Aerco Benchmark 3.0LN Series Installation, Operation & Maintenance Instructions Manual
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Aerco Benchmark 3.0LN Series Installation, Operation & Maintenance Instructions Manual

Gas fired low nox boiler system, condensing, modulating forced draft, hot water boiler 3,000,000 btu/h inpu
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Benchmark 3.0 Low NOx Boiler
GF-116
USER MANUAL
OMM-0038-0E
Applicable for Serial Numbers G-12-0454 and above
Installation, Operation
& Maintenance Instructions
Benchmark 3.0
Series
Gas Fired
Low NOx
Boiler System
Condensing, Modulating
Forced Draft, Hot Water Boiler
3,000,000 BTU/H Input
Latest Revision: October 10, 2017

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Summary of Contents for Aerco Benchmark 3.0LN Series

  • Page 1: Maintenance Instructions

    Benchmark 3.0 Low NOx Boiler GF-116 USER MANUAL OMM-0038-0E Applicable for Serial Numbers G-12-0454 and above Installation, Operation & Maintenance Instructions Benchmark 3.0 Series Gas Fired Low NOx Boiler System Condensing, Modulating Forced Draft, Hot Water Boiler 3,000,000 BTU/H Input Latest Revision: October 10, 2017...
  • Page 2 The information contained in this installation, operation and maintenance manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    CONTENTS GF-116 - AERCO BENCHMARK 3.0LN 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 4 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 5 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 Piping Drawings Startup, Status and Fault Wiring Schematics Messages Recommended Periodic Testing Temperature Sensor Resistance...

  • Page 7: Chapter 5 – Mode Of Operation

    FOREWORD Foreword The AERCO Benchmark 3.0LN Boiler is a modulating unit. It represents a true industry advance that meets the needs of today's energy and 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 9: Warnings & Cautions

    TO QUICKLY AND SAFELY DIS- AERCO Instruction Manual, the installation of CONNECT ELECTRICAL SERVICE. units MUST conform with local building codes, DO NOT AFFIX SWITCH TO UNIT or, in the absence of local codes, ANSI Z223.1...

  • Page 10: Emergency Shutdown

    If there is an emergency, been completed. turn off the electrical power supply to the AERCO boiler and close the manual gas valve CAUTION! located upstream the unit. The installer must DO NOT use this boiler if any part has identify the emergency shut-off device.

  • Page 11: Safety Precautions

    SAFETY PRECAUTIONS 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.
  • Page 12 SAFETY PRECAUTIONS (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer: 1.

  • Page 13: Introduction

    This Chapter provides the descriptions and procedures necessary to unpack, inspect and • Pressure/Temperature Gauge install the AERCO Benchmark 3.0 Boiler. Brief • ASME Pressure Relief Valve descriptions are also provided for each available mode of operation. Detailed procedures for •...

  • Page 14: Chapter 7 – Maintenance Requirements

    INSTALLATION 77" 18" 24" 79" 43" 101" 24" 24" REAR FRONT 4" HIGH PAD Figure 2-1 Benchmark 3.0 Boiler Clearances Remove the four (4) lag screws securing the unit WARNING to the shipping skid. Lift the unit off the shipping KEEP THE UNIT AREA CLEAR AND skid and position it on the 4 inch to 6 inch housekeeping concrete pad (required) in the...

  • Page 15: Supply And Return Piping

    INSTALLATION the insulated metal flex hose on the hot water piping connections. The physical location of the supply outlet of the boiler. In order to install the supply and return piping connections are on the water supply piping, this rod must be removed rear of the unit as shown in Figure 2-4.
  • Page 16 INSTALLATION and a 3/4” NPT x 5” long nipple. Refer to Figure 2-6 and install the trap as follows: NOTE EXHAUST MANIFOLD The condensate trap described in the following steps can be installed on the floor behind the unit as shown in Figure 2- 6.

  • Page 17: Gas Supply Piping

    2.7.2 Manual Gas Shutoff Valve 2.7 GAS SUPPLY PIPING A manual shut-off valve must be installed in the Benchmark 3.0 The AERCO Gas Components gas supply line upstream of the Boiler as shown and Supply Design Guide, GF-3030 must be in Figure 2-7.

  • Page 18: Ac Electrical Power Wiring

    Canadian Electrical Code (CEC) Part I, unit. CSA C22.1 Electrical Code. TERMINAL BLOCK For electrical power wiring diagrams, see the AERCO Benchmark 3.0 Electrical Power W iring Guide, (GF-3060). 208 VAC, 3 PHASE 460 VAC, 3 PHASE UPPER RIGHT CORNER OF FRONT PANEL...
  • Page 19 INSTALLATION TERMINAL STRIPS panel (Figure 2-10) behind the removable front door. To access the I/O Box terminal strips shown in Figure 2-10, loosen the four cover screws and remove the cover. All field wiring is installed from the rear of the panel by routing the wires through one of the four bushings provided.
  • Page 20 RS485 COMM terminals on the I/O Box terminal following paragraphs. strip. Polarity must be maintained and the shield must be connected only at the AERCO BMS. CAUTION The boiler end of the shield must be left floating. DO NOT make any connections to the...
  • Page 21 AUX SENSOR IN and SENSOR remotely monitor Setpoint, Outlet Temp or COMMON terminals and must be similar to Fire Rate Out. AERCO BALCO wire sensor Part No. 12449. A resistance chart for this sensor is provided in 2.10.6 mA OUT Appendix C.
  • Page 22 The exhaust switch should be a normally closed set of relay contacts that are rated for 5 amps at 120 VAC and 5 amps at 30 normally open type switch (such as AERCO Part No. 123463) that closes (trips) at 500°F. VDC.
  • Page 23 Benchmark Venting Combustion Air Guide, GF-2050, must be The AERCO Benchmark 3.0 Boiler is UL listed consulted before any flue gas vent or inlet air for 100% sealed combustion. It can also be venting is designed or installed. U/L listed,...
  • Page 24 Air supplied from outside the building must be Filtering During Construction provided through two permanent openings. Each When the AERCO Benchmark 3.0 Boiler is used opening must have a free area of not less than to provide heat temporarily during ongoing...

  • Page 25: Introduction

    CONTROL PANEL OPERATING PROCEDURES CHAPTER 3 CONTROL PANEL OPERATING PROCEDURES 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the Benchmark 3.0 Boiler using the Control Panel mounted on the front of the unit. It is imperative that the initial startup of this unit be performed by factory trained personnel.
  • 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 Menus

    CONTROL PANEL OPERATING PROCEDURES display the options Bottom-Up 3.3 CONTROL PANEL MENUS sequence. The menu options will wrap- The Control Panel incorporates an extensive around after the first or last available option menu structure which permits the operator to set is reached.

  • Page 29: Operating Menu

    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 PW M Input (BMS)
  • Page 32 CONTROL PANEL OPERATING PROCEDURES positions (% open). This is accomplished by 3.7 TUNING MENU 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 igniter relay is activated The unit checks to ensure that the Proof of and provides ignition spark. Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. The gas Safety Shut-Off Valve (SSOV) See Figure 3-3 for SSOV location. is energized (opened) allowing gas to flow into the Air/Fuel Valve.
  • Page 34 CONTROL PANEL OPERATING PROCEDURES DIAL 8. With the unit firing properly, it will be (DETAIL “A”) 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

    Benchmark Boiler, must be completed for 4.2.2 Installing Gas Supply Manometer each unit for warranty validation. A copy of these sheets must be returned promptly to AERCO at: The gas supply manometer is installed in the gas train as follows: AERCO International, Inc.
  • Page 36 Factory Test Data sheets 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 37 INITIAL START-UP Table 4-1 10. Next, verify that the gas pressure Combustion Oxygen Levels for a 100% downstream of the SSOV is 1.8” W.C. for Open Air/Fuel Valve Position both FM and IRI gas trains. If gas pressure adjustment is required, remove the brass Inlet Air Oxygen % Carbon...
  • Page 38 INITIAL START-UP NOTE NOTE The remaining combustion calibration steps are remaining steps basically repeat performed using the Combustion Cal Menu procedures in steps 18 through 25 for air/fuel included in the C-More Control System. The valve positions of 50%, 40%, 30% and 14% combustion calibration control functions will be open.
  • Page 39 INITIAL START-UP 37. Press the ▼ arrow key until CAL Voltage voltage to the blower motor as indicated on the display. Pressing the ▲ arrow key 40% is displayed. increases the oxygen level and pressing the 38. Press the CHANGE key. CAL Voltage 40% ▼...
  • Page 40 INITIAL START-UP 4.4 UNIT REASSEMBLY Once the combustion calibration adjustments RESET BUTTON FOR are properly set, the unit can be reassembled for MANUAL RESET TEMPERATURE LIMIT service operation. SWITCH 1. Set the ON/OFF switch in the OFF position. 2. Disconnect AC power from the unit. 3.
  • Page 41 RESE appear in the display. The switch comes unit after an from the factory with the code set at 0. alarm AERCO recommends that you do not Button condition. change this code. Increases 7. Press the SET button again to enter the UP Button code.
  • Page 42 INITIAL START-UP...

  • Page 43: Mode Of Operation

    MODE OF OPERATION CHAPTER 5 MODE OF OPERATION area where the average outside air temperature 5.1 INTRODUCTION is expected. The sensor must be shielded from The boiler is capable of being operated in any the sun's direct rays, well as direct one of six different modes.
  • Page 44 Refer to paragraph 3.3 for detailed instructions preset with settings that work well in most on changing menu options. applications. It is suggested that an AERCO representative be contacted, prior to changing 5.4 REMOTE SETPOINT MODES any temperature related function settings.
  • Page 45 I/O Box and the wire used must be a two CPU Board located in the Control Box wire shielded pair from 18 to 22 AWG. Polarity Assembly. Contact your local AERCO must be observed. The source end of the shield representative for details.
  • Page 46 Modbus signaling to the Boiler. BMS II This mode of operation is factory preset and the Model 5R5-384 can utilize only RS485 AERCO BMS controls the firing rate (air/fuel signaling to the Boiler. valve % open position). There are no setup instructions for each individual unit.
  • Page 47 These default settings work well in most Combination Control Panel see the AERCO applications. It is suggested that AERCO be CCP-1 literature. contacted prior to changing settings other than 5.7.1 Combination Control System Field the unit’s setpoint.

  • Page 48: Safety Device Testing

    SAFETY DEVICE TESTING CHAPTER 6 SAFETY DEVICE TESTING 5. While the unit is firing, slowly close the 6.1 TESTING OF SAFETY DEVICES external manual gas shut-off valve. Periodic safety device testing is required to ensure that the control system and safety 6.
  • Page 49 SAFETY DEVICE TESTING 7. Close the drain and pressure relief valve 6.3 HIGH GAS PRESSURE TEST used in draining the unit. To simulate a high gas pressure fault, refer to 8. Open the water shut-off valve in the return Figure 6-1 and proceed as follows: piping to the unit.
  • Page 50 SAFETY DEVICE TESTING that a device such as a pump, gas booster, or louver is operational. 6.6.1 REMOTE INTERLOCK 1. Remove the cover from the I/O Box and locate the REMOTE INTL’K IN terminals. 2. Start the unit in the Manual Mode and set the valve position between 25% and 30%.
  • Page 51 SAFETY DEVICE TESTING 3. Close the manual gas shutoff valve located 6.8 AIR FLOW FAULT TESTS between the Safety Shut-Off Valve (SSOV) These tests check the operation of the Blower and the Air/Fuel Valve (see Figure 6-3). Proof Switch and Blocked Inlet Switch shown in Figure 6-3.
  • Page 52 SAFETY DEVICE TESTING 10.The unit should shut down and again display AIRFLOW FAULT DURING RUN. 11.Return the Iris Air Damper to its previous setting. 12.Press the CLEAR button. The unit should restart. 6.9 SSOV PROOF OF CLOSURE SWITCH The SSOV shown in Figure 6-1 contains a proof of closure switch.
  • Page 53 SAFETY DEVICE TESTING STEPPER 6.11 IGNITION SWITCH OPEN DURING MOTOR DIAL IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: BLOWER 1. Set the unit’s ON/OFF switch to the OFF position.

  • Page 54: Chapter 7 Maintenance

    Table 7-1, following temperature. maintenance kits are available through your local AERCO Sales Representative: • Annual Maintenance Kit, Part No. 58025-01 • 24-Month Waterside/Fireside Inspection Kit, Part No. 58025-04 (See NOTE below) BURNER HOUSING NOTE...
  • Page 55 MAINTENANCE BURNER HOUSING 5. Next, loosen and remove the ignitor-injector HOUSING CENTERLINE from the burner housing using a 1" open-end IGNITOR- INJECTOR wrench. 6. Check the ignitor-injector for evidence of erosion or carbon build-up. If there is evidence of substantial erosion or carbon build-up, ignitor-injector should...
  • Page 56 MAINTENANCE The following replacement parts will 7.3 FLAME DETECTOR necessary for reassembly following inspection: The flame detector, part no. 66034, is located in the body of the burner (see Figure 7-1). The Part No. Description flame detector may be HOT. Allow the unit to 81030 Burner Gaskets (Qty= 2) cool sufficiently before removing the flame...
  • Page 57 MAINTENANCE BURNER HOUSING STAGED IGNITION ASSEMBLY FLAME DETECTOR IGNITOR- INJECTOR BURNER HOUSING BURNER GASKET GASKET BURNER BURNER GASKET Figure 7-3 Figure 7-4 Burner Disassembly Diagram - Top View Burner Assembly - Exploded View REASSEMBLY: 22. Install the ignitor- injector in the burner housing 15.
  • Page 58 MAINTENANCE 3. Loosen the four (4) thumbscrews securing 1. Loosen the clamp securing the hose to the the cover on the condensate trap. Remove condensate drain (Figure 7-6). Disconnect the cover. the hose. 4. Remove the float from the condensate trap. 2.
  • Page 59 MAINTENANCE 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME If the boiler is to be taken out of service for an extended period of time (one year or more), the following instructions must be followed. 1. Set ON/OFF switch on the front panel to the OFF position to shut down the boiler’s operating controls.

  • Page 60: Chapter 8 – Troubleshooting Guide

    6. Paragraph 8.2 and Table 8-2 contain additional troubleshooting information which may apply when no fault message is displayed. If the fault cannot be corrected using the information provided in the Troubleshooting Tables, contact your local AERCO Representative.
  • Page 61 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION AIRFLOW FAULT 1. Blower stopped running due to 1. Check combustion blower for signs of excessive heat or high current DURING IGNITION thermal or current overload drain that may trip thermal or current overload devices. 2.
  • Page 62 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 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 63 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES 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 64 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 7. Carbon or other debris on Burner 7. Remove the burner and inspect for any carbon or debris. Clean and reinstall. 8. Staged ignition ball valve closed. 8.
  • Page 65 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH GAS 1. Incorrect supply gas pressure. 1. Check to ensure gas pressure at inlet of SSOV is 2 psig PRESSURE maximum. 2. Defective SSOV Actuator gas 2.
  • Page 66 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION HIGH W ATER 1. See HIGH WATER TEMPERATURE 1. See HIGH WATER TEMPERATURE SWITCH OPEN. TEMPERATURE SWITCH OPEN. 2. Temp HI Limit setting is too low. 2. Check Temp HI Limit setting. IGN BOARD 1.
  • Page 67 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION INTERLOCK 1. Interlock jumper not installed or 1. Check for a jumper properly installed across the interlock OPEN removed terminals in the I/O box 2. Energy Management System does 2.
  • Page 68 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Defective or shorted switch. 2. If the Air/Fuel Valve does rotate to the ignition position, check the purge switch for continuity between the N.O. and COM terminals.
  • Page 69 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION RESIDUAL 1. SSOV not fully closed. 1. Check open/close indicator window of Safety Shut-Off Valve FLAME (SSOV) and ensure that the SSOV is fully closed. If not fully closed, replace the valve and or actuator.
  • Page 70 TROUBLESHOOTING TABLE 8-1. BOILER TROUBLESHOOTING – Continued FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION (continued) 2. Air/Fuel Valve unplugged. 2. Check that the Air/Fuel Valve is connected to the Control Box. 3. Loose wiring connection to 3. Inspect for loose connections between the Air/Fuel Valve motor stepper motor.
  • Page 71 TROUBLESHOOTING BURNER HOUSING STAGED IGNITION ASSEMBLY FLAME DETECTOR IGNITOR- INJECTOR Figure 8-2 Staged Ignition Solenoid Location FRONT DAMPING ORIFICE SSOV ACTUATOR Figure 8-1 High Pressure Gas Switch & Snubber Locations AIR/FUEL VALVE GAS INLET PARTIAL TOP VIEW Figure 8-3 Damping Orifice Location 8-12...

  • Page 72: Rs232 Communication Setup

    (jaguar) in lower case letters and Diagnostic Menus should only be used press Enter. by Factory-Trained service personnel). 4. “Welcome to Aerco” will appear in the laptop Menu changes will be stored in non- or “dumb terminal” display with a listing of volatile memory.
  • Page 73 RS232 COMMUNICATION 10.To display the Fault (F) Log, Sensor (S) Log as power-up, ignition and turn-off are time or Time (T) Line Log, press F, S or T stamped. Data logged while the unit is running followed by <Rtn>. Refer to paragraph 9.4 for are run-length encoded.
  • Page 74 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 11:50a Table 9-2. Sample Operation Time Log Display Status Fire Rate Flame Run Length Date Time...
  • Page 75 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS MENU LEVEL & OPTION DESCRIPTION OPERATING MENU Active Setpoint This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode.

  • Page 76: Setup Menu

    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 77 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Reset Ratio Permits setting of Reset Ratio when operating boiler 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 78 APPENDIX A APPENDIX A - BOILER MENU ITEM DESCRIPTIONS - Continued MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) HI DB Setpt EN Operating at a Valve Position below this value will inhibit the DEADBAND feature. When operating at a Valve Position below this value, the effective Setpoint is equal to Active Setpoint + DEADBAND HIGH.

  • Page 79: Tuning Menu

    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 81 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 82 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 83 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 85 APPENDIX C 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...
  • Page 86 APPENDIX C...
  • Page 87 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 88 APPENDIX E 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 89 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 90 APPENDIX E Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp...
  • Page 91 APPENDIX E 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 3.0 MBTU Boiler Mode Constant Setpoint Remote Signal...
  • Page 92 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 93 APPENDIX F APPENDIX F...
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  • Page 107 APPENDIX G APPENDIX G...
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  • Page 113 APPENDIX H APPENDIX H...
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  • Page 121: Recommended Periodic Testing

    APPENDIX I 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 122 APPENDIX I...
  • Page 123 APPENDIX K APPENDIX J CONNECTOR BOARD P/N 124366 LOW WATER CUTOFF BOARD P/N 124363 PMC BOARD P/N 124364 DISPLAY BOARD P/N 124365 GREEN LED P/N 124948 ENCLOSURE P/N 124951 ROCKER SWITCH P/N 124947 POWER SUPPLY BOARD V.F.D. DISPLAY P/N 124362 MODULE P/N 124527 IGNITION/STEPPER BOARD...
  • Page 124 APPENDIX J INTERLOCK HARNESS CONNECTOR (16 PIN) TO INPUT/OUTPUT (I/O) SHELL HARNESS CONNECTOR (19 PIN) GAS TRAIN HARNESS CONNECTOR (9 PIN) A/F VALVE HARNESS CONNECTOR (16 PIN) EXT. SENSOR/COMM HARNESS CONNECTOR (24 PIN) TO INPUT/OUTPUT (I/O) SENSOR HARNESS CONNECTOR (7 PIN) BENCHMARK CONTROL PANEL REAR VIEW...

  • Page 125: K Recommended Spare Parts

    2. For boilers with IRI gas train and serial number below G-07-0386, contact your local AERCO Sales Representative for the applicable SSOV Actuator part numbers. 3. If boiler is installed in the State of Kentucky, contact your local AERCO Sales Representative for Temperature Switch rated for 200°F max.
  • Page 126 NOTES...
  • Page 127 04/08/2013 Chris Blair Flame Rod with s/n 66020 Rev E: DIR 355: Updated burner reassembly instructions in 10/10/2017 Chris Blair section 7.6. replaced Flame Detector 66020 with 66034. PIR 764: Updated schematic drawings International Inc. © AERCO International, Inc., 2017...

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