Aerco Benchmark 1.5LN Installation, Operation And Maintenance Manual
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Aerco Benchmark 1.5LN Installation, Operation And Maintenance Manual

Low nox boiler
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Modulating, Condensing,
Forced Draft, Hot Water Boiler
1,500,000 BTU/H Input
Applicable for Serial Numbers:
G-12-1953 and above.
Revised: 10/18/2012
PR1: 10/18//12
Benchmark 1.5LN Low NOx Boiler
Installation, Operation and Maintenance Manual
AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
Benchmark 1.5LN
Low NOx Boiler
USER MANUAL
Installation, Operation, and Maintenance
Benchmark 1.5LN Low NOx Boiler
GF-120
OMM-0041_0E
Page 1 of 166

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  • Page 1 Applicable for Serial Numbers: USER MANUAL G-12-1953 and above. Installation, Operation, and Maintenance Benchmark 1.5LN Low NOx Boiler Revised: 10/18/2012 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 1 of 166...
  • 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. AERCO International is not liable for errors appearing in this manual.

  • Page 3: Table Of Contents

    2.10.10 EXHAUST SWITCH IN (11) ....................26 2.10.11 INTERLOCKS (10, 12) ......................26 2.10.12 FAULT RELAY (13) ........................27 2.10.13 AUXILIARY RELAY CONTACTS (14) ..................27 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 3 of 166...
  • Page 4 5.3.1 Setting the Setpoint ........................62 5.4 REMOTE SETPOINT MODES ......................63 5.4.1 Remote Setpoint Field Wiring ......................63 5.4.2 Remote Setpoint Startup ....................... 64 Page 4 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 5 7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ......90 CHAPTER 8. TROUBLESHOOTING GUIDE ...............91 8.1 INTRODUCTION ........................... 91 8.2 ADDITIONAL FAULTS WITHOUT SPECIFIC FAULT MESSAGES ..........101 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 5 of 166...
  • Page 6 WIRING SCHEMATICS APPENDIX I: RECOMMENDED PERIODIC TESTING CHECK LIST APPENDIX J: BENCHMARK CONTROL PANEL FEATURES APPENDIX K: RECOMMENDED SPARE PARTS LISTS Page 6 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 7 Foreword Foreword The AERCO Benchmark 1.5LN 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 GF-120 Benchmark 1.5LN Low NOx Boiler Installation, Operation and Maintenance Manual OMM-0041 0E (This page left intentionally blank) Page 8 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • 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 The sign shall read, in print size no less than one-half (1/2) inch in size, PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 11 of 166...

  • Page 12: Installation, Operation And Maintenance Manual Gf

    _______________ [End of Extracted Information From 248 CMR 5.08 (2)__________________ Page 12 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 13: Chapter 2. Installation

    This Chapter provides the descriptions and procedures necessary to unpack, inspect and install the AERCO Benchmark 1.5 Boiler. Brief descriptions are also provided for each available mode of operation. Detailed procedures for implementing these modes are provided in Chapter 5.

  • Page 14: Site Preparation

    Commonwealth of Massachusetts. In addition, the installation must comply with all requirements specified in Chapter 1 (Safety Precautions), pages 11 and 12. Page 14 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 15: Setting The Unit

    All piping must include ample provisions for expansion. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 15 of 166...

  • Page 16: Supply And Return Piping

    The procedure to install and connect the condensate drain is provided in paragraph 2.6.1. Page 16 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 17: Exhaust Manifold Condensate Drain

    The maximum condensate flow rate is 20 GPH. The condensate drain trap, associated fittings and drain lines must be removable for routine maintenance. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 17 of 166...

  • Page 18: Gas Supply Piping

    The gas piping used must meet all applicable codes. Page 18 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 19: Gas Supply Specifications

    W.C. to the boiler. CAUTION A lock-up style regulator MUST be used when gas supply pressure will exceed 14” W.C. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 19 of 166...

  • Page 20: Iri Gas Train Kit

    Page 20 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 21: Electrical Power Requirements

    Electrical Power Requirements 2.8.1 The AERCO Benchmark 1.5 Boiler accepts 120 VAC, single-phase, 60 Hz @ 20 A. 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 22: Modes Of Operation And Field Control Wiring

    This mode of operation increases supply water temperature as outdoor temperatures decrease. An outside air temperature sensor (AERCO Part No. 122790) is required. The sensor MUST BE wired to the I/O Box wiring terminals (see Figure 2-10). Refer to paragraph 2.10.1 for additional information on outside air temperature sensor installation.

  • Page 23: Boiler Management System Mode

    BMS to the RS485 COMM terminals on the I/O Box terminal strip. Polarity must be maintained and the shield must be connected only at the AERCO BMS. The boiler end of the shield must be left floating. For additional instructions, refer to Chapter 5, paragraph 5.6 in this manual.

  • Page 24: I/O Box Connections

    OUTDOOR SENSOR IN (1) 2.10.1 An outdoor air temperature sensor (AERCO Part No. 122790) will be 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.

  • Page 25: Air Temp. Sensor (2)

    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 26: Shield (5)

    2.10.10 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. INTERLOCKS (10, 12) 2.10.11...

  • Page 27: Fault Relay (13)

    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 28: Combustion Air

    The AERCO Benchmark 1.5 Boiler is UL listed for 100% sealed combustion. It can also be installed using room air, provided there is an adequate supply. (See paragraph 2.13.3 for more information concerning sealed combustion air).

  • Page 29: Benchmark Pump Relay Option

    Power Box as shown in Figure 2-12. Figure 2-11a: Schematic – System Pump Start using Boiler Pump Relay PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 29 of 166...
  • Page 30 Figure 2-11b: Schematic – System Pump Start using a Separate Contact Relay Figure 2-12: Identifying the Presence of BMK Pump Relay Option 69102 Page 30 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 31: Chapter 3. Control Panel Operation

    Table 3-1. Additional information on these items are provided in the individual operating procedures provided in this Chapter. Page 31 of 166 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 32 Benchmark 1.5LN Low NOx Boiler CHAPTER 3 Installation, Operation and Maintenance Manual OMM-0041 0E OPERATION VALVE POSITION Figure 3-1: Control Panel Front View Page 32 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 33 Low Water Level alarm. Switches Pressing RESET resets the water level monitor circuit. Pressing the CLEAR key (item 6) resets the display. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 33 of 166...
  • Page 34 20 segment red LED bargraph continuously shows the VALVE POSITION Air/Fuel Valve position in 5% increments from 0 to 100% Bargraph Page 34 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 35: Control Panel Menus

    The menu option choices do not wrap around. To select and store a changed menu item, press the ENTER key. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 35 of 166...

  • Page 36: 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). Page 36 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 37: Setup Menu

    RS-232 port. A view-only software version display is also provided to indicate the current Control Box software version. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 37 of 166...

  • Page 38: Configuration Menu

    The Configuration Menu settings shown in Table 3-4 are Factory-Set in accordance with the requirements specified for each individual order. Therefore, under normal operating conditions, no changes will be required. Page 38 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 39 0 min. Pump Delay Timer 0 min. 30 min. 0 min. Aux Start On Dly 0 sec. 120 sec. 0 sec. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 39 of 166...

  • Page 40: Tuning Menu

    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. Page 40 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 41: Start Sequence

    • High Water Temperature switch • High Gas Pressure switch • Low Gas Pressure switch • Blower Proof switch • Blocked Inlet switch PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 41 of 166...
  • Page 42 (100%). c. The VALVE POSITION bargraph will show 100%. MANUAL GAS SHUT-OFF VALVE SSOV AIR/FUEL VALVE INLET Figure 3-3: SSOV Location Page 42 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 43 The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. DIAL (DETAIL “A”) STEPPER MOTOR DETAIL “A” Figure 3-4: Air/Fuel Valve In Purge Position PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 43 of 166...
  • Page 44 Up to 7 seconds will be allowed for ignition to be detected. The igniter relay will be turned off one second after flame is detected. Page 44 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 45: Start/Stop Levels

    (BTU/Hr) (% of Full Capacity) 75,000 5.0% (Stop Level) 157,000 310,000 534,000 783,000 970,000 1,140,000 1,240,000 1,370,000 100% 1,500,000 100% PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 45 of 166...
  • Page 46 GF-120 Benchmark 1.5LN Low NOx Boiler CHAPTER 3 Installation, Operation and Maintenance Manual OMM-0041 0E OPERATION (This Page Is Intentionally Blank) Page 46 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 47: 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 AERCO International, Inc.

  • Page 48: Tools & Instrumentation

    MONOMETER HERE GAS INLET FOR RSI PRESSURE TEST/CALIBRATION) RSI GAS PRESSURE VALVE REGULATOR Figure 4-1: Combustion Calibration & RSI Manometer Installation Locations Page 48 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 49: 1Accessing The Vent Probe Port

    Figure 4.2: Analyzer Probe Hole Location 4.3 RSI REGULATOR SAFE TEST The Benchmark 1.5LN contains a RSI regulator in the Regulated Staged Ignition (RSI) line of the unit. The RSI regulator is calibrated prior to shipment, however the RSI system should be safe tested prior to performing the Combustion Calibration Procedure to ensure it is working properly.
  • Page 50 Paragraph 7.4.1.2 to calibrate the RSI regulator. Do NOT proceed with Combustion Calibration until the RSI is igniting properly. Figure 4-3: Observation Port Location Page 50 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 51: Natural Gas Combustion Calibration

    OMM-0041 0E 4.4 NATURAL GAS COMBUSTION CALIBRATION The Benchmark 1.5LN Boiler is combustion calibrated at the factory prior to shipping. However, recalibration as part of initial start-up is necessary due to changes in the local altitude, gas BTU content, gas supply piping and supply regulators. Factory Test Data sheets are shipped with each unit.
  • Page 52 WRENCH TO INCREASE (CW) OR DECREASE (CCW) INLET AIR IRIS ADJUSTMENT VIEW A - A Figure 4-5: Iris Air Damper Location/Adjustment Page 52 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 53 Press the CHANGE key. SET Valve Position will begin to flash. Press the ▼ arrow key until the SET Valve Position reads 60% and press the ENTER key. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 53 of 166...
  • Page 54 Press the ▼ arrow key until CAL Voltage 30% is displayed. Press the CHANGE key. CAL Voltage 30% will begin to flash. Page 54 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 55 Once the oxygen level is within the specified range at 16%, press the ENTER key to store the selected blower output voltage for the 16% valve position. This completes the natural gas combustion calibration procedure. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 55 of 166...

  • Page 56: Unit Reassembly

    If desired, the over-temperature alarm switch settings can be checked or adjusted using the procedure in paragraph 4.6.1. Page 56 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 57: Digital Alarm Switch Checks And Adjustments

    DIGITAL OVER- TEMPERATURE ALARM SWITCH DETAIL “A” Figure 4-6: Over Temperature Limit Switch Locations Digital Alarm Switch Checks and Adjustments 4.6.1 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 57 of 166...
  • Page 58 If the display does not show the required over-temperature alarm setting, press the ▲ or ▼ arrow button to change the display to the desired temperature setting. Page 58 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 59 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. Press the SET button again to enter the code. The first parameter label (SP) will appear in the display.
  • Page 60 Benchmark 1.5LN Low NOx Boiler CHAPTER 4 Installation, Operation and Maintenance Manual OMM-0041 0E INITIAL START-UP (This Page Is Intentionally Blank) Page 60 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 61: Chapter 5. Mode Of Operation

    Refer to the Indoor/Outdoor reset ratio charts in Appendix D. Choose the chart corresponding to the desired Building Reference Temperature. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 61 of 166...

  • Page 62: Constant Setpoint Mode

    Select desired setpoint using ▲ and ▼ arrow keys (40°F to 240°F) Refer to paragraph 3.3 for detailed instructions on changing menu options. Page 62 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 63: 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 64: Remote Setpoint Startup

    SETTING Boiler Mode Direct Drive Remote Signal 4-20mA/1-5V, 0-20mA/0-5V, or Network Refer to paragraph 3.3 for instructions on changing menu options. Page 64 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 65: 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 66: Bms External Field Wiring

    BMS Setup and Startup 5.6.2 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. To operate the unit in manual mode, press the AUTO/MAN switch. The REMOTE LED will go off and the MANUAL LED will light To change back to the BMS mode, simply press the AUTO/MAN switch.

  • Page 67: 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 68 Benchmark 1.5LN Low NOx Boiler CHAPTER 5 Installation, Operation and Maintenance Manual OMM-0041 0E MODE OF OPERATION (This page is intentionally blank) Page 68 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 69: Chapter 6. Safety Device Testing

    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. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 69 of 166...

  • Page 70: High Gas Pressure Test

    Start the unit in Manual mode at a valve position (firing rate) between 25 and 30%. Slowly increase the gas pressure using the adjustment screw on the SSOV. Page 70 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 71: Low Water Level Fault Test

    HIGH WATER TEMP SWITCH OPEN fault message should be displayed. It should not be possible to restart the unit. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 71 of 166...
  • Page 72 RESET BUTTON FOR MANUAL TEMPERATURE LIMIT SWITCH Alarm DIGITAL OVER- TEMPERATURE ALARM SWITCH DETAIL “A” Figure 6-2: Temperature Limit Switch Setting Page 72 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 73: Interlock Tests

    Flame faults can occur during ignition or while the unit is already running. To simulate each of these fault conditions, proceed as follows: Set the ON/OFF switch to the OFF position. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 73 of 166...
  • Page 74 The unit will execute a 30 second re-ignition delay and display WAIT RETRY PAUSE. c. The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. Page 74 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 75: Air Flow Fault Tests

    .The unit should shut down and again display AIRFLOW FAULT DURING RUN. Return the Iris Air Damper to its previous setting. Press the CLEAR button. The unit should restart. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 75 of 166...

  • Page 76: Ssov Proof Of Closure Switch

    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: Page 76 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 77: Ignition Switch Open During Ignition

    Replace the wire on the Ignition Switch and press the CLEAR button. The unit should restart. AIR/FUEL VALVE COVER (ROTATE CCW TO REMOVE) Figure 6-5: Air/Fuel Valve Cover Location PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 77 of 166...

  • Page 78: 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. Page 78 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 79: Chapter 7. Maintenance

    2 hrs. Inspect & Condensate Drain Trap *Inspect 30 mins. Clean *Only performed after initial 6 month period after initial startup. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 79 of 166...

  • Page 80: Igniter-Injector

    Disconnect the staged ignition assembly from the igniter-injector. Page 80 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 81 120° angle range shown in Figure 7-3. BLOWER INJECTOR IGNITOR- TUBE INJECTOR BURNER PLATE Figure 7-3: Igniter-Injector Orientation PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 81 of 166...

  • Page 82: Flame Detector

    CLOSE the following valves in the unit’s gas train (refer to Figure 7-4): • RSI Gas Supply Valve • RSI Bleed-off Valve Page 82 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 83 Slowly OPEN the RSI Gas Supply Valve and observe the reading on the manometer. It should have a reading of less than 8.0” w.c. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 83 of 166...
  • Page 84 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 in AUTO Mode. Page 84 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 85: Safety Device Testing

    Part No. Description 81063 Burner Gaskets (Qty=2) 81048 Flame Detector Gasket 81064 Blower Gasket To inspect or replace the burner assembly: PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 85 of 166...
  • Page 86 Remove the 10-32 x 1/2" long. grounding screw from the burner plate (Figures 7-4 and 7-5). Disconnect the gas train from the air/fuel valve by removing the four (4) 1/2” bolts and nuts (Figure 7-4). Page 86 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 87 Ensure that the igniter-injector and flame detector cutouts in the burner plate are properly aligned with the heat exchanger top flange. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 87 of 166...

  • Page 88: Condensate Drain Trap

    Loosen the four (4) thumbscrews securing the cover on the condensate trap. Remove the cover. Remove the float from the condensate trap. Remove the orifice gasket from the trap. Page 88 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

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

    Close the water supply and return valves to isolate boiler. Close external gas supply valve. Open relief valve to vent water pressure. PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 89 of 166...

  • Page 90: Placing The Boiler Back In Service After A Prolonged Shutdown

    4. Perform initial startup per Chapter 4. 5. Perform safety device testing and scheduled maintenance procedures per Chapters 6 and 7 of this manual. Page 90 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 91: Chapter 8. Troubleshooting Guide

    If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative. Page 91 of 166 PR1: 10/18//12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 92 12. 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. Page 92 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 93 6. See CORRECTIVE ACTIONS from 3 to 16 for AIRFLOW FAULT DURING IGNITION. AIRFLOW FAULT DURING IGNITION applies for this fault PR1: 10/18/12 Page 93 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 94 The RSI regulator output should be between 3.0” W.C. and 5.0” W.C. 8. Closed RSI Gas Valve in RSI line. 8. Check position of RSI Gas Valve (Figure 8-1). Page 94 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 95 2. If exhaust temperature is greater than 500 F, check incorrect combustion calibration combustion calibration. Calibrate or repair as necessary. PR1: 10/18/12 Page 95 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 96 1. See HIGH WATER TEMPERATURE SWITCH OPEN. TEMPERATURE 2. Temp HI Limit setting is too low. 2. Check Temp HI Limit setting. Page 96 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 97 4. Check “Heartbeat” LED DS1 and verify it is blinking ON & OFF 4. Defective IGST Board every second. If not, replace IGST Board. PR1: 10/18/12 Page 97 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 98 Air/Fuel Valve calibration. If calibration is okay, the problem may be in DURING the Air/Fuel Valve or the Control Box. Refer fault to qualified service IGNITION personnel. Page 98 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 99 (voltage or the type of signal being sent. Check control signal type set in current). Configuration Menu. PR1: 10/18/12 Page 99 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 100 Verify that the VALVE POSITION bargraph and the dial on the Air/Fuel Valve track FAILURE each other to indicate proper operation. If operation is not correct, perform the Stepper Feedback Calibration (GF-112, para. 6.2.1). Page 100 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 101: Additional Faults Without Specific Fault Messages

    1. Check to ensure that the IGST and Power Supply Boards are Rev. E Air/Fuel Valve “hunting” at Control Box are outdated. or higher. the 80% Valve Position PR1: 10/18/12 Page 101 of 166 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 102 Figure 8-1: High Gas Pressure Switch & Snubber Locations AIR/FUEL VALVE BLOWER BURNER PLATE FLAME IGNITOR- DETECTOR INJECTOR STAGED BURNER IGNITION SOLENOID #1 Figure 8-2: Staged Ignition Solenoid Location Page 102 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 103 Operation and Maintenance Manual Menu Items OMM-0041_0E DAMPING ORIFICE SSOV ACTUATOR WITH GAS PRESSURE ADJUSTMENT Figure 8-3: Damping Orifice Location PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 103 of 166...
  • Page 104 GF-120 Benchmark 2.0LN Low NOx Boiler CHAPTER 9 Installation, Operation and Maintenance Manual OMM-0041_0E RS232 COMM. (This page is intentionally blank) Page 104 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 105: Chapter 9. Rs232 Communication

    (if your computer has more than one) and what speed (baud rate) to use when transferring data. For further configuration options (data bits, stop bits, parity, flow control), you can PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 105 of 166...

  • Page 106: 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. Page 106 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 107: Rs232 Communication Setup

    2. Press the Enter key on the laptop. An asterisk (*) prompt should appear. 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:...

  • Page 108: Data Logging

    30 minutes of data can be lost if the unit loses power. Table 9-2 shows a sample Operation Time Log for a boiler: Page 108 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 109: Sensor Log

    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 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 109 of 166...
  • Page 110 GF-120 Benchmark 2.0LN Low NOx Boiler CHAPTER 9 Installation, Operation and Maintenance Manual OMM-0041_0E RS232 COMM. (This page is intentionally blank) Page 110 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 111 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. PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 111 of 166...
  • Page 112 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). Page 112 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 113 Hi Limit is 195°F. Sets the maximum allowable valve position for the Max Valve Position unit (40% to 100%). Default is 100%. PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 113 of 166...
  • Page 114 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) Page 114 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 115 AC current on the input of the Spark Monitor Ignition Transformer. Displays the AC current on the input of the Ignition Spark Current Transformer. PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 115 of 166...
  • Page 116 Warmup PID Timer Range = 1-240 Default = 20 Allows Tuning Menu options to be reset to their Defaults? Factory Default values. Page 116 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 117 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. PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 117 of 166...

  • Page 118: Appendix B: Startup, Status And Fault Messages

    STANDBY also displayed. Prompts the operator to wait. WAIT WARMUP Displayed for 2 minutes during the initial warm-up only. XX sec Page 118 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 119 The Low Water Cutoff board is indicating low water level. LEVEL NETWORK COMM The RS-485 network information is not present or is FAULT corrupted. Page 119 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 120 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. Page 120 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 121: 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 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 121 of 166...
  • Page 122 Temp -10F -15F -20F Table D-2: Header Temperature for a Building Reference Temperature of 60ºF RESET RATIO Temp -10F -15F -20F Page 122 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 123 RESET RATIO Temp Table D-4: Header Temperature for a Building Reference Temperature of 70ºF RESET RATIO Temp -10F -15F -20F Page 123 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 124 Table D-5: Header Temperature for a Building Reference Temperature of 75ºF RESET RATIO Temp -10F -15F Table D-6. Header Temperature for a Building Reference Temperature of 80ºF RESET RATIO Temp -10F Page 124 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 125 Operation and Maintenance Manual OMM-0041_0E RESET RATIO CHARTS Table D-7. Header Temperature for a Building Reference Temperature of 90ºF RESET RATIO Temp Page 125 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...

  • Page 126: Appendix E: Boiler Default Settings

    Setpt Lo Limit 60°F Setpt Hi Limit 195°F Temp Hi Limit 195°F Max Valve Position 100% Pump Delay Timer 0 min Page 126 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 127 Prop Band 70°F Integral Gain 1.00 Derivative Time 0.0 min Warmup Prop Band Warmup Int Gain Warmup PID Timer Reset Defaults PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 127 of 166...
  • Page 128 Cal Voltage 60% 3.80 v Cal Voltage 80% 4.60 v Cal Voltage 100% 6.00 v Set Valve Position Blower Output .00 v Page 128 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 129: Appendix F: Part And Dimensional Drawings

    Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS APPENDIX F: PART AND DIMENSIONAL DRAWINGS Page 129 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 130 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 130 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 131 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 131 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 132 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 132 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 133 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 133 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 134 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 134 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 135 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 135 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 136 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 136 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 137 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 137 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 138 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 138 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 139 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 139 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 140 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 140 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 141 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 141 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 142 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 142 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 143 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX F nstallation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 143 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 144 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX F Installation, Operation and Maintenance Manual OMM-0041_0E PARTS LISTS Page 144 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 145: Appendix G: Piping Drawings

    GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX G nstallation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS APPENDIX G: PIPING DRAWINGS PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 145 of 166...
  • Page 146 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX G Installation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS Page 146 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 147 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX G nstallation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 147 of 166...
  • Page 148 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX G Installation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS Page 148 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 149 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX G nstallation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 149 of 166...
  • Page 150 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX G Installation, Operation and Maintenance Manual OMM-0041_0E PIPING DRAWINGS Page 150 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 151: Appendix H: Wiring Schematics

    GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX H nstallation, Operation and Maintenance Manual OMM-0041_0E WIRING SCHEMATICS APPENDIX H: WIRING SCHEMATICS Page 151 of 166 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 152 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX H Installation, Operation and Maintenance Manual OMM-0041_0E WIRING SCHEMATICS (This page intentionally blank) Page 152 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 153 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX H OMM-0041_0E Installation, Operation and Maintenance Manual WIRING SCHEMATICS PR1: 10/18/12 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 153 of 166...
  • Page 154 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX H Installation, Operation & Maintenance Manual OMM-0041_0E WIRING AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 154 of 166 PR1:10/18/12...
  • Page 155 APPENDIX H GF-120 Benchmark 1.5LN Low NOx Boiler WIRING SCHEMATICS Installation, Operation & Maintenance Manual OMM-0041_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1: 10/18/12 Page 155 of 166...
  • Page 156 GF-120 Benchmark 1.5LN Low NOx Boiler APPENDIX H Installation, Operation & Maintenance Manual OMM-0041_0E WIRING AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 156 of 166 PR1:10/18/12...

  • Page 157: Appendix I: Recommended Periodic Testing Check List

    Operator Code, Section IV Inspect burner See paragraph 7.6 Semi-Annually Service Tech. components Condensate Trap Semi-Annually Operator See paragraph 7.7 PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 157 of 166...
  • Page 158 GF-120 Benchmark 2.0LN Low NOx Boiler APPENDIX I Installation, Operation and Maintenance Manual OMM-0041_0E PERIODIC TESTING (This page is intentionally blank) Page 158 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 159: Appendix J: Benchmark Control Panel Features

    Operation and Maintenance Manual OMM-0041_0E CONTROL PANEL APPENDIX J: BENCHMARK CONTROL PANEL FEATURES Figure J-1: Control Panel Exploded View PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 159 of 166...
  • Page 160 (16 PIN) EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) Figure J-2: Control Panel Rear Panel Page 160 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

  • Page 161: 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. PR1: 10/18/12 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288...
  • Page 162 GF-120 Appendix K Benchmark 2.0LN Low NOx Boiler Spare Parts Installation, Operation and Maintenance Manual OMM-0041_0E (This page is intentionally blank) Page 162 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...
  • Page 163 © AERCO International, Inc., 2012 Page 166 of 166 AERCO International Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR1:10/18/12...

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