnel. To simulate a high gas pressure fault, refer to 7. Close the drain and pressure relief valve Figure 6-1 and proceed as follows: used in draining the unit.
  • Page 53 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 2-9) and are labeled REMOTE INTL’K IN and DELAYED INTL’K IN.
  • Page 54 SAFETY DEVICE TESTING 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: 1.
  • Page 55 SAFETY DEVICE TESTING 5. Re-enable the blower output drive voltage 6. The unit should fault and display SSOV by performing the following steps: SWITCH OPEN. 7. Replace wire #148 and press the CLEAR (a) Press the MENU key until CONFIGUR- ATION MENU is displayed.
  • Page 56 SAFETY DEVICE TESTING 5. The unit should begin it’s start sequence, then shut down and display PRG SWITCH OPEN DURING PURGE. 6. Replace the wire on the Purge Switch and depress the CLEAR button. The unit should restart. 6.11 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve.

  • Page 57: Recommended Spare Parts

    Table 7-1, following • DISCONNECT THE AC SUPPLY BY maintenance kits are available through your local AERCO Sales Representative: TURNING SERVICE SWITCH AND AC SUPPLY CIRCUIT • Annual Maintenance Kit, Part No. 58025-01 BREAKER. • 24-Month Waterside/Fireside Inspection Kit, •...
  • Page 58 MAINTENANCE 4. Refer to the partial exploded view in Figure 7.2 IGNITOR-INJECTOR 7-2. Using a 7/16” open-end wrench, disconnect the compression nut securing the The ignitor-injector (part no. 58023) is located on gas injector tube of the ignitor-injector to the the burner plate at the top of the boiler.
  • Page 59 Figures 7-1 and 7-2). The flame detector may be blower and air/fuel valve in addition to the hot. Allow the unit to cool sufficiently before Benchmark 2.0 Low NOx burner. removing the flame detector. The following parts will be necessary for...
  • Page 60 MAINTENANCE To inspect or replace the burner assembly: 1. Set the ON/OFF switch on the control panel, 7. Using a 7/16” open-end wrench, disconnect to the OFF position. Disconnect AC power the compression nut securing the gas injector tube of the ignitor-injector to the from the unit and turn off the gas supply.
  • Page 61 MAINTENANCE BLOWER 19. Beginning with burner assembly PROOF BLOCKED removed in step 17, reinstall all the SWITCH INLET SWITCH components in the reverse order that they BLOWER AIR/FUEL were removed. During reassembly, replace VAVLE the gaskets for the blower and flame detector with new parts.
  • Page 62 MAINTENANCE 7.9 PLACING THE BOILER BACK IN 4. Remove the float from the condensate trap. SERVICE AFTER A PROLONGED 5. Remove the orifice gasket from the trap. SHUTDOWN 6. Thoroughly clean the trap and gasket. Also After a prolonged shutdown (one year or more), inspect the drain piping for blockage.

  • Page 63: Chapter 8 – Troubleshooting Guide

    This troubleshooting guide is intended to aid fault: service/maintenance personnel in isolating the cause of a fault in a Benchmark 2.0 Boiler. The 1. Observe the fault messages displayed in the troubleshooting procedures contained herein are Control Box display.

  • Page 64: Troubleshooting

    TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped running due to thermal 1. Check combustion blower for signs of excessive heat or high DURING IGNITION or current overload current drain that may trip thermal or current overload devices. 2.
  • Page 65 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION AIRFLOW FAULT 1. Blower not running or running too slow 1. Start the unit. If the blower does not run check the blower solid DURING PURGE state relay for input and output voltage. If the relay is okay, check the blower.
  • Page 66 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION DELAYED 1. Delayed Interlock Jumper not 1. Check for a jumper properly installed across the delayed INTERLOCK OPEN installed or removed. interlock terminals in the I/O box. 2.
  • Page 67 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION (continued) 8. Defective staged ignition solenoid 8. When boiler goes to ignition, listen to solenoid valve to ensure it valve. is opening. 9. Clogged staged ignition piece. 9.
  • Page 68 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION (continued) 3. Defective High Gas Pressure Switch 3. Remove the leads from the high gas pressure switch and measure continuity across the common and normally closed terminals with the unit not firing. Replace the switch if it does not show continuity.
  • Page 69 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION IGN SWTCH CLOSED 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge DURING PURGE (open) position. If the valve does not rotate at all or does not rotate fully open, check the Air/Fuel Valve calibration.
  • Page 70 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION LINE VOLTAGE 1. Line and Neutral switched in AC 1. Check hot and neutral in AC Power Box to ensure they are not OUT OF PHASE Power Box. reversed 2.
  • Page 71 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION PRG SWTCH OPEN 1. Defective purge switch. 1. If the air-fuel valve does rotate, check the purge switch for DURING PURGE continuity when closing. Replace switch if continuity does not exist.
  • Page 72 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION SSOV FAULT See SSOV SWITCH OPEN DURING PURGE SSOV FAULT 1. SSOV switch closed for 15 seconds 1. Replace or adjust microswitch in SSOV actuator. If fault during run.
  • Page 73 TROUBLESHOOTING ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES Refer to Table 8-2 to troubleshoot faults which may occur without a specific fault message being displayed. TABLE 8-2. BOILER TROUBLESHOOTING WITH NO FAULT MESSAGE DISPLAYED OBSERVED INCIDENT PROBABLE CAUSES TROUBLESHOOTING/CORRECTIVE ACTION Hard Light-Off 1.
  • Page 74 TROUBLESHOOTING HIGH GAS PRESSURE DAMPING SWITCH ORIFICE TO AIR/FUEL VALVE SSOV SNUBBER LOW GAS PRESSURE SWITCH MANUAL SHUT-OFF VALVE SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT Figure 8-3 STAGED IGNITION LINE Damping Orifice Location INLET BALL VALVE Figure 8-1 High Pressure Gas Switch & Snubber Locations Figure 8-2 Staged Ignition Solenoid Location 8-12...

  • Page 75: Rs232 Communication Setup

    Enter. Chapter 3, Tables 3-2 through 3-5 for allowable entry ranges and settings for 4. “Welcome to Aerco” will appear in the laptop the Operating, Setup, Configuration and or “dumb terminal” display with a listing of Tuning Menus. (The Calibration and...

  • Page 76: Operation Time Log

    RS232 COMMUNICATION 9.4.2 Operation Time Log (c) Menu changes will be stored in non- volatile memory. The Operation Time Log consists of a string of 9. To redisplay the menu and view the option ASCII records stored in non-volatile memory which was just changed in step 5, enter D within the C-More Control Panel.
  • Page 77 RS232 COMMUNICATION Table 9-1. Sample Fault Log Display Fault Message Cycle Date Time Direct Drive Signal Fault 1/10/02 8:42am Low Gas Pressure 7/04/01 5:29pm Loss of Power 1/01/01 11:50am Table 9-2. Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time...
  • Page 79 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode.
  • Page 80 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - CONTINUED MENU LEVEL & OPTION DESCRIPTION SETUP MENU Password Allows password to be entered. Once the valid password (159) is entered, options in the Setup, Configuration and Tuning Menus can be modified.
  • Page 81 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Reset Ratio Permits setting of Reset Ratio when operating boiler in the Outdoor Reset Mode. Reset Ratio is adjustable from 0.1 to 9.9. Default is 1.2. Outdoor Sensor Allows outdoor sensor function to be enabled or disabled.
  • Page 82 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH.
  • Page 83 APPENDIX A MENU LEVEL & OPTION DESCRIPTION TUNING MENU Prop Band Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature. If the actual error is less than the proportional band setting (1 to 120°F), the fire rate will be less than 100%.
  • Page 85 APPENDIX B APPENDIX B - STARTUP, STATUS AND FAULT MESSAGES TABLE B-1. STARTUP AND STATUS MESSAGES MESSAGE DESCRIPTION DEMAND DELAY Displayed if Demand Delay is active. XX sec DISABLED Displayed if ON/OFF switch is set to OFF. The display also HH:MM pm, pm shows the time (am or pm) and date that the unit was MM/DD/YY...
  • Page 86 APPENDIX B TABLE B-2. FAULT MESSAGES FAULT MESSAGE FAULT DESCRIPTION AIRFLOW FAULT The Blower Proof Switch opened during purge, DURING PURGE or air inlet is blocked. AIRFLOW FAULT The Blower Proof Switch opened during ignition. DURING IGN AIRFLOW FAULT The Blower Proof Switch opened during run. DURING RUN DELAYED The Delayed Interlock is open.
  • Page 87 APPENDIX B TABLE B-2. FAULT MESSAGES - Continued FAULT MESSAGE FAULT DESCRIPTION OUTDOOR TEMP The temperature measured by the Outdoor Air Sensor is out SENSOR FAULT of range. OUTLET TEMP The temperature measured by the Outlet Sensor is out of SENSOR FAULT range: •...
  • Page 89 APPENDIX C TEMPERATURE SENSOR RESISTANCE VOLTAGE CHART (BALCO) TEMP (°F) RES (OHMS) VOLTS* 779.0 1.93 797.5 1.96 816.3 1.99 835.4 2.02 854.8 2.05 874.6 2.07 894.7 2.10 915.1 2.12 935.9 2.15 956.9 2.17 978.3 2.20 1000.0 2.23 1022.0 2.25 1044.4 2.27 1067.0 2.30...
  • Page 91 APPENDIX D APPENDIX D. - INDOOR/OUTDOOR RESET RATIO CHARTS Table D-1. Header Temperature for a Building Reference Temperature of 50F RESET RATIO Temp -10F -15F -20F Table D-2. Header Temperature for a Building Reference Temperatrure of 60F RESET RATIO Temp -10F -15F -20F...
  • Page 92 APPENDIX D Table D-3. Header Temperature for a Building Reference Temperature of 65F RESET RATIO Temp Table D-4. Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F...
  • Page 93 APPENDIX D Table D-5. Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Table D-6. Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F...
  • Page 94 APPENDIX D Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp...

  • Page 95: Configuration Menu

    APPENDIX E BOILER DEFAULT SETTINGS MENU & OPTION FACTORY DEFAULT Setup Menu Password Language English Unit of Temp Fahrenheit Comm Address Baud Rate 9600 Configuration Menu Internal Setpt 130°F Unit Type BMK Boiler LN Unit Size 2.0 MBTU Boiler Mode Constant Setpoint Remote Signal 4 –...
  • Page 96 APPENDIX E BOILER DEFAULT SETTINGS - Continued MENU & OPTION FACTORY DEFAULT Configuration Menu --Continued Network Timeout 30 seconds Hi DB Setpt En Demand Offset Deadband High Deadband Low Tuning Menu Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min...
  • Page 97 APPENDIX F...
  • Page 98 APPENDIX F...
  • Page 99 APPENDIX F...
  • Page 100 APPENDIX F...
  • Page 101 APPENDIX F...
  • Page 102 APPENDIX F...
  • Page 103 COND. TRAP ASSEMBLY SEE DRAWING AP-A- FOR DUAL FUEL DETAILS AERCO INTERNATIONAL, INC. NORTHVALE, NJ 07647 BENCHMARK 2.0 LOW NOx BOILER PARTS LIST PL - A - 158 DRAWN BY: SJD DATE: 10/13/09 (SHEET 2 OF 7) *NOT TO SCALE*...
  • Page 104 APPENDIX F...
  • Page 105 APPENDIX F...
  • Page 106 APPENDIX F F-10...
  • Page 107 APPENDIX F F-11...
  • Page 108 APPENDIX F F-12...
  • Page 109 APPENDIX G...
  • Page 110 APPENDIX G...
  • Page 111 APPENDIX G...
  • Page 112 APPENDIX G...
  • Page 113 APPENDIX H...
  • Page 114 APPENDIX H...
  • Page 115 APPENDIX H...

  • Page 116: Wiring Schematics

    APPENDIX H CONTROL BOX CONNECTORS 16-PIN CONNECTOR 24-PIN CONNECTOR 10 11 13 14 17 18 19 22 23 24 13 12 14 15 INPUT/OUTPUT BOX WIRING SCHEMATIC, BMK 1.5 LN IRI 120 VAC, 60 Hz REF: 68030 REV. C (SHT. 2 OF 2)

  • Page 117: Recommended Periodic Testing

    APPENDIX I RECOMMENDED PERIODIC TESTING CHECK LIST WARNING NOTE: Periodic testing of all boiler controls and safety devices is required to determine that they are operating as designed. Precautions shall be taken while tests are being performed to protect against bodily injury and property damage.
  • Page 119 APPENDIX J BENCHMARK CONTROL PANEL EXPLODED VIEW...
  • Page 120 APPENDIX J BENCHMARK CONTROL PANEL REAR VIEW...
  • Page 121 PART NUMBER C-More Control Box 181197-1 Burner 46012 Temperature Switch - Auto Reset (SEE NOTE 1) 123966 NOTE 1: If boiler is installed in the State of Kentucky, contact your local AERCO Sales Representantive for Temperature Switch rated for 200°F.

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