Watts AERCO Benchmark 2.0LN User Manual
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Watts AERCO Benchmark 2.0LN User Manual

Dual-fuel low nox boiler
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Benchmark 2.0LN Dual-Fuel Low NOx Boiler
Modulating, Condensing,
Forced Draft, Hot Water Boiler
2,000,000 BTU/H Input
Applicable for Serial Numbers:
G-11-2402 and above.
Revised: 04/22/2013
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288
PR2: 04/22/13
Operation and Maintenance Manual
Installation, Operation, and Maintenance
Benchmark
2.0LN Dual-Fuel
Low NOx Boiler
USER MANUAL
Benchmark 2.0LN Low NOx Boiler
GF-127
OMM-0052_0E
Page 1 of 158

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  • Page 1 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E Benchmark Modulating, Condensing, Forced Draft, Hot Water Boiler 2.0LN Dual-Fuel 2,000,000 BTU/H Input Low NOx Boiler Applicable for Serial Numbers: G-11-2402 and above. USER MANUAL Installation, Operation, and Maintenance Benchmark 2.0LN Low NOx Boiler Revised: 04/22/2013 AERCO International, Inc.
  • Page 2 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E Technical Support: (Mon–Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com Disclaimer The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application.

  • Page 3: Table Of Contents

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E Table of Contents CHAPTER 1: SAFETY PRECAUTIONS .................. 9 1.1 WARNINGS & CAUTIONS ..................9 1.2 EMERGENCY SHUTDOWN ................10 1.3 PROLONGED SHUTDOWN ................10 CHAPTER 2: INSTALLATION ....................11 2.1 INTRODUCTION ....................
  • Page 4 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E Interlocks (10, 12) ................... 23 2.10.11 Fault Relay (13)....................24 2.10.12 Auxiliary Relay Contacts (14) ................24 2.10.13 2.11 FLUE GAS VENT INSTALLATION ..............24 2.12 COMBUSTION AIR ................... 24 2.12.1 Combustion Air From Outside the Building ............
  • Page 5 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E 5.3 CONSTANT SETPOINT MODE ................57 5.3.1 Setting the Setpoint ....................57 5.4 REMOTE SETPOINT MODES ................58 5.4.1 Remote Setpoint Field Wiring ................. 58 5.4.2 Remote Setpoint Startup ..................59 5.5 DIRECT DRIVE MODES ..................
  • Page 6 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E 7.8 SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ..81 7.9 PLACING THE BOILER BACK IN SERVICE AFTER A PROLONGED SHUTDOWN ......................81 CHAPTER 8: TROUBLESHOOTING GUIDE ..............83 INTRODUCTION ....................
  • Page 7 OMM-0052_0E Foreword The AERCO Benchmark 2.0LN Dual-Fuel Low NOx (LN) Boiler is a modulating unit. It represents a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 8 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 8 of 158 PR2: 04/22/13...

  • Page 9: Chapter 1: Safety Precautions

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 1: SAFETY PRECAUTIONS OMM-0052_0E CHAPTER 1: SAFETY PRECAUTIONS 1.1 WARNINGS & CAUTIONS Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions.

  • Page 10: Emergency Shutdown

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 1: SAFETY PRECAUTIONS OMM-0052_0E WARNING electrical voltages up to 120 vac may be used in this equipment. Therefore the cover on the unit’s power box (located behind the front panel door) must be installed at all times, except during maintenance and servicing.

  • Page 11: Chapter 2: Installation

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

  • Page 12: Installation Clearances

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E • Access to AC Input Power at 120 VAC, Single-Phase, 60 Hz @ 20 Amps • Access to Natural Gas line at a minimum supply gas pressure of 8.5" W.C. •...

  • Page 13: Supply And Return Piping

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E locations. Two lifting tabs are provided at the top of the heat exchanger. Figure 2-2 shows the location of the tab on the top-left side. The second tab is located on the top-right side of the heat exchanger.

  • Page 14: Condensate Drain And Piping

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E Figure 2-3: Supply and Return Locations 2.6 CONDENSATE DRAIN AND PIPING The Benchmark 2.0LN Boiler is designed to condense water vapor from the flue products. Therefore, the installation must have provisions for suitable condensate drainage or collection.

  • Page 15: Exhaust Manifold Condensate Drain

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E BOILER RETURN EXHAUST MANIFOLD 1/2” NPT CONDENSATE DRAIN CONNECTION HOUSE- KEEPING Figure 2-4: Condensate Drain Connection Location 2.6.1 Exhaust Manifold Condensate Drain NOTE There are two slightly different types of condensate traps that may be used in your configuration;...

  • Page 16: Gas Supply Piping

    OMM-0052_0E Figure 2-5: Condensate Trap Installation: Older (left) and Newer (right) Style 2.7 GAS SUPPLY PIPING The AERCO Benchmark 2.0LN Gas Components and Supply Design Guide, GF-2030 must be consulted prior to designing or installing any gas supply piping. WARNING NEVER USE MATCHES, CANDLES, FLAMES OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.

  • Page 17: Gas Supply Specifications

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E 2.7.1 Gas Supply Specifications. The maximum static pressure to the unit must not exceed 14” W.C. The specifications for natural gas and propane are as follows: Natural Gas: The gas supply pressure to the unit must be of sufficient capacity to provide 2000 cfh while maintaining the gas pressure at 4.0"...

  • Page 18: Ac Electrical Power Wiring

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

  • Page 19: Modes Of Operation And Field Control Wiring

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E 120 VAC, 1 PHASE Figure 2-8: AC Terminal Block Configurations 2.9 MODES OF OPERATION AND FIELD CONTROL WIRING The Benchmark 2.0 Boiler is available in several different modes of operation. While each unit is factory configured and wired for its intended mode, some additional field wiring may be required to complete the installation.

  • Page 20: Indoor/Outdoor Reset Mode

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E utilized (see paragraphs 2.10.11.1 and 2.10.11.2). 2.9.2 Indoor/Outdoor Reset Mode 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).

  • Page 21: I/O Box Connections

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E CCP (Combination Control Panel), and the BMS (Boiler Management System). For ACS applications, the wiring is between the ACS panel, the ACS Relay panel (optional, depending on applications), and the RS485 comm terminals in the I/O box.

  • Page 22: Air Temp. Sensor (2)

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E The factory default for the outdoor sensor is DISABLED. To enable the sensor and/or select an enable/disable outdoor temperature, see the Configuration menu in Chapter 3. The outdoor sensor may be wired up to 200 feet from the boiler.

  • Page 23: Shield (5)

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E valve position = a 95% ON pulse. Shield (5) 2.10.5 The SHIELD terminals are used to terminate any shields used on sensor wires connected to the unit.

  • Page 24: Fault Relay (13)

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

  • Page 25: Combustion Air From Outside The Building

    2.12.3 Sealed Combustion The AERCO Benchmark 2.0LN Boiler is UL listed for 100%-sealed combustion. For sealed combustion installations, the screen on the air inlet duct of the unit must be removed. The inlet air ductwork must then be attached directly to the unit’s air inlet.
  • Page 26 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 2: INSTALLATION OMM-0052_0E • 480 VA Pilot Duty @ 240-277 VAC If pump/valve load exceeds the above contact ratings, use a separate contact relay. See Diagrams 2-1a and 2-1b. To identify if the boiler is equipped with the BMK Pump Relay Option (part no.

  • Page 27: Chapter 3: Control Panel Operation

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 3: CONTROL PANEL OPERATION 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 28 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Figure 3-1: Control Panel Front View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 28 of 158 PR2: 04/22/13...
  • Page 29 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Table 3-1 Operating Controls, Indicators and Displays ITEM CONTROL, INDICATOR OR FUNCTION DISPLAY Four Status LEDs indicate the current operating status as LED Status follows: Indicators Lights when RS-232 communication is occurring...
  • Page 30 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Table 3-1 Operating Controls, Indicators and Displays (Continued) ITEM CONTROL, INDICATOR OR FUNCTION DISPLAY Consists of 6 keys which provide the following functions for the MENU Keypad Control Panel Menus: Steps through the main menu categories shown in Figure 3-2.

  • Page 31: Control Panel Menus

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E 3.3 CONTROL PANEL MENUS The Control Panel incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of five major menu categories which are applicable to this manual.

  • Page 32: Operating Menu

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Figure 3-2: Control Panel Menu Structure NOTE The following paragraphs provide brief descriptions of the options contained in each menu. Refer to Appendix A for detailed descriptions of each menu option.

  • Page 33: Setup Menu

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E 3.5 SETUP MENU The Setup Menu (Table 3-3) permits the operator to enter the unit password (159) which is required to change the menu options. To prevent unauthorized use, the password will time- out after 1 hour.

  • Page 34: Configuration Menu

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E 3.6 CONFIGURATION MENU The Configuration Menu shown in Table 3-4 permits adjustment of the Internal Setpoint (Setpt) temperature regardless of whether the valid password has been entered. Setpt is required for operation in the Constant Setpoint mode.

  • Page 35: Tuning Menu

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Table 3-4: Configuration Menu (Continued) Aux Start On Dly 0 sec. 120 sec. 0 sec. Failsafe Mode Shutdown or Constant Setpt Shutdown *Analog Output Off, Setpoint, Outlet Temp, *Valve Position (See CAUTION at end of Table...

  • Page 36: Start Sequence

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Table 3-6: Combustion Cal Menu – Natural Gas Available Choices or Limits Menu Item Display Minimum Maximum Default CAL Voltage 20% .25 Vdc 10.0 Vdc 1.00 Vdc CAL Voltage 30%...
  • Page 37 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E The DEMAND LED status indicator will light. The unit checks to ensure that the Proof of Closure (POC) switch in the downstream Safety Shut-Off Valve (SSOV) is closed. Figure 3-3 shows the Natural Gas SSOV location for a Factory Mutual (FM) Gas Train.
  • Page 38 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E c) The gas Safety Shut-Off Valve (SSOV) is energized (opened) allowing gas to flow into the Air/Fuel Valve. Figure 3-4: Air/Fuel Valve In Purge Position Figure 3-5: Blower Proof Switch AERCO International, Inc.

  • Page 39: Start/Stop Levels

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Figure 3-6: Air/Fuel Valve In Ignition Position 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 40 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 3: CONTROL PANEL OPERATION OMM-0052_0E Note that the energy input of the boiler is not linearly related to the Air/Fuel Valve position. Refer to Table 3-8 for the relationship between the energy input and Air/Fuel Valve position for a unit running on natural gas.

  • Page 41: Chapter 4: Initial Start-Up

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 4: INITIAL START-UP 4.1 INITIAL START-UP REQUIREMENTS The requirements for the initial start-up of the Benchmark 2.0LN Dual-Fuel Boiler consists of the following: • Complete installation (Chapter 2) •...

  • Page 42: Required Tools & Instrumentation

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E 4.2.1 Required Tools & Instrumentation The following tools and instrumentation are necessary to perform combustion calibration of the unit: • Digital Combustion Analyzer: Oxygen accuracy to ± 0.4%; Carbon Monoxide (CO) and Nitrogen Oxide (NOx) resolution to 1PPM.

  • Page 43: Accessing The Analyzer Probe Port

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E NOTE If a second 16” W.C. manometer is available, it can be installed in the SSOV downstream location to provide continuous monitoring at both the upstream and downstream ports of the SSOV. ]Install the 16”...

  • Page 44: Natural Gas Combustion Calibration

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Flame Observation Port Figure 4-3: Flame Observation Port Location 4.3 NATURAL GAS COMBUSTION CALIBRATION The Benchmark 2.0LN Dual-Fuel 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.
  • Page 45 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Figure 4-4: Gas Pressure Adjustment Screw Location Set the ON/OFF switch to the ON position. 10. Change the valve position to 34% using the ▲ arrow key. The unit should begin its start sequence and fire.
  • Page 46 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Figure 4-5: Iris Air Damper Location/Adjustment NOTE The remaining combustion calibration steps are performed using the Combustion Cal Menu included in the C-More Control System. The combustion calibration control functions will be used to adjust the oxygen level (%) at valve positions of 80%, 60%, 45%, 30% and 20% as described in the following steps.
  • Page 47 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E 25. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys. This will adjust the output voltage to the blower motor as indicated on the display.
  • Page 48 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Table 4-4: Combustion Oxygen Levels for a 45% Air/Fuel Valve Position Oxygen % Carbon Monoxide ± 0.2 6.4 % <50 ppm <20 ppm 41. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys.

  • Page 49: Propane Combustion Calibration

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Oxygen % Carbon Monoxide ± 0.2 8.8 % <50 ppm <20 ppm 57. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys.
  • Page 50 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Set the Fuel Selector Switch (Figure 4-4) to the PROPANE position. 10. Set the ON/OFF switch to the ON position. 11. Change the valve position to 34% using the ▲ arrow key. The unit should begin its start sequence and fire.
  • Page 51 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Table 4-8: Combustion Oxygen Level at Valve Position Oxygen % Carbon Monoxide ± 0.2 4.8 % <150 ppm <100 ppm 25. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys.
  • Page 52 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E 40. The oxygen level at the 45% valve position should be as shown below. Also, ensure that the carbon monoxide (CO) and nitrogen oxide (NOx) readings do not exceed the values shown. Table 4-10: Combustion Oxygen Level at Valve Position Oxygen %...

  • Page 53: Unit Reassembly

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Table 4-12: Combustion Oxygen Level at Valve Position Oxygen % Carbon Monoxide ± 0.2 8.9 % <100 ppm <100 ppm 57. If the oxygen level is not within the specified range, adjust the level using the ▲ and ▼ arrow keys.

  • Page 54: Digital Alarm Switch Checks And Adjustments

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E RESET BUTTON DIGITAL OVER- FOR MANUAL TEMPERATURE TEMPERATURE ALARM SWITCH LIMIT SWITCH ADJUSTABLE TEMPERATURE LIMIT SWITCH FUEL SELECTOR SWITCH Figure 4-6: Over Temperature Limit Switch and Fuel Selector Locations 4.6.1 Digital Alarm Switch Checks and Adjustments The digital alarm switch settings can be checked or adjusted using the controls and display on the front...
  • Page 55 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 4: INITIAL START-UP OMM-0052_0E Table 4-13: Digital Alarm Switch Controls and Display CONTROL or Display MEANING FUNCTION LED Display TEMP status Displays current water temperature or setpoint. RESET Button Resets the unit after an alarm condition.

  • Page 56: Chapter 5: Mode Of Operation

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 5: MODE OF OPERATION 5.1 INTRODUCTION The boiler is capable of being operated in any one of six different modes. The following paragraphs in this Chapter provide descriptions of each of these operating modes. Each boiler is shipped from the factory tested and configured for the ordered mode of operation.

  • Page 57: Constant Setpoint Mode

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E NOTE A design engineer typically provides design outdoor air temperature and supply header temperature data. 4. Once the design outdoor air temperature is chosen, go across the chart to the desired supply header temperature for the design temperature chosen in step 3.

  • Page 58: Remote Setpoint Modes

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E 5.4 REMOTE SETPOINT MODES The unit’s setpoint can be remotely controlled by an Energy Management System (EMS) or Building Automation System (BAS). The Remote Setpoint can be driven by a current or voltage signal within the following ranges: •...

  • Page 59: Remote Setpoint Startup

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E 5.4.2 Remote Setpoint Startup Since this mode of operation is factory preset and the setpoint is being externally controlled, no startup instructions are necessary. In this mode, the REMOTE LED will light when the external signal is present.

  • Page 60: Direct Drive Field Wiring

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E 5.5.1 Direct Drive Field Wiring The only wiring connections necessary for Direct Drive mode are connection of the remote signal leads from the source to the unit’s I/O Box. For either a 4-20mA/0-5V or a 0-20mA/0-5V setting, the connections are made at the ANALOG IN terminals in the I/O Box.

  • Page 61: Bms Setup And Startup

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E front of the boilers. Refer to the wiring diagram provided on the cover of the I/O Box. Wiring connections for RS485 Modbus control are made between connector JP11 on the BMS (boilers 9 through 40) or JP6 on BMS II/ACS (boilers 1-32) and the RS485 COMM terminals in the I/O Box on the front of the boilers.

  • Page 62: Combination Control System Setup And Startup

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 5: MODE OF OPERATION OMM-0052_0E Replay Panel (optional, depending on application), and the RS485 Comm terminals in the I/O box. Wire the units using a shielded twisted pair of 18 to 22 AWG wire. When wiring multiple units, each unit’s wiring must conform to the above.

  • Page 63: Chapter 6: Safety Device Testing

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 6: SAFETY DEVICE TESTING 6.1 TESTING OF SAFETY DEVICES Periodic safety device testing is required to ensure that the control system and safety devices are operating properly. The boiler control system comprehensively monitors all combustion- related safety devices before, during and after the start sequence.

  • Page 64: Propane Low Gas Pressure Fault Test

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E PROPANE GAS HIGH GAS PRESSURE SWITCH NATURAL GAS HIGH PROPANE SSOV GAS PRESSURE SWITCH 1/4” PLUG & LEAK DETECTION BALL VALVE (Install manometer here for High Gas Pressure PROPANE LOW Tests)

  • Page 65: Natural Gas High Gas Pressure Test

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E 6.4 NATURAL GAS HIGH GAS PRESSURE TEST To simulate a natural gas high gas pressure fault, refer to Figure 6-1 and proceed as follows: Ensure that the Fuel Selector Switch (Figure 6-2) is set to the NATURAL GAS position.

  • Page 66: Low Water Level Fault Test

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E 6.6 LOW WATER LEVEL FAULT TEST To simulate a low water level fault: Set the ON/OFF switch to the OFF position Close the water shut-off valves in the supply and return piping to the unit. Slowly open the drain valve on the rear of the unit.

  • Page 67: Interlock Tests

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E Figure 6-2: Temperature Limit Switch Setting 6.8 INTERLOCK TESTS The unit is equipped with two interlock circuits called the Remote Interlock and Delayed Interlock.

  • Page 68: Delayed Interlock

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E 6.8.2 DELAYED INTERLOCK Remove the cover from the I/O Box and locate the DELAYED INTL’K IN terminals. Start the unit in the Manual Mode at a valve position between 25% and 30%. If there is a jumper across the DELAYED INTL’K IN terminals, remove one side of the jumper.

  • Page 69: Air Flow Fault Tests

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E BLOCKED BLOWER PROPANE AIR/FUEL INLET PROOF SSOV VALVE SWITCH SWITCH MANUAL SHUTOFF VALVE NATURAL SSOV Figure 6-3: Manual Gas Shut-Off Valve Location (Partial Left-Side View) 6.10 AIR FLOW FAULT TESTS These tests check the operation of the Blower Proof Switch and Blocked Inlet Switch shown in Figure 6-3.

  • Page 70: Ssov Proof Of Closure Switch

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E (b) The unit will then execute a standard ignition sequence and display WAIT IGNITION RETRY. The unit should perform one IGNITION RETRY cycle and then shut down, since the blower is disabled.

  • Page 71: Ignition Switch Open During Ignition

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E Figure 6-4: SSOV Actuator Cover Location 6.12 IGNITION SWITCH OPEN DURING IGNITION The Ignition Switch (and the Purge Switch) is located on the Air/Fuel Valve. To check the switch, proceed as follows: Set the unit’s ON/OFF switch to the OFF position.

  • Page 72: Safety Pressure Relief Valve Test

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 6: SAFETY DEVICE TESTING OMM-0052_0E Figure 6-5: Air/Fuel Valve Cover Location Figure 6-6: Air/Fuel Valve Purge and Ignition Switch Locations 6.14 SAFETY PRESSURE RELIEF VALVE TEST Test the safety Pressure Relief Valve in accordance with ASME Boiler and Pressure Vessel Code, Section VI.

  • Page 73: Chapter 7: Maintenance

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 7: MAINTENANCE MAINTENANCE SCHEDULE The unit requires regular routine maintenance to keep up efficiency and reliability. For best operation and life of the unit, the following routine maintenance procedures should be performed in the time periods specified in Table 7-1.

  • Page 74: Igniter-Injector

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E 7.2 IGNITER-INJECTOR The igniter-injector (part no. 58023) is located on the burner plate at the top of the boiler. In addition to providing the ignition spark required to light the burner, the igniter-injector also contains a gas injector tube which connects to the staged ignition assembly.
  • Page 75 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E IMPORTANT Prior to removing the igniter-injector, note the position of the gas injector tube relative to the burner plate and blower. This is necessary to ensure that the igniter injector is reinstalled in the proper orientation when it is reconnected to the staged ignition assembly.

  • Page 76: Flame Detector

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E Figure 7-3: Igniter-Injector Orientation 8. Reinstall the igniter-injector in the burner plate. Torque to 15 ft-lbs. Do not over tighten. 9. Connect the staged ignition assembly to the gas injector tube of the igniter-injector by securing the compression nut to the elbow of the staged ignition assembly.

  • Page 77: Combustion Calibration

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E 7.4 COMBUSTION CALIBRATION The Combustion Calibration settings must be checked at the intervals shown in Table 7-1 as part of the maintenance requirements. Refer to Chapter 4 for combustion calibration instructions.
  • Page 78 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E BURNER 3/8-16 PLATE NUTS (8) GROUNDING SCREW IGNITOR- (10-32 x 1/2" LG.) INJECTOR BLOWER STAGED IGNITION ASSEMBLY AIR/FUEL VALVE FLAME DETECTOR 1/2” BOLTS & NUTS (4) CONNECT AIR/FUEL VALVE TO GAS TRAIN Figure 7-5: Burner Assembly Mounting Details...
  • Page 79 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E 12. Disconnect the gas train from the air/fuel valve by removing the four (4) 1/2” bolts and nuts (Figure 7-5). 13. Disconnect the inlet air flex hose from the air/fuel valve by loosening the hose clamp. 14.

  • Page 80: Condensate Drain Trap

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E 19. Beginning with the burner assembly removed in step 17, reinstall all the components in the reverse order that they were removed. During re-assembly, replace the gaskets for the blower and flame detector with new ones.

  • Page 81: Shutting The Boiler Down For An Extended Period Of Time

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E Figure 7-7: External Condensate Trap 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.
  • Page 82 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 7: MAINTENANCE OMM-0052_0E (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 82 of 158 PR2: 04/22/13...

  • Page 83: Chapter 8: Troubleshooting Guide

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 8: TROUBLESHOOTING GUIDE 8.1 INTRODUCTION This troubleshooting guide is intended to aid service/maintenance personnel in isolating the cause of a fault in a Benchmark 2.0LN Boiler. The troubleshooting procedures contained herein are presented in tabular form on the following pages.
  • Page 84 GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING FAULT PROBABLE CAUSES CORRECTIVE ACTION INDICATION 1. Blower stopped running due to thermal or Check combustion blower for signs of excessive heat or high current overload current drain that may trip thermal or current overload devices.
  • Page 85 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1. Blower not running or running too slow 1. Start the unit. If the blower does not run check the blower solid state relay for input and output voltage.
  • Page 86 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT PROBABLE CAUSES CORRECTIVE ACTION INDICATION 1. Delayed Interlock Jumper not installed or 1. Check for a jumper properly installed across the delayed interlock removed.
  • Page 87 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION Unstable gas pressure. 7. Refer to “Gas Pressure Requirements” section of GF-2030: BMK Gas Supply Design Guide. Carbon or other debris on Burner.
  • Page 88 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT PROBABLE CAUSES CORRECTIVE ACTION INDICATION 1. Faulty Water temperature switch. 1. Test the temperature switch to insure it trips at its actual water temperature setting.
  • Page 89 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 1. Air/Fuel Valve not rotating 1. Start the unit. The Air/Fuel Valve should rotate to the purge (open) position.
  • Page 90 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT PROBABLE CAUSES CORRECTIVE ACTION INDICATION 1. Interlock jumper not installed or 1. Check for a jumper properly installed across the interlock terminals in the removed I/O box 2.
  • Page 91 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 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.
  • Page 92 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT PROBABLE CAUSES CORRECTIVE ACTION INDICATION 1. SSOV not fully closed. 1. Check open/close indicator window of Safety Shut-Off Valve (SSOV) and ensure that the SSOV is fully closed.

  • Page 93: Additional Faults Without Specific Fault Messages

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E TABLE 8-1. BOILER TROUBLESHOOTING (Continued) FAULT INDICATION PROBABLE CAUSES CORRECTIVE ACTION 2. Air/Fuel Valve unplugged. 2. Check that the Air/Fuel Valve is connected to the Control Box. 3.
  • Page 94 GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E PROPANE GAS HIGH GAS PRESSURE SWITCH NATURAL GAS HIGH GAS PRESSURE SWITCH PROPANE SSOV SNUBBERS PROPANE LOW GAS PRESSURE SWITCH MANUAL GAS To 2 SOLENOID VALVE VIA SHUT-OFF VALVE FLEX GAS LINE NATURAL GAS SSOV...
  • Page 95 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E Figure 8-3: Damping Orifice Location AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 95 of 158...
  • Page 96 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 8: TROUBLESHOOTING GUIDE OMM-0052_0E (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 96 of 158 PR2: 04/22/13...

  • Page 97: Chapter 9: Rs232 Communication

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E CHAPTER 9: RS232 COMMUNICATION 9.1 INTRODUCTION The RS232 communication feature permits viewing or changing of Control Panel menu options and also provides access to data logs showing Event Time Line, Fault and Sensor log displays. The RS232 port on the front panel of the C-More Control Box (Figure 3-1) can be interfaced to a laptop computer or other suitable terminal using a RS232 adapter cable.

  • Page 98: Running A Command On A Remote Machine Using Putty

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 9: RS232 COMMUNICATION OMM-0052_0E Now, to connect to the remote server, simply click the Open button at the bottom of the dialog box. A new terminal window will pop up and ask you to log in. So that you don't have to enter this information every time you wish to connect to your server, you can save this configuration by typing an appropriate name in the Saved Sessions text box in the PuTTY “Basic Options”...

  • Page 99: Rs232 Communication Setup

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 9: RS232 COMMUNICATION OMM-0052_0E 9.2 RS232 COMMUNICATION SETUP Regardless of the terminal emulation utilized, the following guidelines must be adhered to when setting up the RS232 communicati on link: o Baud Rate –...

  • Page 100: Data Logging

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 9: RS232 COMMUNICATION OMM-0052_0E m3 = Tuning Menu m4 = Calibration Menu m5 = Diagnostic Menu 8. To change a value or setting for a displayed menu option, proceed as follows: a) Enter C, followed by the number to the right of the displayed option to be changed, and then press <Rtn>.

  • Page 101: Sensor Log

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 9: RS232 COMMUNICATION OMM-0052_0E terminal device. Ten operation time records are displayed for each T command entry. The operation time log can be cleared ONLY by factory authorized personnel using the Clear Log option in the Factory menu.
  • Page 102 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual CHAPTER 9: RS232 COMMUNICATION OMM-0052_0E (This page left intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 102 of 158 PR2: 04/22/13...

  • Page 103: Appendix A: Menu Item Descriptions

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX A: MENU ITEM DESCRIPTIONS Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION OPERATING MENU This is the setpoint temperature to which the control is set when operating in the Constant Setpoint, Remote Setpoint or Outdoor Reset Mode.
  • Page 104 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX A: MENU ITEM DESCRIPTIONS OMM-0052_0E Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION SETUP MENU Allows password to be entered. Once the valid password (159) is entered, options in Password the Setup, Configuration and Tuning Menus can be modified.
  • Page 105 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX A: MENU ITEM DESCRIPTIONS OMM-0052_0E Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Permits setting of Reset Ratio when operating boiler Reset Ratio in the Outdoor Reset Mode.
  • Page 106 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX A: MENU ITEM DESCRIPTIONS OMM-0052_0E Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION CONFIGURATION MENU (Cont.) Operating at a Valve Position below this value will inhibit the DEADBAND feature.
  • Page 107 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX A: MENU ITEM DESCRIPTIONS OMM-0052_0E Table A-1: Boiler Menu Item Descriptions MENU LEVEL & OPTION DESCRIPTION TUNING MENU Generates a fire rate based on the error that exists between the setpoint temperature and the actual outlet temperature.
  • Page 108 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX A: MENU ITEM DESCRIPTIONS OMM-0052_0E (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 108 of 158 PR2: 04/22/13...

  • Page 109: Appendix B: Startup, Status And Fault Messages

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E 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 Displayed if ON/OFF switch is set to OFF. The display DISABLED also shows the time (am or pm) and date that the unit HH:MM pm, pm...
  • Page 110 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES OMM-0052_0E 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.
  • Page 111 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES OMM-0052_0E 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.
  • Page 112 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX B: STARTUP, STATUS AND FAULT MESSAGES OMM-0052_0E This page left intentionally blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 112 of 158 PR2: 04/22/13...

  • Page 113: Appendix C: Sensor Temperature Resistance

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX C: SENSOR TEMPERATURE RESISTANCE TABLE C-1: 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...
  • Page 114 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX C: SENSOR TEMPERATURE RESISTANCE OMM-0052_0E This page left intentionally blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 114 of 158 PR2: 04/22/13...

  • Page 115: Appendix D: Indoor/Outdoor Reset Ratio Charts

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E 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 Temperature of 60F RESET RATIO Temp -10F...
  • Page 116 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS OMM-0052_0E 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...
  • Page 117 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS OMM-0052_0E 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 118 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX D: INDOOR/OUTDOOR RESET RATIO CHARTS OMM-0052_0E Table D-7. Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 118 of 158 PR2: 04/22/13...

  • Page 119: Appendix E: Boiler Default Settings

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX E: BOILER DEFAULT SETTINGS Table E-1: 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...
  • Page 120 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX E: BOILER DEFAULT SETTINGS OMM-0052_0E Table E-1: 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...

  • Page 121: Appendix F: Part And Dimensional Drawings

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX F: PART AND DIMENSIONAL DRAWINGS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 121 of 158...
  • Page 122 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 122 of 158 PR2: 04/22/13...
  • Page 123 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 123 of 158...
  • Page 124 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 124 of 158 PR2: 04/22/13...
  • Page 125 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 125 of 158...
  • Page 126 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 126 of 158 PR2: 04/22/13...
  • Page 127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 127 of 158...
  • Page 128 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 128 of 158 PR2: 04/22/13...
  • Page 129 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 129 of 158...
  • Page 130 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 130 of 158 PR2: 04/22/13...
  • Page 131 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 131 of 158...
  • Page 132 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 132 of 158 PR2: 04/22/13...
  • Page 133 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 133 of 158...
  • Page 134 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 134 of 158 PR2: 04/22/13...
  • Page 135 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX F: PART AND DIMENSIONAL DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 135 of 158...
  • Page 136 GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 136 of 158...

  • Page 137: Appendix G: Piping Drawings

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E APPENDIX G: PIPING DRAWINGS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 137 of 158...
  • Page 138 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 138 of 158 PR2: 04/22/13...
  • Page 139 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 139 of 158...
  • Page 140 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 140 of 158 PR2: 04/22/13...
  • Page 141 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 141 of 158...
  • Page 142 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX G: PIPING DRAWINGS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 142 of 158 PR2: 04/22/13...

  • Page 143: Appendix H: Wiring Schematics

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX H: WIRING SCHEMATICS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 143 of 158...
  • Page 144 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX H: WIRING SCHEMATICS OMM-0052_0E (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 144 of 158 PR2: 04/22/13...
  • Page 145 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 145 of 158...
  • Page 146 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX H: WIRING SCHEMATICS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 146 of 158 PR2: 04/22/13...
  • Page 147 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX H: WIRING SCHEMATICS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 147 of 158...
  • Page 148 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX H: WIRING SCHEMATICS OMM-0052_0E AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 148 of 158 PR2: 04/22/13...

  • Page 149: Appendix I: Recommended Periodic Testing Check List

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E 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 150 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX I: RECOMMENDED PERIODIC TESTING CHECK LIST OMM-0052_0E This page left intentionally blank AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 150 of 158 PR2: 04/22/13...

  • Page 151: Appendix J: Benchmark Control Panel Features

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX J: BENCHMARK CONTROL PANEL FEATURES Figure J-1: Control Panel Exploded View AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 PR2: 04/22/13 Page 151 of 158...
  • Page 152 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX J: BENCHMARK CONTROL PANEL FEATURES OMM-0052_0E Figure J-2: Control Panel Rear Panel AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 152 of 158 PR2: 04/22/13...

  • Page 153: Appendix K: Bmk 2.0 Dual-Fuel Switchover Instructions

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS OMM-0052_0E APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS Prior to operating a Benchmark 1.5 Dual-Fuel Unit on either Natural Gas or Propane, a number of checks and procedural steps must be performed prior to performing the initial start-up and combustion calibration.
  • Page 154 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS OMM-0052_0E Figure K-1: Benchmark 2.0 Dual-Fuel Front View – Door Removed AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 154 of 158 PR2: 04/22/13...
  • Page 155 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS OMM-0052_0E TO AIR/FUEL VALVE OPEN PROPANE GAS BALL VALVE CLOSE NATURAL GAS BALL VALVE PROPANE INLET NATURAL GAS INLET Figure K-2: Ball Valve Positions for PROPANE Gas Operation TO AIR/FUEL VALVE CLOSE PROPANE...

  • Page 156: Switchover From Propane To Natural Gas

    Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX K: BMK 2.0 DUAL-FUEL SWITCHOVER INSTRUCTIONS OMM-0052_0E SWITCHOVER FROM PROPANE TO NATURAL GAS To switch from Propane to Natural Gas operation, proceed as follows: Refer to Figure K-1 and locate the Fuel Selector Switch on the front of the unit. Set the Fuel Selector Switch to the NATURAL GAS position.

  • Page 157: Appendix L: Recommended Spare Parts Lists

    GF-127 Benchmark 2.0LN Dual-Fuel Low NOx Boiler Operation and Maintenance Manual OMM-0052_0E APPENDIX L: RECOMMENDED SPARE PARTS LISTS NOTE Refer to the Parts List Illustrations in Appendix F for the locations of the recommended and optional spare parts listed in the following Tables. Table L-1: Recommended Emergency Spare Parts DESCRIPTION PART NUMBER...
  • Page 158 Benchmark 2.0LN Dual-Fuel Low NOx Boiler GF-127 Operation and Maintenance Manual APPENDIX L: RECOMMENDED SPARE PARTS LISTS OMM-0052_0E This page left intentionally blank © AERCO International, Inc., 2013 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 158 of 158 PR2: 04/22/13...

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