Aerco Benchmark Series User Manual
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Aerco Benchmark Series User Manual

Gas fired boiler system
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Benchmark 2.0 Gas Fired Boiler
GF-107
USER MANUAL
OMM-0009_0A
Used for Serial Numbers G-00-711 thru G-01-095
Benchmark
Series
Gas Fired
Boiler System
Condensing, Modulating
Forced Draft,
Natural Gas Fired, Hot Water Boiler
2,000,000 BTU/H Input
06/06/01
Printed in U.S.A.

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  • Page 1 Benchmark 2.0 Gas Fired Boiler GF-107 USER MANUAL OMM-0009_0A Used for Serial Numbers G-00-711 thru G-01-095 Benchmark Series Gas Fired Boiler System Condensing, Modulating Forced Draft, Natural Gas Fired, Hot Water Boiler 2,000,000 BTU/H Input 06/06/01 Printed in U.S.A.
  • Page 2 CONTENTS GF-107 THE AERCO Benchmark 2.0 GAS FIRED BOILER Operating & Maintenance Instructions FOREWORD Page Section 1 SAFETY PRECAUTIONS----------------------------------1-1 Safety Warnings Prolonged Shut-Down Emergency Shut Down Section 2 INSTALLATION PROCEDURES-------------------------2-1 Receiving the Unit Aux. Contacts Unpacking Enable/Disable Interlock Installation Fault Relay Wiring Gas Supply Piping 2.10...

  • Page 3: Table Of Contents

    CONTENTS Page Section 6 SAFETY DEVICE TESTING PROCEDURES---------6-1 Testing of Safety Devices Flame Fault Test Gas Pressure Fault Test Air Pressure Fault Test Low Water Level Fault Test Purge Interlocks Fault Test Water Temperature Fault Test Safety Pressure Relief Valve Test Section 7 MAINTENANCE REQUIREMENTS---------------------7-1 Maintenance Schedule...
  • Page 4 FOREWORD Foreword The AERCO Benchmark boiler is a true industry advance that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the Benchmark's modulating capability relates energy input directly to fluctuating system loads.
  • Page 5 ALL INCOMING AND OUTGOING instructions. In addition to all the WATER SHUTOFF VALVES AND requirements included in this instruction manual by AERCO, the installation of units CAREFULLY DECREASE ALL MUST conform with local building codes, or, TRAPPED PRESSURES TO ZERO in the absence of local codes, ANSI Z223.1...
  • Page 6 If there is an emergency, turn off the electrical power supply to the Aerco boiler and close the manual gas valve located before the unit. The installer is to identify the emergency...
  • Page 7 NOTE: container or are factory installed on the boiler. AERCO is not responsible for lost or • Spare Spark Ignitor damaged freight. •...
  • Page 8 The unit must be installed with the prescribed clearances for service as shown in Figure 2.1. BURNER The minimum clearance dimensions, required by AERCO, are listed below. Local building codes may require more clearance and take precedence Minimum clearances required: Sides 24"...
  • Page 9 Do not hard pipe. prevent access between the Unit and walls, or another unit. 2.4. GAS SUPPLY PIPING The AERCO Gas Fired Equipment Gas Components and Supply Design Guide (GF- EXHAUST MANIFOLD 1/2"NPT CONDENSATE DRAIN CONN. 3/4" NPT EXHAUST GAS CONDENSATE DRAIN CONN.
  • Page 10 1" droop from minimum to full fire. A Maxitrol RV-91 gas supply regulator is supplied by AERCO and must be positioned as shown in figure 2.7. Maximum gas pressure to Figure 2.7 the RV-91 is 14" W.C. If the gas supply pressure Gas Supply Regulator and Manual Shut-Off will exceed 14"...
  • Page 11 INSTALLATION complete the installation. This wiring is typically run to the Control Box located on the front of the TERMINAL BLOCK unit behind the removable Front Door (see Fig. 2.10). Field wiring for each particular mode of operation is described in the following sections. TOP OF CONTROL BOX Figure 2.9 Figure 2.8...
  • Page 12 INSTALLATION only at the AERCO boiler management system and must be left floating at the boiler. For further wiring instructions see the GF-108, BMS Operations Guide. 2.6.4 4 to 20mA REMOTE SETPOINT and DIRECT DRIVE MODES The BENCHMARK boiler can be controlled with a 4-20mA signal from an energy management system or an external controller.
  • Page 13 2.11 COMBUSTION AIR start and stop. The circuit is labeled Enable/Disable and is located on the inside of The AERCO Venting and Combustion Air Guide, the control panel door. The circuit is 120 VAC, GF-2050, MUST be consulted before any flue or and comes factory pre-wired closed (jumped).
  • Page 14 See the AERCO Venting and Combustion Air Guide, GF- 2050. When using the boiler in a sealed combustion air configuration, each unit must have a minimum 8"...
  • Page 15 CONTROL PANEL OPERATING PROCEDURES Chapter 3 - CONTROL PANEL OPERATING PROCEDURES The following is a guide to the operation of the circuits. There are six separate accessible control panel. Initial start-up of this unit must be controls or displays available to the operator, performed by factory trained start-up personnel.
  • Page 16 CONTROL PANEL OPERATING PROCEDURES 3.2 THE TEMPERATURE CONTROLLER The last two LED’s, “ F” and “ C”, indicate whether the temperature displayed is The temperature controller is a PID °Fahrenheit or °Celsius, (see Fig. 3.2). programmable controller that utilizes feedback information to accurately maintain a desired set point.
  • Page 17 CONTROL PANEL OPERATING PROCEDURES 3.3 THE PRIMARY MENU To access the firing rate percentage, press the MENU button while in the primary menu until The primary menu is the default menu. When in (Pct) is displayed in the lower LED. While in another menu level and there is no activity for 5 manual mode, (see section 3.3.4);...
  • Page 18 CONTROL PANEL OPERATING PROCEDURES In manual mode, the controller no longer The secondary menu allows access to the automatically controls the firing rate of the unit. It following temperature control features: is up to the operator to control the outlet temperature and firing rate.
  • Page 19 CONTROL PANEL OPERATING PROCEDURES The following table shows the messages ANNUNCIATOR DISPLAY displayed after accessing the CYCLES and SET DATE displays. The number of times # CYCLES = the controller has “DATE” “TIME” completed it’s start cycle, and the time and date of the last reset SET DATE:...
  • Page 20 CONTROL PANEL OPERATING PROCEDURES DURING the end of the trial for This lights when the ignition period. controller is in a IGNITION TRIAL ALARM LOCKOUT condition. LOCKOUT RUN The air pressure switch AIR FLOW opened after flame was proven. LOCKOUT RUN Flame signal was lost FLAME after flame was proven.
  • Page 21 CONTROL PANEL OPERATING PROCEDURES PROOF OF CLOSURE SWITCH SAFETY SHUT-OFF VALVE Figure 3.10 Water Level Test and Reset Switch Locations Figure 3.11 Proof of Closure Switch Location 3.8 ON/OFF SWITCH 3. The system next checks for proof of closure The ON/OFF switch is located on the front of the of the safety shut-off valve, (see Fig.
  • Page 22 CONTROL PANEL OPERATING PROCEDURES A/F VALVE TO FRAME HARNESS Figure 3.13 Blower Proof Switch Location 6. Simultaneously, the AIR FLOW LED on the combustion safeguard lights, and the unit begins its 7-second purge cycle. Figure 3.14 Air/Fuel Valve in Ignition Position, Engaging the 7.
  • Page 23 CONTROL PANEL OPERATING PROCEDURES minimum required flame signal for operation of the burner is 6 VDC. 3.13 FLAME TEST JACKS The front of the combustion safeguard has two test jacks marked + and - for flame monitoring, (see Fig. 3.15). To access the test jacks remove the combustion safeguard cover by turning the center screw counterclockwise.
  • Page 24 6 to complete procedures, recommended for troubleshooting. the initial unit start-up. 4.2.2 INSTALLING THE SUPPLY GAS An AERCO Gas Fired Startup Sheet included MANOMETER with each BENCHMARK must be completed for 1. Close the manual gas supply valve up each unit for warranty validation and a copy stream of the unit.
  • Page 25 INITIAL START-UP REGULATOR CAP CAP GASKET REGULATOR ADJUSTMENT TOOL (P.N. 123643) DIFFERENTIAL PRESSURE REGULATOR Figure 4.3 Differential Regulator Adjustment Tool Installation Figure 4.1 4.2.4 INSTALLING THE DIFFERENTIAL 1/8” Gas Plug Location REGULATOR ADJUSTMENT TOOL 4.2.3 PREPARING THE FLUE VENT 1. Remove the cap from the differential PROBE HOLE pressure regulator (see Fig.
  • Page 26 INITIAL START-UP Adjust only the differential regulator at 40% 4. Place the green ON/OFF switch in the OFF control signal; do not adjust the iris air position. Turn on AC power to the unit. The damper. temperature controller and annunciator displays should light.
  • Page 27 INITIAL START-UP 5.2% <100ppm screw, and then turning the tool out of the top of the regulator. 5.6% <100ppm 6.0% <100ppm 4. Remove the gasket from the tool and place 6.4% <100ppm it back onto the regulator cap. 6.8% <100ppm 5.
  • Page 28 MODE OF OPERATION Chapter 5 - MODE OF OPERATION The following is a detailed description of the 6 the control wiring terminal strip located at the different modes of operation for the Benchmark bottom left hand corner of the control panel. Boiler.
  • Page 29 There are no external sensors necessary to preset with settings that work well in most operate in this mode. While it is necessary to set applications. It is suggested that an AERCO the desired setpoint temperature it is not representative be contacted prior to changing necessary to change any other temperature- any temperature related function settings.
  • Page 30 Secondary Lore in the most efficient manner possible. Eight Secondary FUNC Cont boilers can be managed by a single AERCO Primary Auto BMS 168 system using pulse width modulation. The AERCO BMS monitors all system-related 5.4.1 4-20mA DIRECT DRIVE FIELD...
  • Page 31 Provided the domestic This mode of operation is factory preset and the hot water load is satisfied the domestic boilers AERCO BMS Model 168 controls the firing rate. will then become space-heating boilers. If the There are no setup instructions for each domestic hot water load is not satisfied, the individual unit.
  • Page 32 When the boiler is switched to BMS mode, the setting the desired setpoint of the unit. This must AERCO BMS controls the firing rate. There are be done when the unit is in combination no setup requirements to the boiler(s) in this (constant setpoint) mode.

  • Page 33: Safety Device Testing Procedures

    SAFETY DEVICE TESTING Chapter 6 SAFETY DEVICE TESTING PROCEDURES 6.1 TESTING OF SAFETY DEVICES Periodic testing of all controls and safety devices is required to ensure that they are operating as designed. Precautions must be taken while tests are being performed to protect against bodily injury and property damage.

  • Page 34: Flame Fault Test

    SAFETY DEVICE TESTING 6. The ON-OFF switch should not illuminate switch should not be illuminated and the unit when placed in the ON position and the unit should not start. should not start. 4. Reset the temperature limit switch setting to 7.

  • Page 35: Air Pressure Fault Test

    SAFETY DEVICE TESTING 4. Start the unit. 9. Reset the Combustion safeguard and CLEAR the Annunciator. 5. The unit should shutdown and displays the message “LOCKOUT RUN”. 10. Start the unit. 6. Clear the Annunciator. Turn the ON/OFF 6.6 AIR PRESSURE FAULT TEST switch to the OFF position.

  • Page 36: Safety Pressure Relief Valve Test

    SAFETY DEVICE TESTING 13. Reconnect wire #172 to the air/fuel valve purge position switch. VALVE COVER 14. Disconnect wire #170 from the ignition position switch. This is the switch closest to the blower of the unit (See Fig. 6.8). COVER SCREWS 15.
  • Page 37 MAINTENANCE Chapter 7 - MAINTENANCE 7.1 MAINTENANCE SCHEDULE BURNER 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 carried out in the time periods specified. See Appendix I for complete CSD-1 inspection check list WARNING!

  • Page 38: Maintenance Requirements

    MAINTENANCE Table1 - Maintenance Schedule Labor SECTION ITEM 6 Mos. 12 Mos. 24 Mos. Time Spark Inspect Replace 15 mins. Ignitor Flame Inspect Replace 15 mins. Detector Combustion Check Check 1 hr. Adj. Testing of See CSD-1 Safety Chart in 20 mins.

  • Page 39: Exhaust Manifold And Combustion Chamber

    MAINTENANCE The burner assembly is located at the top of the B U R N E R H O S E C L A M P unit. The burner assembly may be HOT. Allow the unit to cool sufficiently before removing the burner assembly.
  • Page 40 MAINTENANCE 2. Disconnect and remove the condensate 7.8 SHUTTING THE BOILER DOWN FOR drain trap assembly from the exhaust AN EXTENDED PERIOD OF TIME manifold. 1. If the boiler is to be taken out of service for an extended period of time, one year or 3.

  • Page 41: Troubleshooting

    This troubleshooting section is intended to serve as a guideline to determining and solving faults 2. Check the static pressure to the unit. It on the Benchmark Series boiler. Whenever a should be between 9” to 14” W.C. fault occurs, proceed as follows: 3.
  • Page 42 Contact a qualified service technician continuity. or your local AERCO representative for more information. 3. Replace the high gas pressure switch if it does not show continuity.
  • Page 43 TROUBLESHOOTING Note: The procedures in step 4 test and 5. If 120 VAC is read on the AC voltmeter, ensure the integrity of wiring inside and disconnect power to the unit and ground the outside of the control panel as well as the probe to the unit shell.
  • Page 44 TROUBLESHOOTING wire #138 on the unit. Also check continuity temperature has dropped 20 degrees or between wire #60 in the control panel and more before the temperature switch will the unit shell. reset.) 5. If there is no continuity repair as necessary. 5.

  • Page 45: Lock Out Run Flame

    8” and 16” Manometers and may not be sending a stop start signal 8.5.1 FLAME FAULT WHILE FIRING to the AERCO boilers or BMS when the system pumps are not running. 1. If the combustion control has a keyboard display module installed, the flame signal 4.
  • Page 46 TROUBLESHOOTING 3. Once flame is established, a steady reading If the flame fault still persists after the above, of greater than 1.25 VDC should be replace the combustion safeguard. observed on the voltmeter. 8.5.3 SAFETY SHUT-OFF VALVE 1. Start the unit. 4.
  • Page 47 TROUBLESHOOTING 17. Check the pin on wire #145 at the 1" 8.5.6 IGNITION CIRCUIT connector end, for proper insertion or wear. 1. Disconnect AC power to the unit. 18. Make any necessary repairs. 2. Close the manual leak detection valve, located between the safety shut-off valve 19.
  • Page 48 TROUBLESHOOTING 4. Reconnect AC power to the unit. 18. Disconnect the 1 ¾" connector from the control panel, and wires #140 and #141 from 5. An AC voltage reading of approximately 230 the ignition transformer. VAC should be observed. 19. Remove the cover plate from the AC wiring 6.

  • Page 49: Lock Out Run Air Pressure

    TROUBLESHOOTING 8.6.3 BLOWER If there is an increase in gas pressure, 1. Locate wire #81 & #83 on the motor replace the gas train. contactor located inside the control panel. 8.5 LOCK OUT RUN AIR PRESSURE 2. Connect an AC voltmeter between wire #81 A LOCKOUT RUN AIR FLOW indicates that the and wire #83 and the unit frame.

  • Page 50: System Fault Low Air Pressure Or Purge

    TROUBLESHOOTING 11. Reconnect the 1 ¾" connector to the control 2. If the blower does starts and the message panel. SYSTEM FAULT PURGE INTERLOCKS is displayed proceed to section 8.6.4 12. Reconnect AC power to the unit and start the unit. 3.
  • Page 51 TROUBLESHOOTING 8.7.5 SSOV PROOF OF CLOSURE SWITCH 5. The blower proof switch should show 1. Disconnect AC power to the unit. continuity while the blower is running. 2. Loosen the two setscrews securing the 6. If the blower proof switch does not show safety shut-off valve actuator to the safety continuity, remove the switch and check for shut-off valve body.
  • Page 52 TROUBLESHOOTING 9. If the switch shows continuity, proceed to 17. Referring to system schematic 161453 in Step 11. Appendix H, locate wires #148 and #149, check each for continuity using an 10. If the switch does not show continuity, ohmmeter. replace the switch.
  • Page 53 3 volts DC during PURGE 13. If the system fault still persists contact your and 1 to 1.3 volts during ignition. local AERCO representative for further assistance. 17. If the voltage is correct replace the air\fuel valve driver board.
  • Page 54 APPENDIX A PRIMARY MENU ITEM DESCRIPTIONS This is the actual outlet water tout temperature of the heater. It is designated by the code (tout). Percentage of firing rate is a number, in percent, that is directly related to the input BTU’s of the unit. For instance a 50% signal equals a 1,000,000 BTU gas input while a 75 % signal equals a 1,500,000 BTU gas...
  • Page 55 APPENDIX A SECONDARY MENU ITEM DESCRIPTIONS CONSTANT SETPOINT This indicates the mode of operation FUNC the temperature controller is in. Common modes Oart, indoor\outdoor reset, Cont, constant setpoint, and FDFO for a water heater. This menu item turns the outside air OSAT enable\disabl feature on or off.
  • Page 56 APPENDIX A This is the integral rate, in minutes, for the feedback of the controller. It is adjusted with the and . Press ENTER to accept changes. This is the derivative rate in % /.1°/sec. This adjusts response time to temperature changes at the outlet of the unit.
  • Page 57 APPENDIX A SECONDARY MENU ITEM DESCRIPTIONS INDOOR-OUTDOOR RESET MODE This displays the mode of the FUNC temperature controller. Common modes are Oart, indoor\outdoor reset, Cont, constant setpoint, and FDFO for a water heater. This is the building reference REFT temperature. It is the desired temperature that the inside of the building is to maintained.
  • Page 58 APPENDIX A This is High Limit Temperature alarm. This feature shuts down the unit and places the temperature controller into alarm if the outlet water temperature exceeds this setting. Outlet water temperature must be below this setting before the unit will restart Proportional Band refers to the error between the setpoint and the actual water temperature.
  • Page 59 APPENDIX B TEMPERATURE CONTROLLER QUICK REFERENCE PROGRAMMING GUIDE The following is a “How To” guide that quickly shows how to access menu levels and their parameters, and how to make changes to them. PRIMARY MENU to SECONDARY MENU • ⇑ Press ENTER and the arrow key.
  • Page 60 APPENDIX B NOTE: The temperature controller defaults back to the PRIMARY menu from the SECONDARY menu or the SECURE menu if there is no activity in either of those menus after 4 minutes. • TO CHANGE TO THE SECURE MENU ⇓...
  • Page 61 APPENDIX B ⇓ While in the SECURE menu press INDEX and the arrow key. This will place you in the ⇓ SECONDARY menu. Press INDEX and the arrow key again to return to the MAIN menu. The display will indicate: •...
  • Page 62 APPENDIX C Temperature Sensor Resistance Chart (Balco)
  • Page 63 APPENDIX D INDOOR\OUTDOOR RESET RATIO CHARTS Header Temperature for a Building Reference Temperature of 50F RESET RATIO Temp -10F -15F -20F Header Temperature for a Building Reference Temperatrure of 60F RESET RATIO Temp -10F -15F -20F Header Temperature for a Building Reference Temperature of 65F...
  • Page 64 APPENDIX D RESET RATIO Temp Header Temperature for a Building Reference Temperature of 70F RESET RATIO Temp -10F -15F -20F...
  • Page 65 APPENDIX D Header Temperature for a Building Reference Temperature of 75F RESET RATIO Temp -10F -15F Header Temperature for a Building Reference Temperature of 80F RESET RATIO Temp -10F...
  • Page 66 APPENDIX D Header Temperature for a Building Reference Temperature of 90F RESET RATIO Temp xiii...
  • Page 67 APPENDIX E BOILER DEFAULT SETTINGS CONSTANT SET POINT MODE MENU LEVEL DESCRIPTION OF CODE FACTORY & CODE DEFAULT PRIMARY MENU tout OUTLET TEMPERATURE ACTUAL PERCENTAGE OF FIRING RATE ACTUAL setp UNIT’S SETPOINT TEMPERATURE airt OUTSIDE AIR TEMPERATURE ACTUAL auto AUTOMATIC\MANUAL MODE AUTO ON SECONDARY MENU func...
  • Page 68 APPENDIX E BOILER DEFAULT SETTINGS INDOOR /OUTDOOR RESET MODE MENU LEVEL DESCRIPTION OF CODE DEFAULT & CODE VALUE PRIMARY MENU tout OUTLET TEMPERATURE ACTUAL PERCENTAGE OF FIRE RATE ACTUAL SEtP UNIT’S SETPOINT TEMPERATURE Airt OUTSIDE AIR TEMPERATURE ACTUAL Auto AUTO\MANUAL MODE AUTO ON SECONDARY MENU Func...
  • Page 69 APPENDIX F...
  • Page 70 APPENDIX F xvii...
  • Page 71 APPENDIX F xviii...
  • Page 72 APPENDIX F...
  • Page 73 APPENDIX F...
  • Page 74 APPENDIX G xviii...
  • Page 75 APPENDIX G...
  • Page 76 APPENDIX H...
  • Page 77 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 78 An Officer of AERCO must do any modifications to this warranty in writing. AERCO MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES.
  • Page 79 Benchmark Gas-Fired Hydronic Boiler CONDITIONS OF WARRANTY Should an AERCO gas-fired Hydronic boiler fail for any of the above reasons within the specified time period from the date of original shipment(s), AERCO shall at its option modify, repair or exchange the defective item. AERCO shall have the option of having the item returned, FOB its factory, or to make field replacements at the point of installation.

This manual is also suitable for:

Benchmark gf-107Benchmark g-00-711Benchmark g-01-095

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